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Ice cube makers use more water than just the water contained in
the ice. This equipment can often be very inefficient in water
use. The typical icemaker uses 2 or 3 times more water than
needed to make the ice we consume. These water using
machines can be found everywhere; hospitals account for 39.4
percent of all commercial ice-maker purchases, followed by hotels
(22.3 percent), restaurants (13.8 percent), retail outlets (8.5
percent), schools (8.5 percent), offices (4.3 percent) and grocery
stores (3.2 percent).
There are two basic equipment designs: air-cooled refrigeration
units and water cooled refrigeration units. The air-cooled units
are usually more water efficient; while the water cooled units are
usually more energy efficient. Both types vary greatly in water
efficiency, even within its own design type. The water efficiency
is measured by the industry in gallons of water per 100 lbs
(45.36 kg) of ice. Perfect water efficiency would equate to 11.97
gallons (45.3 L) of water to produce 100 lbs (45.36 kg) of ice.
Most ice makers water use ranges between 18 to 200 gallons (68
L to 756.9 L) of water per 100 lbs (45.36 kg) of ice. This
represents a water efficiency range of 66% to only 5%. Thus,
34% to 95% of the water used is dumped down the drain. The
water varies for several reasons.
As the ice is formed in the freezing trays, minerals in the water
collect in the equipment. These minerals must be occasionally
rinsed off the freezing trays and the water reservoirs. Ice makers
have a variable setting to initiate a rinse cycle at desired
frequencies. The frequency of rinse is to be determined by local
water quality and site requirements. Some new model actuate
the rinse cycles based on sensor readings of minerals. Often the
ice maker is set to rinse more often than necessary, resulting in
water waste.
The quality of the ice can also affect water use. Some ice
makers are designed to produce clearer and smoother ice by
using a repeated freezing and partial thawing cycle while the ice
is produced. This results in ice cubes that are smoother, without
air bubbles and more crystalline like. Unfortunately, this aesthetic
quality wastes a lot of water and serves no useful purpose; frosty
ice cools just as well as clear ice.
Water cooled ice makers are often the most inefficient in water
use, although sometimes providing significant energy savings at
the point of use. It is important to note that there are many aircooled ice machines more energy efficient than some watercooled ice machines. Water cooled machines generally use
potable water to remove heat from the refrigeration equipment.
In years past, most of these machines used single-pass cooling
dumping the water into the sewer as it exited the
machine. Fortunately, many manufacturers are started to
abandon this wasteful design. Some newer designs re-circulate
the water after it passes through a cooling tower or heat
exchanger, but these still require large amounts of make up
water. While air-cooled machines generally have a water
efficiency of 40% to 66%, water cooled machines are usually less
than 15% water efficient.
Problem Statement:
Nickel- or tin-plated copper is most commonly used for the ice
forming pockets in cube ice machines today. Such pockets may be
formed by fitting notched strips of copper together in an "egg
crate" relationship to form a grid of four sided pockets. The strips
are then soldered to a backing pan. At the same time a serpentine
piece of copper tubing (forming the evaporator section of the
refrigeration system) can be soldered to the back of the pan. The
entire evaporator/ice forming assembly is then nickel or tin
plated. The plating is required by National Sanitation Foundation
Compression
Condensation
Expansion
Vaporization
Figure 1
Figure 2
COMPRESSORS
Introduction :
A refrigerator compressor is the center of the
refrigerator cycle . Compressor may be called as a heart of any
vapour compression system . It works as a pump to control the
circulation of the refrigerant, and it adds pressure to the
refrigerant, heating it up . The compressor also draws vapour
away from the evaporator to maintain a lower pressure and lower
temperature before sending it to the condenser.
CLASSIFICATION OF COMPRESSORS :
According to the method of compression :
Reciprocating compressors
Rotary compressors
Centrifugal compressors
Figure 3
Figure 4
HERMATICALLY SEALED :
Compressor Lubrication
In order to lubricate the moving parts
of the compressor, an oil is added to the refrigerant during
installation or commissioning. The type of oil may be mineral or
synthetic to suit the compressor type, and also chosen so as not
APPLICATION:
Refrigerators
Deep freezer
Water cooler
Bottle coolers
Room air conditioners
CONDENSOR
Introductions :
Condensors and evaporators are basically heat exchangers in
which the refrigerant undergoes a phase change. Next to
compressors, proper design and selection of condensers and
evaporators is very important for satisfactory performance of any
refrigeration system. Since both condensers and evaporators are
essentially heat exchangers, they have many things in common
as far as the design of these components is concerned. In
condensers the refrigerant vapour condenses by rejecting heat to
an external fluid, which acts as a heat sink. Normally, the external
fluid does not undergo any phase change, except in some special
cases such as in cascade condensers, where the external fluid
(another refrigerant) evaporates. In evaporators, the liquid
refrigerant evaporates by extracting heat from an external fluid
(low temperature heat source). The external fluid may not
undergo phase change, for example if the system is used
forsensibly cooling water, air or some other fluid. There are many
refrigeration and air conditioning applications, where the external
fluid also undergoes phase change. For example, in typical
summer air conditioning system, the moist air is dehimidised by
condensing water vapour and then, removing the condensed
liquid water. In many low temperature refrigeration applications
freezing or frosting of evaporators takes place. These aspects
have to be considered while designing condensers and
evaporators.
Classification of condensers:
Condensers may be classified on the following basis:
On the basis of cooling medium used:
(a) Air cooled condenser
(b) Water cooled condenser
(c) Evaporative condenser
On the basis of construction:
(a) Shell type condenser
(b) Shell and coil condenser
(c) Double pipe condenser
(d) Finned condenser
Purpose of a Condenser:
The purpose of a condenser in the cycle of compression
refrigeration is to change the hot gas being discharged from the
compressor to a liquid prepared for use in the evaporator. The
condenser accomplishes this action by the removal of sufficient
heat from the hot gas, to ensure its condensation at the pressure
available in the condenser. The heat is shifted to another medium,
like water or air, to cool the condenser.
Figure 5
EXPANSION DEVICES
Introduction:
An expansion device is another basic component of a
refrigeration system. The basic functions of an expansion device
used in refrigeration system are to:
1. Reduce pressure from condenser pressure to evaporator
pressure, and
2. Regulate the refrigerant flow from the high-pressure liquid
line into the evaporator at a rate equal to the evaporation
rate In the evaporator.
The expansion devices used in refrigeration system can
be divided into fixed opening type or variable opening type.
As the name implies, in fixed opening type in the flow area
changes with changing mass flow rates. There are basically
seven types of refrigerant expansion devices. These are:
1. Hand (manual) expansion valves
2. Capillary Tubes
3. Orifice
4. Constant pressure or Automatic Expansion Valve (AEV)
5. Thermostatic Expansion Valve
6. Float type Expansion Valve
a) High Side Float Valve
b) Low Side Float Valve
7. Electronic Expansion Valve
Figure 6
Capillary Tube:
A capillry tube is long narrow tube of constant diameter. The word
capillry is a misnomer since surface tension is not important in
refrigeration application of capillary tubes. Typical tube diameters
of refrigerab=nt capillary tubes range from 0.5mm to 3 mm and
the length ranges from 1.0m to 6m. The pressure reduction in
capillary tube occurs due to the following two factors:
1. The refrigerant has to overcome the frictinal resistance
offered by the walls. This leads to some pressure drop, and
2. The liquid refrigerant flashes (evaporates) into mixture of
liquid and vapours its pressure reduces. The density of
vapour is less than that of the liquid. Hence, the average
density of refrigerant decreases as it flows in the tube. The
mass flow rate and the tube diameter (hence area) being
constant, the velocity of refrigerant increases since. The
increase in velocity or acceleration of the refrigerant also
Figure 7
EVAPORATORS
Introductions:
An evaporators, like condenser is also a heat exchanger. In an
evaporator, the refrigerant boils or evaporates and in doing so
absorb heat from the substance being refrigerated. The name
evaporator refers to the evaporation process occuring in the heat
exchanger.
Figure 8
REFRIGERANTS
A refrigerants is a substance used in heat cycle usually including,
for enhanced efficiency, a reversible phase change from a liquid
to a gas. Traditionally, fluorocarbons, especially
chlorofluorocarbons, were used as refrigerants, but they are being
phased out because of their ozone depletion effects. Other
common refrigerants used in various applications are ammonia,
sulphur dioxide, and non- halogenated hydrocarbons such as
methane.
Introductions:
Physical properties:
The ideal refrigerant has favorable thermodynamic properties, is
uncreative chemically, and is safe. The desired thermodynamic
properties are boiling point somewhat below the target
temperature, a high heat of vaporization, a moderate density in
liquid form, a relatively high density in gaseous form, and a high
critical temperature. Since boiling point and gas density are
affected by pressure, refrigerants may be made more suitable for
a particular application by choice of operating pressure. These
properties are ideally met by the chlorofluorocarbons, but
environmental science regards stability as being an undesirable
property of a refrigerant, leading to recommendations such as
Supercritical carbon dioxide as a possible future cooling agent for
use in vehicles.
Refrigerant R-134a:
INSULATION
Insulation is the reduction of heat transfer between objects in
thermal contact or in range of radiative influence. Heat transfer
is the transfer of thermal energy between objects of differing
temperature. The means to stem heat flow may be especially
engineered methods or processes, as well as suitable static
objects and materials.
Figure 9
Purpose of Insulation:
A thermal insulator is a poor conductor of heat and has a low
conductivity. Insulation is used in buildings and in manufacturing
processes to prevent heat loss or heat gain. Although its primary
purpose is an economic one, it also provides more accurate
control of process temperatures and protection of personnel. It
prevents condensation on cold surfaces and the resulting
corrosion. Such materials are porous, containing large number of
dormant air cells. Thermal insulation delivers the following
benefits:
Reduces over-all energy consumption.
Offers better process control by maintaining process
temperature.
Insulation material:
Insulation materials can also be classified into organic and
inorganic types.
Inorganic insulation is based on Siliceous/Aluminous/Calcium
materials in fibrous, granular or powder forms. Example: Mineral
wool, Calcium silicate etc.
Organic insulations are based on the hydrocarbon polymers,
which can be expanded to obtain high void structures. Example
Thermocol (Expanded Polystyrene) and Poly Urethane Foam (PUF).
Puff stands for poly Urethane Foam. Polyurethane (PUF) is used
extensively in applications of lower temperatures.
BRAZING:
Figure 10
Fundamentals:
In order to obtain high-quality brazed joints, parts must be closely
fitted, and the base metals must be exceptionally clean and free
of oxides. In most cases, joint clearances of 0.03 to 0.08 mm
(0.0012 to 0.0031 in) are recommended for the best capillary
action and joint strength. However, in some brazing operations it
is not uncommon to have joint clearances around 0.6 mm
(0.024 in). Cleanliness of the brazing surfaces is also important,
as any contamination can cause poor wetting (flow). The two
main methods for cleaning parts, prior to brazing, are chemical
cleaning and abrasive or mechanical cleaning. In the case of
mechanical cleaning, it is important to maintain the proper
surface roughness as wetting on a rough surface occurs much
more readily than on a smooth surface of the same geometry.
Torch brazing
Figure 11
ELECTRIC MOTOR
An electric motor is an electromechanical device that converts
electrical energy to mechanical energy.
Figure 12
Figure 13
Rotor
In an electric motor the moving part is the rotor which turns the
shaft to deliver the mechanical power. The rotor usually has
conductors laid into it which carry currents that interact with the
magnetic field of the stator to generate the forces that turn the
shaft. However, some rotors carry permanent magnets, and the
stator holds the conductors.
Stator
The stationary part is the stator, usually has either windings or
permanent magnets. The stator is the stationary part of the
Air gap
In between the rotor and stator is the air gap. The air gap has
important effects, and is generally as small as possible, as a large
gap has a strong negative effect on the performance of an electric
motor.
Windings
Windings are wires that are laid in coils, usually wrapped around a
laminated soft iron magnetic core so as to form magnetic poles
when energized with current.
Electric machines come in two basic magnet field pole
configurations: salient-pole machine and nonsalient-pole machine.
In the salient-pole machine the pole's magnetic field is produced
by a winding wound around the pole below the pole face. In
the nonsalient-pole, or distributed field, or round-rotor, machine,
the winding is distributed in pole face slots. A shaded-pole
motor has a winding around part of the pole that delays the phase
of the magnetic field for that pole.
Some motors have conductors which consist of thicker metal,
such as bars or sheets of metal, usually copper, although
sometimes aluminum is used. These are usually powered
by electromagnetic induction.
Commutator
Rotary Switch:
Figure 14
Figure 15
WELDING
Figure 16
Figure 17
CORE WIRE
A wire is a single, usually cylindrical, flexible strand or rod of
metal. Wires are used to bear mechanical loads or electricity and
Uses:
Wire has many uses. It forms the raw material of many
important manufacturers, such as the wire netting industry,
engineered springs, wire-cloth making and wire rope spinning, in
which it occupies a place analogous to a textile fiber. Wire-cloth of
all degrees of strength and fineness of mesh is used for sifting
and screening machinery, for draining paper pulp, for window
screens, and for many other purposes. Vast quantities
of aluminum, copper, nickel and steel wire are employed for
telephone and data cables, and as conductors in electric power
transmission, and heating. It is in no less demand for fencing, and
much is consumed in the construction of suspension bridges, and
cages, etc. In the manufacture of stringed musical instruments
and scientific instruments wire is again largely used. Carbon and
stainless spring steel wire have significant applications for
engineered springs for critical automotive or industrial
manufactured parts/components. Among its other sources of
consumption it is sufficient to mention pin and hairpin making,
the needle and fish-hook industries, nail, peg and rivet making,
and carding machinery; indeed there are few industries into which
it does not enter.
Not all metals and metallic alloys possess the physical properties
necessary to make useful wire. The metals must in the first place
be ductile and strong in tension, the quality on which the utility of
wire principally depends. The metals suitable for wire, possessing
almost equal ductility, are platinum, silver, iron, copper,
aluminium and gold; and it is only from these and certain of
their alloys with other metals, principally brass and bronze, that
wire is prepared (For a detailed discussion on copper wire, see
main article: Copper wire and cable.).
By careful treatment extremely thin wire can be produced. Special
purpose wire is however made from other metals
(e.g. tungsten wire for light bulb and vacuum tube filaments,
because of its high melting temperature). Copper wires are also
plated with other metals, such as tin, nickel, and silver to handle
different temperatures, provide lubrication, provide easier
stripping of rubber from copper.
INNOVATIONS:
Figure 18
Ice making machines in the field described have had their grids
disposed so that the rearward walls and also the outermost edges
of the grid are disposed in vertical planes. This has the
disadvantage that, during harvest cycle, the earlier melting of the
lower part of the ice assembly has little effect on how soon the ice
assembly can fall out of the grid because the entire ice assembly
or cake must come out at once. In other words, it comes out
whenever the uppermost portions have melted away from the
grid and are loose.
In such prior art machines, the entire ice assembly or cake cannot
become loosened until a much longer time period has passed for
defrosting than is necessary with the ice machine of my concept.
It is an objective of this invention to provide a grid, the outer
surfaces of which are included approximately with respect to the
vertical so that as the lower portions of the ice cake melt free of
the grid, then the weight of the lower portions, being pulled by
gravity, will have the effect of prying the upper portions loose
faster. Speed of harvest is important in ice machines.
In prior art ice machines, the water flowing down across the
outerside of a grid flows down across the upper wall of a
compartment in a vertical direction and must make a turn of
approximately 105 in order to cling to the underside of the upper
wall of a compartment as the water moves on its way to the back
end wall of a compartment. Because the water must turn at such
a sharp angle as a 105, the ice cubes made by such a machine of
the prior art are not as uniform as is desired.
However, by using my concept of having the water flow
downwardly across the outer surface of the upper wall of a
compartment at an inclination of 15 with respect to the vertical,
therefore, the amount of turn that the water must make in order
to flow back across the upper surface of a compartment on its
way to the rearward end wall of the compartment is only a 90
turn. Since water can make this 90 turn much more easily, the net
result is a desirably uniform ice cube.
It is not possible with prior art concepts to simply reduce the
amount of the angle of inclination of the upper wall of the
compartment with respect to the horizontal in order to cause
water not to need to flow around such a sharp angle because a
substantial inclination is already needed for the purpose of
desirable harvest and so that a ice cake is not held unduly long by
its grid.
And so, with this invention, even though the upper wall of an ice
compartment is slanted the same as in the prior art, yet the
amount of turning that the water must make in order to follow the
upper wall is a much less sharp turn by the amount of 15.
A particular disadvantage of the prior art machines of the kind
described has been that ice tends to build up below the outer tip
edges of the upper wall of each compartment. This build-up of ice
curtails the flow of water in the desired fashion back up along the
underside of the upper wall because the amount of turn the water
must make is even greater because of the ice build-up. This ice
WORKING PRINCIPLE:
Figure 19
from the metal pipes and the air around the refrigerant. This cools
the pipes and the attached metal ice tray.
The icemaker has a water pump, which draws water from
a collection sump and pours it over the chilled ice tray. As the
water flows over the tray, it gradually freezes, building up ice
cubes in the well of the tray. When you freeze water layer by layer
this way, it forms clear ice. When you freeze it all at once, as in
the home icemaker, you get cloudy ice .
After a set amount of time, the icemaker triggers a solenoid
valve connected to the heat-exchanging coils. Switching this
valve changes the path of the refrigerant. The compressor stops
forcing the heated gas from the compressor into the narrow
condenser; instead, it forces the gas into a wide bypass tube.
The hot gas is cycled back to the evaporator without condensing.
When you force this hot gas through the evaporator pipes, the
pipes and the ice tray heat up rapidly, which loosens the ice
cubes?
Typically, the individual cube cavities are slanted so the loosened
ice will slide out on their own, into a collection bin below. Some
systems have a cylinder piston that gives the tray a little shove,
knocking the cubes loose.
This sort of system is popular in restaurants and hotels because it
makes ice cubes with a standard shape and size. Other
businesses, such as grocery stores and scientific research firms,
need smaller ice flakes for packing perishable items
The ice cube making machine provides ice cube with very
less power consumption.
any other ice makers. We are forming ice cube with the help of
copper grid system which is kind of new in ice makers.
Our ice cube making machine is enable to
produce about 70 cubes which is quite high as compared to
freezer in domestic refrigerator.