Post on 30-Jul-2015
MCX & X1 cassette – Design and Optimization
Srikanth A
Innovation…… X1 Metallic cassette
Overview
• At the beginning of 2013, we set out to optimize our product line and
increase the packing efficiency of our commercial merchandizer
coolers.
• Increasing the packing efficiency within the same external dimensions
added 33% more load on the refrigeration system.
• The same cooling mechanism needed to be packaged in a volume
25% lower than any existing designs for similar applications.
• This new product line needed to be cheaper to manufacture while
meeting energy and performance requirements.
• The new coolers were to be manufactured in our Spartanburg facility
without excessive tooling and overheads.
Sku & Loading
Existing product line MCX 14Existing product line MCX 11
Cassette Envelop, Weight , Size
25% Smaller cassette envelop than
any existing cassette design.
Low height design – additional
usable space to customer with the
same external cooler height.
Better component layout and
improved volumetric efficiency.
Existing product lineX1 concept
X1 cassette concept
Components
• Most of the critical components had to be re-
designed from scratch due to the difference in
the layout from previous iterations.
• This included the heat exchangers, plastic and
sheet metal enclosures, refrigeration tubing,
structural members etc.
• For OEM components, the designs were done in
collaboration with external suppliers around the
world.
Air flow Optimization – Cassette & Cabin
• Due to the asymmetric nature of
the design, extensive design
studies were done before
finalizing critical components.
• Air deflectors and distributors
were integrated into structural
members and insulation modules
to avoid additional costs and
assembly parts.
Performance tests
MCX 14 R134aMCX 14 R290MCX 14 R744
• The system was designed to take in different refrigerants along
with their unique critical components with minimal changes.
• The below graphs show the same design working with three
different refrigerants with only the critical components
exchanged.
Shipping tests
Vibration Test Rotational Flat Drop Test Incline Impact Test
Free Fall Drop Test Compression Test
The new design proved to be
better at structural strength and
vibration handling while being
lighter than previous models.
Structure & Assembly
• Manufacturing processes were made simpler using sub-assemblies and simpler steps.
• This increased efficiency in the process flow helped us achieve 30% more yield in the same 8 hr shift as
compared to previous designs.
Product Optimization
Design features and innovations of X1 cassette
Better component layout and improved volume efficiency.
25% Smaller cassette envelop than any existing cassette design.
Improved sealing - better isolation of intake and outlet regions.
Electronic Control, for Energy Management & Defrost control.
Fast pull down and Best-in-class Energy performance that meet 2014 Energy Star requirements.
Service friendly design with easy access to serviceable components.
Complete modular design that enables interchangeable cassettes and eliminates cooler down time.
Light yet solid design that makes handling and maintenance easy.
Thank you