DESIGN AND DEVELOPMENT OF A LOW

COST AIR COOLER

V. S. Shammy, *Srinivasa, H. S. Lohit
Department of Design,
M. S. Ramaiah School of Advanced Studies, Bangalore 560 058
*Contact author e-mail: [email protected]

Abstract
Air Cooler is one of the appliances that keeping the atmosphere cold. The basic concept of water cooling is to find a
medium that can handle and transport heat more efficiently than air. Water has a very good ability to retain heat, in the
mean time stay in a liquid form. This project is to design and develop a low cost air cooler which can be used in houses
and office
Secondary researches have been carried out to collect data regarding the present design of air cooler. Various types
of air cooler available in the market have been identified. Ethnographic study and questionnaire survey has been done for
understanding the user product interface. The issues related to current air cooler have been found out. QFD and PDS are
prepared based on the data collected.
Concepts are generated according to the PDS prepared. Concepts of a air cooler with additional of a separate fan to
spread the water in to the air for cooling. Air cooler with a separate fan is selected as the final concept through weighted
ranking method. Colours are chosen according to its applications to make it aesthetically good. A working model of the
final concept is made using wood.
Keywords: Blower, Air cooler, Exhaust Fan, Water Pump, Blower Motor
Abbreviations earlier form of air cooling, the wind catcher, was
QFD Quality Function Deployment invented in Persia (Iran) thousands of years ago in the
PDS Product Design Specification form of wind shafts on the roof, which caught the wind,
passed it over subterranean water in aquanaut and
discharged the cooled air into the building. Nowadays
1. INTRODUCTION Iranians have changed the wind catcher into an
evaporative cooler and use it widely. There are 9 million
Air Cooler is one of the appliances that
evaporative coolers in central Iran, and in just the first
keeping the atmosphere cold. The basic idea of water
two months of year 1385 in the Persian/Iranian calendar
cooling is to find a medium that can handle and
(April–May 2006) 130,000 evaporative coolers were
transport heat more efficiently than air. Water has a
sold in Iran [1].
good ability to retain heat, in the mean time stay in a
liquid form. As long as can circulate cool water to the
hot parts. Water can cool it down more efficiently than
air.
Method of Air cooling is a dessipating heat.
which works by making the object to be cooled have a
larger surface area or have an increased flow of air
.Evaporative cooling is based on a physical
phenomenon in which evaporation of a liquid into
surrounding air cools an object or a liquid in contact
with it. As the liquid turns to a gas, the phase change
absorbs heat. Latent heat of evaporation. Water is an
excellent coolant because it is plentiful, non-toxic, and
evaporates easily in most climates. Fig 1.Air Cooler [5]
The concept, was refined, became the The evaporative cooler was the subject of
evaporative coolers which will provide a low-cost, numerous US patents in the 20th century; many of these,
alternative to refrigerated air conditioning. Fresh outside starting in 1906, suggested or assumed the use of
air is pulled through moist pads where it is cooled by excelsior (wood wool) pads as the elements to bring a
evaporation and circulated through a house or building large volume of water in contact with moving air to
by a large blower. Air Cooler is one of the appliances allow evaporation to occur.
that keeping the atmosphere cold.
A typical design, as shown in a 1945 patent,
includes a water reservoir (usually with level controlled
1.1 History of air cooler by a float valve), a pump to circulate water over the
Civilizations throughout the ages have found excelsior pads and a squirrel-cage fan to draw air
ingenious ways to combat the heat in their region. An through the pads and into the house. This design and

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this material remain dominant in evaporative coolers in  Unlike the other kinds of personalized air
the American Southwest, where they are also used to coolers, you can install these portable swamp
increase humidity. In the United States, the use of the coolers anywhere and anytime.
term swamp cooler may be due to the odor of algae
produced by early units.

Fig. 3 Portable Swamp Coolers [2]

2.3 Window or Wall Mounted Air Coolers
Fig 2. Schematic diagram of an Iranian wind catcher The window or wall mounted air coolers
[4] are evaporative coolers in which the evaporative cooling
happens more effectively. The blower is even more
powerful as compared to the rest of the swamp coolers.
2 TYPES OF AIR COOLER The other advantages of these evaporative coolers are
the large tank capacity, easy cleaning options and lower
Evaporative air coolers also called swamp noise levels.
coolers is one of the most popular types of air coolers in
India. Most of the air cooler dealers recommend this
type of air coolers for users. The cost effectiveness of
the evaporative air coolers makes it easy for common
man in India to fight the heat during the summer. The
major advantages of evaporative air coolers are easy
installation, easy maintenance. There are various types
of evaporative air coolers. Here are a few examples and
their features.
2.1 Direct and Indirect Evaporative Coolers
These are evaporative air coolers in which the
evaporative cooling of the air is carried out directly with
the help of pads soaked in water. They are the most
efficient and also simple in design .The indirect
evaporative air coolers are also same as the direct ones Fig. 4 Window or Wall Mounted Air Coolers [6]
but the only difference is that the latter one is a closed 2.4 Add-on Evaporative Coolers
circuit system
The evaporative coolers are best for the
areas that experience a humid climate. It consists of a
refrigerated cooling system in which the evaporative
cooling is effective. The major advantage of using this
type of air coolers is that the cooling costs are reduced.
The quality of the air indoors is also better. There is also
an alternate cooling system that can take over the
evaporative cooling if the main system breaks down.
The evaporative or the swamp coolers are greatly
beneficial in many ways as compared to the other types
of air coolers. You can find the one that suits you best
and install it at home or office.
Fig. 3 Direct and Indirect Evaporative Coolers [2]
2.2 Portable Swamp Coolers
3. PRODUCT STUDY
 This is the most popular type of evaporative
air coolers in India. Most evaporative air Product study has been conducted to
coolers are of portable type. understand the product in detail. Energy efficient
evaporative air coolers help meet the needs of today's
 The evaporative cooling is done only for a world. Evaporative air coolers are engineered to provide
small area and can work best for moderate the most natural way of creating cool air with
climates. significant savings on energy cost compared to using air

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conditioners. Coolers are widely range of products offer A large fan draws air through the pads,
options for indoor as well as outdoor cooling. where evaporation drops the temperature approximately
20 degrees. The fan then blows this cooled air into the
Evaporative air coolers offer an energy house. Small units can be installed in a window,
efficient option for cooling your home or workplace in blowing cooled air directly into a room. Larger units can
the most natural way. Evaporative air coolers do not
blow air into a central location, or the air can travel
require power hungry components like compressors. through ductwork to individual rooms.
The low power consumption translates into significant
savings on energy bills compared to using air Normal air conditioning is a closed system,
conditioners. taking air from inside a house and recycling it. For air
conditioning to function properly, doors and windows
should be closed. Evaporative cooling, however, takes
air from outside the house. For evaporative cooling to
work properly, the cooled outside air must be allowed to
escape. By choosing which doors or windows in your
home you leave open, we can to help direct the flow of
cooled air to areas where it is needed (Figure 7).
3.2 Cooling Pad
Most of the cooling pads are made of either
aspen fibre or cellulose. A cellulose pad typically needs
Fig. 5 Add-on Evaporative Coolers [5] more air and water flow than does an aspen pad. More
evaporation can take place through a 6-inch pad than a
4-inch pad. Wide Range of Evaporative Cooling Pads is
available in the market. Evaporative Cooling is the
process in which air is cooled by using the heat in the
air to evaporate the water from an adjacent surface. A
temperature reduction of 10 to 200C (50-68 degree F)
can be achieved by passing the hot fresh air through the
wetted pads.
Eco Cool Evaporative Cooling Pads that
were manufactured using special cellulose material. Top
quality material is useful in achieving high cooling
efficiency and ensuring degradation resistance. The
Fig. 6 Product Study pads are known for their exceptional wetting properties
3.1 Working Principle and airflow to achieve maximum

An evaporative cooler is essentially a large

fan with water-moistened pads in front of it. The fan
draws warm outside air through the pads and blows the
now-cooled air throughout the house. The pads can be
made of wood shavings, wood from aspen trees is a
traditional choice - or other materials that absorb and
hold moisture while resisting mildew. Aspen wood
pads, also called excelsior, need to be replaced every
season or two, and generally cost $20 to $40 for a set.
Small distribution lines supply water to the top of the
pads. Water soaks the pads and, thanks to gravity, Fig. 8 Cooling Pad [6]
trickles through them to collect in a sump at the bottom 3.3 Blower motor
of the cooler. A small re-circulating water pump sends
the collected water back to the top of the pads. Forced air is passed through heating or
cooling elements and circulated to the desired locations.
Blower motors provide that air movement. A blower
motor is a term that actually describes a combined unit--
an electrical motor and a fan. Most often, a centrifugal
fan, which looks like a 6- to 10-inch hamster cage, is
used. These fans--mounted in "housings"--are used to
force hot or cold air through ducting and vents.
These blower motors are compact in
structure and elegant in design, and highly demanded
due to their minimum energy consumption and
requirement of low maintenance. These Cooler Motors
are commonly installed in a variety of coolers.

Fig. 7 Working Principle [2]

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 coolers available in the market. There are lot of
companies who manufacture Air Cooler. The following
are some of leading companies manufacturing Air
Cooler.

4. DESIGN CONSIDERATION
 Giving more importance for the working
mechanism of cooling
Fig. 9 Blower motor [6]  Try to avoid the cooling pad
3.4 Blower Fan  Material used for the manufacture should be
one among wood, aluminum, steel or
Air cooling systems in Cooler most fiberglass.
commonly rely on forced air. Forced air is passed
through cooling elements and circulated to the desired  It should be portable and easy to use.
locations. Blower provides this air movement.  It should be easy to maintenance and for
assembly also
 Safety locks should be there to avoid
accidental movements.

Fig. 10 Blower Fan

Fan efficiency is the ratio between the
power transferred to the air stream and the power
delivered by the motor to the fan. The power of the
airflow is the product of the pressure and the flow,
corrected for unit consistency. Another term for
efficiency that is often used with fans is static
efficiency, which uses static pressure instead of total
pressure in estimating the efficiency. When evaluating
fan performance, it is important to know which Fig. 12 Market Study
efficiency term is being used. The fan efficiency
depends on the type of fan and impeller. As the flow 4.1 QFD Chart
rate increases, the efficiency increases to certain height
(Figure 10).
3.5 Re-circulating water pump
A re-circulating pump draws water from the
basin under the pumps it through a system of sprays (or
water distributors) from which the water is directed onto
the tube surfaces. Air is induced or forced over the
wetted tube surfaces and through the rain of water
droplets. By intimate contact of the air with the wetted
tube surfaces and water droplets evaporation of part of
the water occurs thus cooling both the tube surfaces and
the water simultaneously. In this manner evaporation is
used to increase the rate of heat transfer from the tubes
to the air.

Fig. 11 Re-circulating water pump [6]

3.6 Market Study
Market study has been conducted to know
details regarding the current domestic air cooler
available in the market. There are wide varieties of Air

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4.2 Product Design Specification (PDS) area. One water out let tube is connected with
circulating pump. Blower is shown at the top of the
cooler connected with a motor and a fan with motor is
provided beneath the blower. In this concept fan is fixed
just behind the blower. The working principle for this
concept is once the water circulating pump is started the
water begins to flow through the water outlet tube, the
end of this tube is fixed behind the fan as a result the
water flows at high pressure through the water out let
tube and collapse with leaf of the running fan. As a
result the water begins to mix with the air and the air
inside the air cooler becomes cool. This cooled air will
flow out of the air cooler with the help of the blower.
5.3 Concept-3
In this concept copper tube is added. The
garbage can is filled with ice water, which is then fed by
gravity through the copper tubing coiled along the back
of the fan. The hot air passing through the tubing warms
the cold water, cooling the air. Waste warm water is
then pumped outside. The system will cool an average
room to a comfortable level in approximately 15-20
minutes. Depending on flow rate, a full bucket of water
5. CONCEPT GENERATION will last approximately 1-3 hours. Once the water runs
out, the house has cooled off enough that the fan alone
5.1 Concept-1 provides sufficient cooling.

Fig. 13 Concept-1 Fig. 14 Concept – 2

In this concept the cooling mechanism is
entirely different from the current air coolers. For
storing water a water storage area is provided at the
bottom of the cooler. Water circulating pump is
provided inside the water storage area. One water out let
tube is connected with circulating pump .Blower is
shown at the top of the cooler connected with a motor
and an exhaustion fan is provided beneath the blower.
The working principle for this concept is
once the water circulating pump is started the water
begins to flow through the water outlet tube; the end of
this tube is fixed behind the fan as a result the water
flows at high pressure through the water out let tube and
collapse with leaf of the running fan. As a result the
water begins to mix with the air and the air inside the air
cooler becomes cool. This cooled air will flow out of Fig. 15 Concept-3
the air cooler with the help of the blower. The main factor affecting the performance
5.2 Concept – 2 is the temperature of incoming water. Cool water will
work, but ice water will result in a cooler room, quicker.
The working principle of this concept is We can attach the tubing to the front of the fan as well.
same as in the first concept. In this fan is provided in the This will increase performance, just make sure that fan
back of the blower. For storing water a water storage can handle the additional torque of tubing full of water
area is provided at the bottom of the cooler. Water attached to the front.
circulating pump is provided inside the water storage

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 begins to flow through the water outlet tube; the end of
this tube is fixed behind the fan as a result the water
5.4 Concept-4 flows at high pressure through the water out let tube and
An important point is to understand that the collapse with leaf of the running fan. As a result the
temperature of the water does not have any real effect water begins to mix with the air and the air inside the air
on the cooling produced by the evaporation process.. cooler becomes cool. This cooled air will flow out of
Imagine being sprayed with water at either of those the air cooler with the help of the blower.
temperatures on a hot day, as it evaporated off your skin
you would feel much cooler.
6. WORKING MODEL

Fig. 16 Concept-4
The construction of an evaporative cooler is
such that filter pads are located at the back or sides (or
both) of the machine and the surrounding warm air is
sucked into the machine through the pads. The pads are
kept damp either by water being pumped from an
internal reservoir around and through the pads or from
an external water source. As the outside warm air moves
across the wet pad the water is evaporated removing the
heat from the air therefore when that air exits the
machine it is in a cooler state than when it entered the
machine.
5.5 Concept-5

Fig. 18 Working Model

7. VALIDATION

Fig. 17 Concept-5
The working principle of this concept is
same as the second concept. In this fan is provided in
the bottom side of the blower. For storing water a water
storage area is provided at the bottom of the cooler.
Water circulating pump is provided inside the water
storage area. One water out let tube is connected with Fig. 19 Validation
circulating pump .Blower is shown at the top of the Validation of the Working Model has been carried out
cooler connected with a motor and a fan with motor is with the end users. The model has been taken various
provided beneath the blower. In this concept fan is fixed houses to get the feedbacks from the users (Figure 19).
just behind the blower.
The working principle for this concept is
once the water circulating pump is started the water

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8. SUMMARY AND CONCLUSION
The whole work of the project can be summarized as
follows.
 Secondary research method like literature
review was conducted by referring
magazines, journals, manuals,
publications, websites etc.
 Data collection was done by product
study, user study and market study through
ethnography, interviews, images, videos
etc at houses, shops and manufacturing
units of air cooler
 QFD was prepared using the data collected
during the research and the needs
identified.
 Then the target PDS is arrived based on
the QFD
 Concepts were generated using mind
mapping according to the PDS
 The concepts are then digitalized using
3D modelling software Unigraphics NX6
and rendered using Key shot 2.
 A final concept was then selected from
those concepts using weighted ranking
method
 Detailed drawing of the concept was
prepared.
 Working model of the final concept is
made in Wood.
A low cost air cooler for residential use
has been made to meet the requirements of the
customers. All the product design specifications
arrived after research has been fulfilled at the end
of this project. The project gave an excellent
opportunity to go through the end to end life cycle
of a product.

9. REFERENCES
[1] McClellan, C. H., Evaporative cooling
Application Handbook, Sun Manufacturing,
Texas, 1989.
[2] Watt J. R., Evaporative Air-conditioning Hand
book, Second Edition, 1986
[3] Arora S. C., Domkundwar S., A course in
refrigeration and air conditioning, 3rd edition
1985.
[4] Brown. W. K, Application of Evoporative
Cooling Concept to Save Energy while improving
the indore Environment, ASAHRE Transaction 97
pt2, 2013.

TECH Journal
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