About Client:

Our client is one of the European HVAC System Manufacturers, specialized in production of heating, air conditioning, heat pumps and TMS (Thermal management system) systems for battery modules and for complete commercial and off-highway vehicles.

Client’s Need:

APA is working as an extended design team for the HVAC System design & Simulation and sourcing the HVAC components. APA can help your successful business in one-stop solutions.

Scope

The scope is to design the complete HVAC system involving right from the conceptual layout design to series design and validation through FEA, CFD simulation, 1D Heater core and system level simulation.

Design Challenges Involved:

  • ✔ Designing the HVAC system within the limited available space.
  • ✔ Selecting and sizing the appropriate components like Condenser, compressor, Evaporator, Expansion valve, Heater core, fans & Blowers…etc to increase the performance and the lifetime.
  • ✔ Optimizing the layout for the component placements within the space.
  • ✔ Designing the system with easily accessible for the service.
  • ✔ Designing the system to assemble the parts easily.
  • ✔ Considering the Acoustic and air distribution inside the cabin for the driver comfort.
  • ✔ Finalizing the housing for the series production such as metal or Plastic part.
  • ✔ Maintaining the existing provision for mounting the HVAC system in the cabin.
  • ✔ Designing the system with proper water drain.
  • ✔ Performing the FEA to validate the robust structure for the heavy-duty application.
  • ✔ Validating the system performance by using 1D & 3D simulation software’s.

Design Process:

The steps involved in the design process are:

  • ✔ Creating the Layout concept design as per the customer requirement.
  • ✔ Choosing the components and system simulation.
  • ✔ Designing the duct for the air distribution right from ambient to inside the cabin.
  • ✔ Creating the Prototype design and validating the performance.
  • ✔ Checking the Manufacturing and functional feasibility.
  • ✔ Selecting the material based on the applications.
  • ✔ Validating the FEA & CFD simulation.
  • ✔ Modifying the design as per the FEA & CFD result.
  • ✔ Preparing the DFM report for the HVAC unit.
  • ✔ Performing the mold flow analysis if required.
  • ✔ Finalizing the series design and completing the manufacturing drawings.

Value Delivered:

  • ✔ Increasing the performance of the HVAC system.
  • ✔ Supporting from single component up-to the driver comfort.
  • ✔ Cost effective and specialized in the HVAC domain.

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