One of the principal U.S. HVAC manufacturers wanted to test the viability of converting its copper A/C components to aluminum. “The primary impetus for the proposed conversion was to avoid formicary corrosion of pipes,” says Steve Kersen, president of NVision. “Before greenlighting the conversion, the manufacturer wanted to assess the results of converting to aluminum to ensure that all the parts would meet manufacturing specifications. To accomplish this, the new aluminum parts needed to be precision-measured to a degree that was impossible with traditional measurement tools, such as calipers.
A CT scanner uses X-rays to produce 3D representations of external and internal components. Because the scanner’s accuracy depends on material density, aluminum is ideal for CT inspection, allowing for an accuracy of 0.0004 in.
“The HVAC company had done extensive research and understood the high level of accuracy that noncontact scanning brings to part measurement and inspection,” says Kersen. “They asked NVision to conduct first-article inspections, spot-checking parts from the first production run to confirm that they matched all the manufacturing tolerances.”
After scanning the pans with a HandHeld laser scanner, NVision engineers used the point clouds to create STL (stereolithography) models of each pan’s average dimensions, followed by the creation of 3D models. These were then converted to CREO, which is, along with SolidWorks, one of the five major 3D CAD platforms. The manufacturer used these models to make the desired modifications to its A/C drip pans.
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The near-essential nature of A/C makes HVAC a highly competitive industry. Improving efficiency, dependability, and affordability is essential to staying alive in the A/C market. To address these challenges, some A/C manufacturers are following the example of the automotive industry and converting their copper system components to aluminum.
Air conditioning is hotter than ever—hot as in demand, a must-have, a comfort most of us want, and, with higher-trending temperatures generating heat-related health issues, one that many can no longer live without.
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NVision engineers began scanning the converted A/C components, which required multiple noncontact scanners, including its HandHeld laser and CT scanners. The NVision team measured the system’s U-shaped coils, as well as its casings, soldering joints, and more.
“The scanning results confirmed that the new aluminum parts met all of the manufacturer’s specifications, so the company proceeded to convert its A/C parts from copper to aluminum,” says Kersen.
A/C parts scanned by NVision engineers included the system’s coils, casings, and soldering joints. (Note: Image is not from this project.)
The company was going to modify the drip pans on five of its A/C units but needed accurate CAD (computer-aided design) models of the current pans to serve as the starting point for the redesign. Drip pans play a vital role in the A/C process because they collect the condensate produced as evaporator coils come into contact with the surrounding warmer air of a home.
More than a century after Willis H. Carrier built the first modern electrical air conditioning unit, A/C systems are a fixture in most U.S. homes. According to the U.S. Energy Information Administration (EIA), nearly 90% of U.S. households in 2020 were using A/C. Internationally, the use of A/C is expected to rise during the next 30 years, with the world’s hottest regions producing much of the demand.
NVision, a leader in 3D noncontact optical scanning and engineering, has worked extensively with the HVAC (heating/ventilation/air conditioning) industry for more than 30 years and recently helped major HVAC manufacturers successfully:
• Evaluate and confirm the viability of converting copper system components to aluminum
• Reverse-engineer and improve the design of air conditioning (A/C) drip pans
Metrology
NVision’s 3D Scanning Helps HVAC Makers Keep Their Cool
Scanning plays a role in extending life span and improving design of A/C systems
When it comes to A/C components, aluminum offers several advantages over copper. Aluminum is the more abundant metal, thus less expensive. It’s also lighter, providing more options for system designers and engineers. But perhaps more significant, it’s impervious to formicary corrosion, which attacks copper and copper alloy tube walls, creating a network of microscopic tunnels culminating in pinholes and leaks in coils and piping. Formicary corrosion can cause premature equipment failure and reduce the longevity of system components.
