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