Technically Complex

Product
Room Heating System

Sahaj Ghose
8050221064

Guides: Anirudh Nattu

Niren Paresi
Introduction

We were required to develop a design brief and redesign a product which was already in the market.
The product that I had taken was a room heating device.

Room heating is an ancient concept, The first traces of a proper system employed were found as
early as 5000 B.C. in Korea and China.

The modern heaters employ a variety of technologies and materials to increase the efficiency but
there are still areas in which intervention of design research and redesign are required.
Methodology Followed
Product Research Market Survey User Research
Types of Heaters
Heating Techniques used
around the world
Product History

Concept Generation Generation of Analysis of a Heater

Design Brief
Working Based Concepts Factors effecting heating
Form Based Concepts
Factors effecting
Thermal Comfort

Material and Part

Analysis of a Heater
Product Research
Types of Heater

Space
Heating

Surface
Heating
Product Research
Space Heating

Radiative Heating: This heat directly warms people and objects in the
room, rather than warming the air. This style of heater is particularly useful in areas
which unheated air flows through.

Convection Heating: In a convection heater, the heating element heats the

air next to it by convection. Hot air rises up, cool air takes its place. This sets up a
constant current of hot air that leaves the appliance, heating the surrounding space.

Fan Heater: A fan heater, is a type of convection heater that includes

an electric fan to increase the airflow. This reduces the thermal resistance between
the heating element and the surroundings faster than passive convection, allowing
faster transfer of heat
Product Research
Surface Heating

Oil heaters consist of metal columns with hollow cavities, inside which oil
flows freely around the heater. A heating element at the base of the heater heats up
the oil, which then flows around the cavities of the heater by convection. The oil acts
as a heat reservoir or buffer, with a relatively high specific heat capacity
Product Research
Surface Heating

Hydronic Heating System •Hydronic systems use water or a mix of

water and anti-freeze such as propylene glycolas. The heat transfer fluid in a
"closed loop" that is re-circulated between the floor and the boiler.

Electrical Underfloor Heating: Electric systems employ non-

corrosive, flexible heating elements like cables, pre-formed cable mats, bronze
mesh, and carbon films. Due to their low profile they can be installed in a thermal
mass or directly under floor finishes.
Product Research
Heating Techniques Arround
the World

Ondol An Ondol, in Korean traditional architecture, is under floor heating which

uses direct heat transfer from wood smoke to the underside of a thick masonry
floor.
High exhaust vents jutting sideways

The main components of Ondol are

Exhaust vents as sideways oriented pipes
a firebox/ stove accessible from an
-
adjoining room, a raised floor
underlain by horizontal smoke
passages, and a vertical,
freestanding chimney on the
opposite exterior providing a draft
Chimney for fumes
Product Research
Heating Techniques Arround
the World

European Heating System: a centralized heating

system had developed in Europe, providing warmth to the
whole interior of a building (or portion of a building)
from one point to multiple rooms.

Central Heating Unit

The difference between the modern central heating system and the heating style of the
Europeans was that the Europeans used a central heating unit like a boiler which
transmitted the heat through pipes through out the rooms. While in the modern
heating system there heat is produced all long the heating coils underlaid in the floor.
 Product History

During this period there The development of Discovery of several trade Development in
was a slow development proper cities result in the routes between west and technology also evolves
of heating systems, and building of Hypocausts by east result in the west the heating system,
people mostly used the Greeks and the adopting several heating electric heating introduces
central heating places and development of Ondols in meathods into there own new room heaters. In
chimneys to transfer the Asia building construction. 1980 standards for floor
heat later radiant heating is heating are developed &
also adopted research on thermal
comfort is also initiated
5000 B.C - 500 B.C 500 A.D - 1500 A.D 1700 A.D - 1900 A.D 1900 A.D - 2000 A.d
Initial Design Brief
After the initial research on types of heaters and its different application and method of usage I had
come up with the initial design brief on basis of which I would be narrowing down my research and
coming up with a more specific design brief.

To design a fan based convection room/space heater

which runs on conventional or non conventional energy
supply or both. The heater could be wall mounted or a
table top heater. It should be safe and cost efficient.
Market Survey
Heater Manufacturers & Market Share
Morphy Richards
?
Morphy Richrds

Bajaj Electricals
?

?
USHA Bajaj Electricals
Usha Electricals
?

? Kenwood
Kenwood
?
Market Survey
Bajaj Electricals
Technical Specifications
Model Bajaj Majesty RX10
Power Supply 230 Volts, 50Hz AC
Wattage 2000 Watts

Technical Specifications
Model Bajaj Majesty RX10
Power Supply 230 Volts, 50Hz AC
Wattage 1000/2000 Watts

Technical Specifications
Model Usha Heat Convector 423
Power Supply 230 Volts, 50Hz AC
Wattage 665/1330/2000 Watts
Market Survey
Bajaj Electricals
Technical Specifications
Model Morphy Richard Heat Convector 5000
Power Supply 230 Volts, 50Hz AC
Wattage 1000W/2000W

Technical Specifications
Model Morphy Richards Portable Heaters Tipsy
Power Supply 230 Volts, 50Hz AC
Wattage 1000/2000 Watts

Technical Specifications
Model Kenwood Halogen Heater - KHH1230
Power Supply 230 Volts, 50Hz AC
Wattage 400/800/1200W
Market Survey
Bajaj Electricals
A general Catalogue of Bajaj
Heaters, in different price
ranges. This gives a general idea
about the price range and the
levels of efficiency in
comparison to the price range.
This also acts as a point of
references for understanding the
technology being used and the
scope of improvement and
development in various fields.
Heater Analysis
Heater Power
2000w, 230v ac< 50hz.

In two different types-

(a) with thermal cut-out only.

(b) with adjustable thermostat and thermal cut-out

Material used
Body: Mild Steel Body with powder coating and aluminum front plate.

Heating element: an alloy of nickel and chromium.

Heater Analysis
List of components found in the heater: The Fan consists of longitudinal
blades which draw the cold air
Fan
? from the vent and blows it out To
the heating coil which again
blows out hot air
Heating Coil
?

Thermostat
?
Direction of motion is clockwise
Motor
?

Metal Strip to circulate the heat flow

?

Temperature control buttons

?

An electric motor runs the

Fan for pumping the air out.
Heater Analysis
List of components found in the heater:

Fan
?

Heating Coil
? Heating coils attached
with insulating strips
Thermostat
?

Motor
?

Metal Strip to circulate the heat flow

?

Temperature control buttons

?

Heating coil attached to

the Thermostat
Heater Analysis
List of components found in the heater:

Fan
?

Heating Coil
?

Thermostat
?
Thermostat is being exposed to the heating coil
Motor
? though the gap. And is attached to the auto cutoff
switch for the heater.
Metal Strip to circulate the heat flow
?

Temperature control buttons

?
Heater Analysis
List of components found in the heater:

Fan
?

Heating Coil
?

Thermostat
?

Motor
?
Attachment of the motor to the fan
Metal Strip to circulate the heat flow
?
AC motor
Temperature control buttons
? 18 Watt/220V

1000 RPM
Heater Analysis
List of components found in the heater:

Fan
?

Heating Coil
?

Thermostat
? Metallic Strip directing the flow
of air towards the heater
Motor
?

Metal Strip to circulate the heat flow

?

Temperature control buttons

?
Heater Analysis
Working of the Electrical Circuit
H M ON

When the heater is switched ON to blow

air only
- ive is connected to Fan
- ive is connected to Indicator
+ ive is connected to ON switch
This connection creates a potential difference (V)
between the fan, indicator and the ON switch thus
making the fan rotate and indicator light up.
Heater Analysis
Working of the Electrical Circuit
H M ON

When the Medium (M) heating is switched on

This connection creates a potential
- ive is connected to heater through the Thermostat (T)
difference (V) between the heater and
the M switch making the heater coil
+ ive is connected to M
produce heat
In case of overheating - (- ive)connection to heater through T is
disconnected
Heater Analysis
Working of the Electrical Circuit
H M ON

When the High (H) heating is switched on

This connection creates a bigger
- ive is connected to heater through the Thermostat (T)
potential difference (V) between the
heater and the H & M switch thus
+ ive is connected to H & M
making the heater produce more heat
In case of overheating - (- ive)connection to heater through T is
disconnected
Heater Analysis
Placement of Parts
Motor

Thermostat
Front Pannel

Switch Control
Fan
Airflow direction
Motor

Circuit Distributor

Base Plate
Factors Affecting Heating
Loss of Heat

Conduction: heat conduction is the transfer of thermal energy between

regions of matter due to a temperature gradient. Heat spontaneously flows from a
region of higher temperature to a region of lower temperature, and reduces
temperature differences over time, approaching thermal equilibrium

Transfer of heat (along the arrow)

from hot region to the cold region

Convection: is the movement of molecules

within fluids (i.e. liquids, gases). It cannot take place in solids,
since neither bulk current flows nor significant diffusion can
Flow of heated molecules in air and liquid take place in solids.
and liquid
Factors Affecting Heating
Loss of Heat

Radiation: Thermal radiation is considered one of the fundamental

methods of heat transfer, although it does not involve the transport of heat which
is in thermodynamics the current of thermal energy across a system boundary
Factors Affecting Heating
Methods of Electric Heating
Tubular Fluid Based Heating : long low wattage strip heaters are strapped to pipes
carrying viscous material like tar

The benefit of generating heat even after the heater has been switched off, due to the
heated coil.

The detriment of using this type of heating is that it will take a long time to heat the
heating fluid and increase the price of the heater.
Thermostat

Heating Fluid

Holding Strip
Insulation

Stip Heater

Cross section of Tubular Heater

Factors Affecting Heating
Methods of Electric Heating
Oil Filled Radiators: These heaters operate by warming up a special
heat-conserving oil inside the heater. Then it circulates the oil throughout the coils
and fins of the radiator to heat them. Those coils and fins radiate the heat into the
rest of the room through convection.

The benefit of using an oil filled radiator heater is for safety and a
silent operation as there are no moving parts like a fan, in a convection heater.

The Detriment of oil filled radiators is that it is very expensive to buy

The Oil needs to be changed in a regular interval

The running costs are high as it takes a longer time to heat the oil thus
to generate heat.
Factors Affecting Heating
Methods of Electric Heating
Ceramic Heaters: Ceramic heaters are space heaters that generate heat by passing electricity through heating
wires embedded in ceramic plates. The plates heat aluminium baffles, and a fan blowing across the baffles heats the air

Ceramic heater’s are cheap to manufacture thus low cost for the buyer as well.

As the heating coil is directly in contact with ceramic material it transfers its energy, thus life of the coil is
also extended.

The ceramic in which the wire is embedded is electrically non-conducting and has a very good absorption
and emission characteristics which allow it to radiate or emit heat, increasing its efficiency.

The Ceramic heaters are unsafe for use as the coils are usually exposed

The running costs depends on the room size, bigger the room longer it takes to heat
 Factors Affecting Heating
Size of the room and insulation
Measure the length and width of the room to determine total square
footage and multiply according to the insulation in the room.

Select your level of insulation

Poor - Little insulation (Older homes) - 12.5 watts per foot
Average Wooden floors and low ceiling- 10 watts per square foot

A room that is 10 feet wide by 13 feet wide with an 8 foot ceiling and
Average insulations =
10 x 13 = 130 then 130 x 10 watts/per square foot = 1300 Watts
Factors Affecting Heating
Type of Fan Blades
The type of blade increases or decreases the flow of air into
the heating unit. the type of blades for producing thrust are
Tube Axial: this has greater pressure rise and
is usually used ducting and produce high
noise.

Axial fans
Centrifugal (radial) fans
Axial Fan: are those in which
the air flows axially through the
blades.

Propeller fans
Tube axial fans

Propeller Fan: has very little pressure rise

through it and gives large discharge.
Factors Affecting Heating
Type of Fan Blades
A Centrifugal fan is a mechanical device for moving air or other gases. It has a fan wheel composed
of a number of fan blades, or ribs, mounted around a hub

Forward-curved blades
The blades in this type of fan are fixed and the tips are
tilled to the direction of rotation, volume of air delivered is the
highest

Backward-curved blades
The tips of blade is curved backward, opposite to the
direction of rotation this results in medium specific speed
applications-- high pressure, medium flow applications.

Straight Blades
The blades have no curvature and produce greater noise
the fans have higher speeds and low volumes of air are
transferred.
Factors Affecting Heating
Thermostat
A thermostat is a device for regulating the temperature of a
system so that the system's temperature is maintained near a
desired setpoint temperature.

Bimetallic mechanical or electrical sensors

?
Expanding wax pellets
?
Electronic thermistors
?

. Bimetallic mechanical sensor: These sense the air

temperature using the differential expansion of two metals to
actuate an on/off switch. Typically the central system would be
switched on when the temperature drops below the set point on
the thermostat, and switched off when it rises above
Factors Affecting Heating
Thermostat
. Expanding Wax Pellets: This type of thermostat operates mechanically. It makes use of
a wax pellet inside a sealed chamber. The wax is solid at low temperatures but as the
engine heats up the wax melts and expands. The sealed chamber has an expansion
provision that operates a rod which opens a valve when the operating temperature is
exceeded.

Electronic thermistors: A thermistor is a type of resistor whose resistance

varies significantly with temperature, more so than in standard resistors.
The material used in a thermistor is generally a ceramic or polymer,
User Survey
User 1
Users Name: SK01D
Occupation: Shop Keeper
Age : 35

The Seller works in an electronics shop in

M.G road, Pune he has been working there
for 6 years. The shop mostly deals in
ceramic and convection heaters. They deal
with mostly Bajaj and Morphy Richards
company.
. The shop usually sells 10 to 15 units during
winters. People usually prefer to buy the
convection heaters despite being more
expensive than ceramic heaters. The customers
usually require it for there bedrooms with
average room size being 12ft X 15ft
User Survey
User 2
Users Name: AH02U
Occupation: Student
Age : 21
The user is a student in
his final year. He is a
Kashmiri but stays in
Chandhigar. Both being a
cold place I decided to
record his experience
with cold weather.
.Kashmiri generally use a earthen pot
covered with a type of straw with burning
coal inside, and place it under there
clothing's called phiran. They are known as
Kangri.
In the older houses they have a under floor
heating system. They have a boiler in there
basement and it supplies hot steam to
through out the floor of the house by mean
of under floor pipes the presence of carpets
also helps in keeping the floor warm.
User Survey
User 3
Uses heater for around 5
Users Name: SS03U months. Even in winter seasons
Occupation: Accountant General’s office, Gantok they use heater when needed as
Age : 52 it generates a lot of electricity
bill.
They prefer using clothing
and personal insulation
including electric blankets
The user was born and
and sweaters for keeping
brought up in Darjeeling and is
warm. Earlier they used the
now settled in Gantok. He has
ceramic insulated coil heater,
a family of 4. They have an 3
but maintenance became a
room apartment in Gantok
major problem.
with wooden flooring. As
The heater he currently uses is
Gantok is a hill station they
a Bajaj Majesty RH 9F room
have mostly cold weather.
heater and places it in the
bedroom or the living room.
User Survey
User 4
Users Name: MR04U
Occupation: Student
Age : 20
User was born and brought up
in Dera Doon. She stays with
her parents and a brother. The
architechture of there house is
from the British era and has an
central heating system.
They use the central heating system for 3 to 4
months of winters and sometimes during the
rainy season. There is a central chimney which
passes through all the floors of the house (3
floored building). But due to the smoke and the
dust produced there are certain inherit problems
regarding the cleaning and maintenance of the
heating system. In the more traditional houses
people use the heat produced form the cooking
area to heat the house. There are pipes which run
through the whole house which carry the boiled
water or air heating the house through
conduction
User Survey
User 5
Users Name: NK05U
Occupation: Professor
Age : 37
The user is a professor in a
college and stays in Pune. He
recently had a new born in his
house and had bought a heater
to keep the room of the baby
warm during the winters
The user has a Bajaj
convention heater model. He
required the heater to keep the
babies room warm during the
winter. The main problem
which he used to face was to
keep the room from getting
overheated, he needed to come
in and check wether the room
got too hot or not. He also had
problems of cleaning the heater
as dust settles in the inner vent
of the heater.
 User Survey
Conclusion
There should be a
temperature control
Easy to Manufacture
Prevent covering of
the vents
Safety Cost Efficient
Safety from heater over Should be priced less
heating to attract user/buyer

Safe for Children

Easy to
Increase the heating efficiency Dismantle/Assemble

Easy to run and maintain

Functionality Clealiness
Easy to Clean
Design Primarily for heating, secondary
functions should be avoided
User Desirables
Multi Usability,
? using the heater for cooking or drying clothes.
?

Using the
? heat generated from cooking to heat the room/rooms.
?

Incorporate
? an air humidifier into the heater to help increase the room humidity.
?

Creating
? a personal heating device, which would help in heating up a particular body part.
?

Be easy to
? clean and maintain for a longer time.

Making the
? design more user friendly, users are usually reluctant to use heaters.
?

Keep in mind
? that the air vents should not be blocked which would cause major electrical problems
?

.The heater
? should be easy to Disassemble and Assemble, for cleaning purpose
?

The safety
? of the heater is very important. There should not be any part of the heating element which might
be exposed.
Design Brief

To design a convection fan room/space heater keeping in mind cost effective, safety, efficiency,
and easy cleaning. The heater should perform the primary function of heating well, and secondary
functions should be looked there after.

Target Consumers: Middle Class to Upper Middle Class / Hotels / Lobbies

Mood Board
Simple
Safe

Efficient Cheap
Warmth

Reliable
Concept Sketches-1

Keeping in mind the design of the

fan in the dissected heater I had
decided to construct a simple fan
which would radiate heat
generated by the central heater.
Concept Sketches-2
These designs were made
considering personal
heating as an option where
in the user wears these
devices whenever required
and he could carry this
around anywhere he moves.
The inspiration was taken
from Kashmiri Kangri.

Taking into consideration the

concept of distributed heating I
had designed this heater with
plate on top which would help
to distribute the heat that is
generated. Thus improving the
efficiency.
Concept Sketches-3
The cold air being heavy is being sucked in from the
bottom using ventilation fans and is then directed onto
the heater. The cold air is then pushed onto the heater
where it is constricted and heated using a nichrome
heater. Due to the absorption of heat the air becomes
light
and is blown out from the top.

In this design I have changed the

internal flow of air through the heater
so that it is concentrated onto a single
area where the heating is maximum
and then is let out from small vents on
top to be transferred into the
atmosphere.
Concept Sketches-4
I had tried out diffrent form
variations of the same concept of
collected air heating, in some of
the concepts an humidifier has
also been added.
Concept Sketches-5

Using the concept of tubular heating,

illustrated above I had developed several
forms for this type of a heater.
Illustrated Concepts-1
Upper Blade Holder

This heater uses a central

heating unit arround
Heating Coil which there are 4 blades
of a fan rotating
Ceramic Casing inclockwise direction
which push out the air Top View
which is heated in the
Fan Blades center.
The motor is housed
in the base of the heater.
Lower Blade Holder The heater is electrically
powered.

Base

No safety as the blades are exposed

May not cover a large area of heating
Exposed heating coil when blades are stationary
Simple table top design
The Design of the blade is such that it would
be pushing out air which is heated in the center
by the heating coil. Thus effectively
distributing the heat around the user
 Illustrated Concept-2
This heater has a ceramic heating coil and a Centrifugal fan which blows the air in through the
bottom of the heater, the Ceramic heater then heats the air and is then thrown towards the tapered
end of the exit. Due to the tapered shape the hot air gets accumulates, and through convection
heats up the fresher air being pushed up. Thus increasing the efficiency of the heater.

Control Unit

Ceramic Heater The cold air is first sucked in from the lower
vents by the Centrifugal fan which is then
heated by the Ceramic heater. The heated air
Metal Plate to direct air flow then moves towards the tapered exit where
Centrifugal Fan earlier heated air already exists. This causes
Cleaning in the corners might be a problem the air exiting the heater to become hotter
and finally exits through the vents
Restricted outlet of air
Outer Thermoplastic Casing
Single outlet of hot air

Heating element is hidden and not reachable

Illustrated Concept-3
Keeping in mind the design brief I had designed this wall mounted room heater called OTTO.

This design has three outlets to dissipate the heat and the unwanted outlets can be blocked allowing the hot air
to be exited from other outlet.

Air flow directing

pannel

Fiber Glass Insulation Axial Fan

Ceramic Heater

Outer Casing

Back Cover
The heating is multidirectional, heating

Multiple outlet of hot air

Heating element is hidden and not reachable

Dimensions

All the measurements

are in mm
Control Pannel
The controls for the heater would
be quite simple with 3 heat settings
and a knob to personalizes the
temperature. The three heat settings
are Monsoon (Normal), Spring
(Medium) Summer (High). I had
decided to name the settings
according to the seasons as an
element of change and this would
also remind the user about the
seasons through out the year.
Suggested Material
Parts Type/Material
Outer Casing Polymethyl Methacrylate

Insulation Glass Fiber

Heating Coil Nichrome wire

Motor 18 watt / 1000 rpm

Fan Blades Centrifugal Fan/Aluminium

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http://en.wikipedia.org/wiki/Radiant_heating11:40 AM 12/7/2010

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http://www.ushalexus.com/product_range.asp?ptype=Heater&s1=&pagenum=17:58 AM 12/8/2010
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Product Design
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By Kevin Otto and Kristin Wood

The Plastics Handbook (rotovision)

Basic Mechanical Engineering 2009 edition by B.L Singhal and R.B Patil
Thank You