ERI 25 water coolers: « design-to-cost » and series production

ERI 25 water coolers - Energy mobility

The transition to electric mobility requires an ever-increasing need for charging.

Indeed, the larger the fleet of electric vehicles, the more electricity storage and distribution infrastructure must be deployed.

This is the specialty of the MOB ENERGY group, based in the Lyon region, which has been deploying charging station solutions for customers and visitors, employees, and vehicle fleets across the region for many years.

What are the challenges surrounding the deployment of these charging points?

Maximize the energy efficiency of the facilities to be able to charge as many vehicles as possible simultaneously, with optimal performance and reliability in all weather conditions.

"Energy storage and distribution" also means "precise and reliable temperature management," especially since the devices are often installed outdoors and are subject to significant variations in ambient temperature, which can affect the internal components and the efficiency of the entire system (condensation, humidity, excessive ventilation: everything must be optimized to reduce energy consumption).

And it is naturally EURODIFROID that is supporting the ramp-up of this deployment, focusing on the "cold" brick, with an initial industrial specification with a strong "design-to-cost" focus.

What is “design-to-cost”?

Series production of ERI 25 water coolers

Design to Cost (DTC) is a product design methodology that aims to control product development and manufacturing costs from the earliest design phases.

Costs are integrated into the product from the earliest conceptual decisions, and by making the right design decisions early on, unnecessary costs can be avoided in later phases of the product lifecycle.

This approach enables teams to design high-quality devices while meeting predetermined cost targets from the outset. It also avoids costly and delayed engineering change orders and brings new products to market faster.

Unlike target costing, which aims to achieve a defined cost, DTC considers costs throughout the development cycle to avoid unnecessary expenditures.tiles.

Talking about these ERI 25…

On paper, an ERI 25 water cooler isn't a particularly complex device to design: we're used to handling much larger and more complex devices!


But that's precisely why: the challenge of cost optimization (components, assembly, etc.) becomes all the more challenging when the product is simple and compact.

During the initial redesign, the chassis, for example, was completely redesigned: instead of a two-tiered assembly, the entire cooler is now assembled on a single base, which is much more compact and economical.

Thus, while maintaining the same performance as the initial product, our design enabled a significant reduction in cost (around 20%), while also improving production capacity (simplified assembly).

 

Its main features include:

  • A cooling capacity of 2800 W at 20°C outlet water temperature, 45°C ambient temperature
  • A hermetic rotary compressor running on R134a (HFO blend refrigerant, GWP index 631)
  • An integrated copper coil evaporator
  • A non-ventilated, micro-channel air-cooled condenser
  • A 15 mm PE tank with a capacity of 45-50 L with an electric water level
  • A 500 W in-line heater
  • A Pedrollo Jetm 1A centrifugal pump
  • 3 returns/outlets with a flow switch on each return
  • A hydraulic pressure transducer
  • A connection system using male and female Parker self-sealing fittings (total of 6 pairs)
  • A one-piece frame and galvanized screws, with pre-drilled holes and parts for a mounting system, for integration into the customer's chassis
  • A remote IP55 Fibox control box plastic
  • An ELIWELL Free Smart controller manages compressor and heater start-up based on tank temperature
  • And RS485 ModBus communication with system start/stop, read/write of setpoints (hot/cold), tank temperature reading, and fault reporting (flow rate, level, circuit breaker).

Today, the ERI 25 series are rolling off our assembly line (in batches of 5-6 units) and confirm our ability to support industrialization projects for air conditioning and cooling systems.

 

+ Do you also need a refrigeration unit to integrate into an industrial solution?

+ Are you planning series production or large-scale deployments?

+ Are you looking for a specialist partner in climate engineering and cooling units to support your ramp-up?

> Let's meet!