flowair elis ax

/01/ Overview

Air curtain available in four lengths and up to 16 product variants.

Preventing heat loss is as important as generating it from sustainable sources. Flowair, the Polish leader in the European HVAC industry, approached Aleto to design their next air curtain. The new addition to the existing portfolio of building technologies had to be available in four lengths: 1 m, 1.5 m, 2 m, 2.5 m, be mountable in horizontal and vertical orientation and be powered by energy-efficient EC fans. The Aleto team applied our tested methodological approach. After initial research, we devised a performance testing prototype that allowed precise adjustments of the angle and location of internal components to test the layouts for maximum performance and minimal energy consumption. Encouraged by excellent performance results, we also crafted the industrial design of the product to seamlessly complement even the most luxurious commercial spaces. Before releasing production parts to the client, we created two rounds of pre-production prototypes to ensure a thorough assessment of tolerancing, assembly sequence, assembly ease, material finishes, and product performance.

Services:

Industrial Design
Proof of Concept Prototyping (POC)
Performance Engineering
Design for Manufacturing and Assembly (DMFA)
Pre-production Prototyping
Technical Documentation
Project Management

Brand:

Flowair

/02/ Industrial design

Visualisation of HVAC air curtain above glass door.

Visualisation of two HVAC air curtains above double glass doors.

Visualisation of two HVAC air curtains vertically mounted by double glass doors.

Elis AX mounted to the floor with an innovative floor mount.

Close up on the industrial design of HVAC air curtain, Elisa AX.

Close up on the industrial design of HVAC air curtain, Elis AX.

Top view of the industrial design details for an air curtain for the HVAC industry.

Bottom view of the industrial design details for an air curtain for the HVAC industry.

3/4 view of an industrial design of air curtain for the HVAC industry.

Front view of the industrial design details for an air curtain for the HVAC industry.

Side view of the industrial design details for an air curtain for the HVAC industry.

Figures 1-12.

Industrial design of ELiS AX air curtain with clean, familiar but distinctive language seamlessly complementing even the most luxurious commercial spaces like 5*hotels, luxury car dealers or restaurants.

/02/ Prototyping

Figure 13.

Performance test prototype featuring adjustable components to identify the optimal combination of location and size for superior performance.

Performance testing prototype made using laser cutting and metal fabrication.

Figure 14.

After a thorough study of requirements and the availability of off-the-shelf components like industrial fans, the performance prototype was engineered to provide a detailed picture of how they work together.

Figure 15.

The two-person design and engineering team responsible for both the prototype and the entire product.

Design and engineering team standing proudly next to assembled performance testing prototype.

When establishing ambitious performance parameters, our design studio EMPHASISES a methodological prototyping and testing approach. This meticulous process provides the detailed insights needed for informed engineering decisions, ensuring our designs are not only high-performing but also cost-effective and manufacturable. Precision is our commitment, delivering excellence from concept to manufacturing.

/03/ Performance optimisation

Figure 16.

Performance rig with test equipment for maximum performance. The prototype enabled linear and angular precision on position of internal components like fan plate and heat exchanger down to 1mm and 1 degree.

Prototype performance testing with air pressure sensors.

Figure 17.

With over 150 tests performed, the team created a detailed picture of factors influencing performance to inform the next phases of the design process.

Engineers performing and analysing test data from performance tests.

/03/ Pre-production

Throughout the design process, several types of prototypes are created. In the final development phases, a different approach is taken as most of the parameters and features are set. The focus then turns to details, evaluations of assembly procedures, and Colour, Material, and Finishes (CMF). Two rounds of pre-production prototypes were created before the final technical documentation was handed over to the client.