Development of Cost Model for Heat Exchanger of Residential and Industry Application

Abstract

The manual cost estimation process for heat exchangers is known to be less accurate compared to supplier quotations and faces several challenges, such as relying on assumptions, inaccurate process time estimation, and outdated data collection from the plant. The objective of this work was to develop an accurate, reliable, and time-saving cost model using the aPriori cost estimation tool for heat exchangers. The aPriori cost estimation tool consists of two parts: the Virtual Production Environment (VPE) and the Cost Model (CM). VPE serves as the digital copy of the specific plant, requiring data such as material, machine, process, and plant data, which were collected using templates. CM was developed using the Cost Scripting Language (CSL) to build logic, formulae, and define cost taxonomy, machine selection rules, and material selection rules. VPE and CM were developed for manual brazing, robotic brazing, tube expansion, tube insertion, and turret press processes. Manufacturing times and cost variables were validated for each process successfully. The aPriori cost estimation model reduced overall production time, improved productivity, and enhanced product quality. It estimated that the manufacturing cost of fin and tube heat exchangers could save around 19% annually compared to manual process cost estimation of the fin and tube heat exchanger.