Fridge Freezers Electrical Product Pathfinder Group - Version
←
→
Page content transcription
If your browser does not render page correctly, please read the page content below
Electrical Product Pathfinder Group Fridge Freezers Identifying failure drivers and opportunities for life extension. Version 1 October 2013
Introduction Submit
About this project… feedback
This work aims to provide simple and accessible guidance on How to use this deck
how to reduce return rates and improve brand value by building
1. Please view in ‘Slide Show’ to activate hyperlinks.
more durable products. Between September 2013 and March
2. To access the slide’s content either browse one
2014 WRAP is working with a consortium of specialists to
page at a time or use the navigation bar below to
develop these outputs through targeted research and
jump between the main sections. Throughout the
engagement with industry and other bodies. This document is
deck there are links to external sources of interest.
the first step in this process and presents the consolidation of
3. We would like to encourage feedback on the
evidence around perceived failure rates and opportunities that
contents of this deck and your thoughts on the
will be further expanded upon from November 2013.
identified failure points, drivers and resolutions.
Please click the ‘Submit feedback’ links on each page
About the Electrical Product Pathfinder Group to contribute.
WRAP is helping the electrical and electronic product sector to
cut costs, reduce resource use, and build reputation for
corporate responsibility. The EPPG aims to:
• identify the most significant changes in the supply and sale
of electrical and electronic products in the UK that would use
less material resources, reduce cost and reduce business
risk, while improving profit;
• implement changes on key products, measure the benefits
and distil good practice; and
• share insight on consumers understanding and attitudes to
product lifetime.
Introduction Short-Term Failure Long-Term Failure Best Practice Opportunities
Short-Term Key Failure Points Submit
feedback
Notes
Purchase Failure Expected Life • Failure points based on
very limited published
Failure Point Driver data, mainly from
Which? surveys and
Why product is being returned Why failure has occurred
from anecdotal
evidence.
User mishandling or poor
Broken shelves, trays etc. ! design/manufacture, inappropriate
• Early failures are mainly
due to poor quality of
material choice manufacture that result
in customer returns.
Inadequate cooling flow over condenser
Unable to maintain cooling ! circuit; poor placement/too enclosed;
• If the main refrigeration
circuit does not fail in
Ambient temp too low or high
first year it is unlikely to
Thermistor or control board; Poor fail later in life except
Thermostat failure ! design or manufacture, poor quality for user error / user
components mishandling.
• Poor instructions/user
Inherent weakness in tungsten filament error contribute to
Bulb failure ! bulbs; extreme thermal cycling from several types of fault.
cold to warm
Rare but could be down to
Gas leakage ! manufacturing fault or damage of circuit
in mishandling of unit or manual
defrost, e.g. using a knife
Introduction Short-Term Failure Long-Term Failure Best Practice OpportunitiesLong-Term Key Failure Points Submit
feedback
Notes
Purchase End of Life • Fridge Freezers are
generally very reliable
Failure Point Driver compared to most other
appliances
Why product is being replaced Why failure has occurred
• According to a survey
Burn out of windings can be due to reported in the EU
Compressor motor failure ! overload caused by poor placement or preparatory study, 30%
high ambient temperature. of washing machines
have been repaired at
Moisture ingress through door seal due least once during their
to seal or twist in door; or defrost
Ice build up ! system fault; Poor design / manufacture
life, 18% of
dishwashers, 12% of
/ inappropriate material choice refrigerators and 5% of
User error in not keeping defrost drain freezers.
Blocked drain hole/water build up in ! hole clear of detritus or poor design
fridge (could also be short term) • Defrost operation – lots
(e.g. narrow drain hole; unsuitable of possible problems
coating) e.g. defrost sensing
Circulation fan failure (if there is one); thermistor, defrost
Uneven or inadequate cooling ! Poor design / materials / manufacture heater, PCB controller
fault.
Door hangs on wrong side for new Hinge problems/no interchangeability of
kitchen or door starts to tilt on one side
! hinges/handles; Poor design / materials
/ manufacture
Introduction Short-Term Failure Long-Term Failure Best Practice OpportunitiesBest Practice Submit
feedback
Component Specification
Testing Standards
Specifications are required for durability around:
• Motor/compressor; e.g. 10yr + with no maintenance? • There are no standards on Fridge Freezer durability,
• Control electronics / thermostat even in latest eco-design regulation
• Shelves, trays, internal fridge mouldings etc. • EU eco-labels only specify warranty/parts availability
• Drain hole and defrost provision • EN 60335-1 on appliance safety (not specific)
• Bulb • Various performance standards: IEC/EN 60034;– TBC
• Door seal and hinges see last slide
• Defrost heater if present
• Circulation fan if present
• Insulation to minimise load on compressor
Design User Instruction
• Fridge Freezers need to give good performance whilst using • Need to be clear and short with diagrams
very little energy and making little noise to achieve high • Emphasise ambient temperature range for proper operation
standards (A+ etc.) under EU labelling. • Ensure good airflow around condenser matrix at back of fridge
• Good design features for durability include built in spacers at • Emphasise not to remove ice using a metal object e.g. a knife
back of condenser matrix, well located and reinforced glass • Emphasise need to not leave door open unnecessarily
shelves, strong (e.g. PC) trays, heavy duty hinges, high quality • Emphasise need to clean drain hole regularly
replaceable door seal, robust electronics, LED bulb and a • Explain how users can clean trays and seals etc.
good large drain hole that doesn’t block easily; Better • Explain how users can replace bulb and door seal
insulation will also reduce compressor work load.
Introduction Short-Term Failure Long-Term Failure Best Practice OpportunitiesOpportunities (i) Submit
feedback
Failure Mode Cause Early/ Opportunity Implementation Cost
Late Mechanism Implications
Compressor Overload/ Both Improve quality of windings; improve Provide Auto reset
Motor burn out surge suppression; Fit resetting manufacturer with switches cost ~£1.
thermal overload switch. Better design
quality insulation (and integrity of specifications; motor
cabinet to reduce insulation life > X hours;
deterioration) will also reduce the thermal switch to
load on the compressor (although a comply with EN
balance to achieve space vs energy 60335-1 Annex D
use).
Shelves, Poor quality / Both Well located/supported and Provide More robust
Drawers and design toughened/reinforced glass shelves, manufacturer with shelves and trays
Trays strong (e.g. PC) trays/drawers. design / material and better
Strong internal fridge moulding with specifications. moulding will be a
no stress concentrations and good little more
bonding to foam insulation expensive. TBD
Electronics and Poor design; Both Specify type of components and Specification and Better quality parts
Thermostat/ poor connectors (gold plated where better quality control will be slightly
Thermistors connectors; vibration risk); surface mount on at factories to ensure more expensive;
no surge PCBs where possible; better loom good quality e.g. gold plated
protection; no support; provide vibration and parts/PCBs and connectors may
humidity or humidity protection e.g. rubber manufacture. add £1 per unit .
vibration mounts, acrylic PCB coatings,
protection encapsulation
Introduction Short-Term Failure Long-Term Failure Best Practice OpportunitiesOpportunities (ii) Submit
feedback
Failure Mode Cause Early/ Opportunity Implementation Cost
Late Mechanism Implications
Door seals Poor quality and Late Better quality with more uniform Specify type of Small development
can crack; catch profile and no stress concentrations. material, profile cost and unit cost
dirt and difficult to Easy to clean feature and and replaceability increase. Better
clean replaceable aspects; Better instructions cheap;
user instructions TBD
Door hinges Poor quality; lack Both Heavy duty hinges, high quality door Specify type and Slightly higher cost
and handles of seal, side interchangeable handles interchange due to extra
interchangeability and hinges feature; User manufacturing time
from side to side instructions and better quality
parts. TBD
Bulb Inherent short life Both Replace with LED bulb (AMDEA Specify type to be £3 to £4 higher
of tungsten bulbs note that this is happening) used. cost at present
Inadequate / Inadequate space Both Fix spacers/ surround at back to Specify that a Slightly higher cost
uneven cooling at back of unit for ensure adequate ventilation; Better condenser spacer
condenser; quality fan fitted at factory –
circulation fan not as an option
failure for user.
Introduction Short-Term Failure Long-Term Failure Best Practice OpportunitiesOpportunities (iii) Submit
feedback
Failure Mode Cause Early/ Opportunity Implementation Cost
Late Mechanism Implications
Rollers and Poor quality Late Better quality rollers and strong Specify type of Small unit cost
adjustment legs roller, mounts mounts to ensure that regular material and fixing increase for better
and adjustable movement e.g. for cleaning is and repeated; load rollers etc.. Better
supports not a problem; Strong that it must withstand instructions; TBD
adjustable legs to ensure even – e.g. full
placement and reduce refrigerator; Better
vibration/noise instructions on
movement and
levelling of fridge
Refrigeration Poor quality pipes Early Highest standard pipework Specify materials May result in
circuit pipework and any joints (thicker or corrosion protected) and provide standard higher cost. TBD
and joints can lead to leaks and highest quality brazing. if possible
Good mechanical support to
exposed pipes.
Defrost heater Poor design; poor Later Specify type of components Specification and May result in
and controller connectors; no and connectors (gold plated better quality control higher cost. TBD
humidity or where vibration risk); surface at factories to ensure
vibration mount on PCBs where good quality
protection possible; provide vibration and parts/PCBs and
humidity protection e.g. rubber manufacture
mounts, acrylic PCB coatings,
encapsulation
Introduction Short-Term Failure Long-Term Failure Best Practice OpportunitiesInternational Standards - performance
Submit
feedback
• EN 60335-1 2012; Safety standards for electrical appliances
• IEC 60034-1 ‘Ratings and Performance’ of electric motors
• EN 60704-2-14; Household and similar electrical appliances - Test code for the determination of airborne acoustical noise
Part 2-14: Particular requirements for refrigerators, frozen-food storage cabinets and food freezers
• CSA C300-12; Energy performance and capacity of household refrigerators, refrigerator-freezers, freezers, and wine
chillers
Introduction Short-Term Failure Long-Term Failure Best Practice OpportunitiesYou can also read
