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Low Weight, High Speed Automative Fan Design by 3D Inverse Design Method

The cooling system of modern automobiles is the subject of intense reflections to maximize efficiency and reduce the energy consumption. Large fan design diameters are preferred to enhance thermal exchanges over the large surface of the radiator, whereas high rotational speeds are seeking to benefit from higher efficiency and low weight of the electrical motor that drive the fan. This leads to reconsider the design of the blades for these conditions for which  stagger angles are very high and the aerodynamic load very low. These unconventional geometries are so far little known, but represent an interesting potential in terms of design of the cooling system, which could benefit from a high permeability favorable to the heat transfer when the vehicle is moving, even at low speed.

blade loading distribution with parameters

The aim of this paper is to apply 3D inverse design method coupled with multi-objective/multi-point automatic optimization method to design a low loaded axial fan. In this approach Design of Experiment Method (DoE) is used to create a Response Surface (RSM) relating the various performance parameters to inverse design base design parameters. Multi-objective Genetic Algorithm (MOGA) is then run on the response surface to find the trade-offs between design  parameters and constraints. All designs are evaluated by using unsteady 3D CFD simulation to create the Response Surface. An estimate of aeroacoustics far field noise is obtained by using an acoustic FW&H model. Some experimental results from a prototyped version are also presented to evaluate the accuracy of numerical simulations.  

performance table from optimization

Two designs are selected by the optimization process with different compromises in term of multi-objectives performances, and their final qualities are assessed by a thermal simulation on a cooling module. These proposed new geometries represent a proof of concept that is analyzed for performance  evaluation before further developments for the automotive application.

optimized fan designs

 

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About Advanced Design Technology

We provide software and services for the design and optimization of turbomachinery, based on our unique 3D Inverse Design technology. Our tools and services help customers achieve innovative “breakthrough” designs, delivering market leading solutions at dramatically reduced development costs.

ADT, headquartered in London, UK, was established in 1999 as a joint venture between University College London and The Ebara Research Co Limited of Japan. We are considered as one of the leading global turbomachinery design software providers, with our TURBOdesign Suite tool set in use across a very wide range of applications and sectors. 

Our design consultancy services deliver cutting-edge solutions to our global customers. Whether the task involves a complete solution, from concept to final design for manufacturing, or is facing challenging multi-point / multi-objective design optimization, we work closely with our customers and support them throughout the entire design process.

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