FRIENDSHIP SYSTEMS > Case Studies > Axial Fan Optimization Workflow: A Case Study of Turbomachinery Design Optimization

Axial Fan Optimization Workflow: A Case Study of Turbomachinery Design Optimization

Technology Category

Sensors - Flow Meters
Sensors - Liquid Detection Sensors

Applicable Industries

Electrical Grids
Semiconductors

Applicable Functions

Product Research & Development

Use Cases

Digital Twin
Virtual Reality

Services

Hardware Design & Engineering Services

About The Customer

The customer in this case study is not explicitly mentioned. However, it can be inferred that the customer is a manufacturer or designer of axial fans, seeking to improve the efficiency and air flow capacity of their product. The customer likely operates in the turbomachinery industry, where the design and optimization of fans, turbines, and other rotating machinery are critical. They require a solution that not only enhances the performance of their product but also integrates seamlessly with their existing workflow. The customer values efficiency, productivity, and the ability to leverage their available hardware resources to the fullest extent.

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The Challenge

The case study revolves around the optimization of an axial fan's design using TCFD® and CAESES® software. The primary challenge was to develop a new, highly efficient fan or improve the parameters of an existing one. The existing axial fan had specific parameters, including a diameter of 280 mm, RPM of 3000, maximum power of 100 W, maximum pressure of 410 Pa, maximum air capacity of 1100 m3/h, and peak efficiency of 69%. The study aimed to maximize the fan's efficiency in the range of flow rates from 576 m3/h to 1296 m3/h and increase the air flow capacity. The challenge also involved creating a smart and efficient turbomachinery design optimization workflow by connecting the two software packages, TCFD® and CAESES®.

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The Solution

The solution involved creating a fan geometry using CAESES®, which provides a CAD environment for robust and easy geometry variation, efficient parametrization, and simulation-ready export. A CFD simulation setup template for the exported geometry was created in TCFD® and returned back into the CAESES® software connector. An optimization process in CAESES® was preset, and each geometry variation was automatically processed and simulated with TCFD®. The axial fan flow domain was created to fit CFD requirements, and the geometry was split into rotor and stator domains. The optimization process involved a complex set of tasks, including a global sensitivity analysis (Sobol) and a local analysis (TSearch) in the neighborhood of the best design obtained from the global analysis. The objective function was defined as a sum of efficiencies for all six simulated points imported from TCFD®.

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Operational Impact

The operational results of this case study demonstrate the power of combining TCFD® and CAESES® for turbomachinery design optimization. The process was fully automated, allowing for a smooth and efficient workflow. The optimization process improved the fan's efficiency and air flow capacity significantly, demonstrating the potential of these software packages for similar applications. The case study also highlighted the ability to use available hardware resources to their full potential, without any restrictions. This flexibility makes the solution suitable for engineers across diverse industries, not just those with high levels of expertise in turbomachinery design. The optimized design also had a wider working range, indicating its versatility for various operating conditions.

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Quantitative Benefit

Efficiency of the fan improved by about 25% for each simulated point.
Optimized design has a maximum air capacity over 1500m3/h, an increase from the original 1100 m3/h.
Peak efficiency increased to 72%, up from the original 69%.

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