Session: 10-02 Fan Applications

Paper Number: 124082

124082 - Numerical-Experimental Comparison of the Performance of a Mixed-Flow Fan Designed for Electric Vehicles 

Due to the ecological-green transition, Battery Electric Vehicles (BEV) will replace the Internal Combustion Engine ones (ICE), since they are less pollutant in terms of carbon and noise emissions. Inside a BEV one of the major sources of noise, especially during battery charging, is related to the cooling system, which is composed by one or two axial fans and the heat
exchangers. This work aims to investigate the possibility of reducing the noise emission as well of increasing the efficiency of the cooling system using a mixed-flow fan since it can supply comparable performances when compared to an axial fan but with quite lower rotational speed, i.e. with lower noise and reduced friction losses. In the first phase of the present work, the mixed-flow fan has been designed with a design procedure based on the available literature, starting from the inputs received from the customer, i.e. geometrical constraints, pressure drop, and power consumption. After this preliminary design process, detailed CFD simulations have been performed in order to validate the assumptions made. Thereafter the initial fan geometry has been modified to take into account the manufacturability constraints, related to the plastic injection molding process, and the fan geometry has been optimized and finalized. Different numerical approaches have been studied to evaluate the influence of the numerical setup on the results. Finally, the optimized geometry has been prototyped and tested in a standard airflow test bench in order to assess the real performance of the mixed-flow fan and in order to identify the most suitable numerical approach that should be used to simulate this kind of turbomachine.

Presenting Author: Mattia Piovan University of Ferrara

Presenting Author Biography: Graduated in Mechanical Engineering at the University of Ferrara in 2022. Since the same year he has been a PhD student in Engineering Sciences at the Engineering Department of the University of Ferrara. His research activity is focused on the development of innovative methodologies for predicting and reducing the noise emitted by fans, mainly using an open-source numerical approach. Other topics of interest: development of design criteria for high-efficiency turbomachinery. The research activity is collected in scientific articles presented at national and international conferences and published in the sector scientific journals.

Authors:

Nicola Aldi University of Ferrara
Michele Pinelli University of Ferrara
Mattia Piovan University of Ferrara
Alessio Suman University of Ferrara
Nicola Zanini University of Ferrara
Enrico Mollica SPAL Automotive Srl
Filippo Menichini SPAL Automotive Srl