Fan Optimization for Power Tools using HyperWorks

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Fan Optimization for Power Tools using HyperWorks

  1. 1. 1Fan Optimization for Power Tools using Hyper Works(Combination of Acusolve, HyperMorph, HyperStudy & SimLab)byRaúl Cano
  2. 2. Agenda• Introduction (Company & Products)• Hammer description• Problem description• Fan Optimization Process• Results
  3. 3. 3Introduction (Company & Products)Stanley Black & Decker - DeWaltDEWALT today is the leading brand of professional power tools in North America andin the last 5 years the fastest growing power tool brand in the world.Compact Hammers Mid Size Hammers Big Size Hammers
  4. 4. Agenda• Introduction (Company & Products)• Hammer description• Problem description• Fan Optimization Process• Results
  5. 5. Hammer description
  6. 6. Agenda• Introduction (Company & Products)• Hammer description• Problem description• Fan Optimization Process• Results
  7. 7. Problem descriptionFanHeat generating partsHeat generating partsAll this heat generating parts mustbe cool down by the air flow producedby the fan inside the hammerHigh resistance – small gaps
  8. 8. 8Problem descriptionVolume Flow 4Kg. HammerInletOutletInlet FanOutlet FanInletOutletInlet FanOutlet FanInletOutletInlet FanOutlet Fan0510152025FansVolumeFlow(l/s)Fan 1 Fan 2 Fan 3Fan 1Fan 2
  9. 9. Problem description90,00100,00200,00300,00400,00500,00600,000,00 0,05 0,10 0,15 0,20 0,25 0,30 0,35 0,40 0,45 0,50Powerin[W]Torque in [Nm]If the Air Flow Is increased,the Power out, produced by the motorcould be also increasedMotor power outfor the Motor G59x30480 W Power outwith low air flow500 W Power outwith high air flow
  10. 10. Problem descriptionMotor power outair flow power out influence(Not a real case)
  11. 11. Agenda• Introduction (Company & Products)• Hammer description• Problem description• Fan Optimization Process• Results
  12. 12. 12Fan Optimization ProcessWorkflow optimization Process(Altair GmbH)
  13. 13. Fan Optimization ProcessFEM Model for a4 Kg HammerInletOutletBaffleFan
  14. 14. 14Fan Optimization ProcessCAD PartsCAE PartsBaffle FanFanSimplified BaffleKey Parts
  15. 15. Fan Optimization ProcessMorph Volume & HandlesMorph ElementsSimplified symmetric model for the 4 Kg. Hammerone fin model from 17 fins in total
  16. 16. 16Inlet OutletFanBaffleAngle VerticalFin HeightCurvatureFin lengthFin Height 2Curvature 2ThicknessFan Optimization ProcessSimplified ModelSymmetric Modelfor the 4 Kg Hammer.Faster wayto evaluate the mostinfluence parameters.
  17. 17. Agenda• Introduction (Company & Products)• Hammer description• Problem description• Fan Optimization Process• Results
  18. 18. Results• Until now we got an increase of 10% in themass flow, it is possible to increase thisvalue.• New process and understanding ofHyperMorph-Acusolve-HyperStudycombination. New optimization parametersare possible: Fan Torque optimization, finsgearbox optimization, temperaturedistribution.

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