SynchronBlow

Development of an innovative cross-flow fan with a outlet velocity of 180 km/h

Description of the subject:

For driving simulations on vehicle test benches, air fans are used to simulate the effect of the airflow on the vehicle. Areas of application are exhaust gas tests, chassis dynamometers, or climate chamber tests. The air fan provides the missing airstream in dynamometers and driving simulations. The airflow created by the fan is directed towards the vehicle radiator and under the vehicle. This simulates the cooling effect of the airflow on the engine temperature of the vehicles being tested. Due to the confined space and limited outlet cross-sections in vehicle test benches, current airflow fans can only reach a simulated speed of 160 km/h at most. A simulation of an airflow speed of 180 km/h is urgently needed in order to be able to simulate the influence of higher driving speeds on vehicles and individual components. Asynchronous motors are currently used to drive cross-flow fans. To achieve higher energy efficiency, the project is using a synchronous reluctance machine.

Project aims:

The main aim of the SynchronBlow cooperation is to develop a cross-flow fan with a outlet velocity of 180 km/h with a very compact device construction by using an innovative and optimised synchronous reluctance motor. WMB, a partner in the project, is developing the new cross-flow fan. For the synchronous reluctance motor, an optimised stator and rotor as well as the overall design are being developed to achieve the speed of 2300rpm concurrently with an increase in efficiency. BEN, another partner, is responsible for the mechanical design, technical production, and investigating the vibration behaviour of the synchronous reluctance motor. At the Technische Hochschule Nürnberg, besides the electromagnetic design and simulation of the synchronous reluctance machine, optimisation to the required target values will be carried out using the institution’s own simulation program for electrical machines. This involves both an analytical calculation using reluctance networks and the use of numerical FEM for the targeted optimisation.

Project lead: Prof. Armin Dietz

Researcher: Michael Schmidt, M.Eng.

Project partners: BEN Buchele Elektromotoren GmbH, WMB Ventilatoren GmbH

Project management organisation of the BMWi ZIM joint project

Project duration: 2.5 years