No-Moving-Parts Fan
MICHIGAN STATE
U N I V E R S I T Y
Objective
Experimental Analysis
Airmaster Fan Company is a business
strictly devoted on the creation,
manufacturing, and sales of fans.
Airmaster has presented four
engineering students and one
marketing student with the specialized
task of developing the current
prototype in order to create an
optimal no-moving-parts fan. The fan
was designed with respect to the air
flow, cost, manufacturing process,
efficiency and noise radiation. A viable
marketing vehicle was designed to fit
the product and the company’s
objectives
Given the working prototypes, an
analytical study of the velocity
distribution was conducted on the inlet
portion of Airmaster’s original prototype,
prototype 1, and the prototype that was
created by the engineers, prototype 2.
The velocity distribution was obtained by
collecting data at various points along the
cross-sectional area of the inlet portion.
The velocity at each independent point
was determined by using an Anemometer
measuring meters per second. This data
was then used to validate the Fluent
model. The pictures below show the 3D
velocity profiles of prototype 1 and the
recommended prototype 2.
Essential Design
Parameters
The CFD software analysis began with a
simple 2D rectangular model of the nomoving-parts fan. The final model, was
identical in dimensions and complexity to
the prototype fan. The output data from
the verified CFD model proves that the
optimum gap size for the 12 inch nomoving-parts fan operating at 90 Psi is
0.1438 inches.
gap (inches)
In order for the no-moving–parts fan to
be viable, the operational noise and cost
needs to be reduced whereas the CFM
rating has to increase. Using Airmaster’s
resources and current methods of
manufacturing, this product is not
feasible. If Airmaster was willing to
consider new production methods such as
CNC machining or casting, a feasible
product would be possible pending
additional research.
mass flow rate
Iteration
(Kg/s)
0.0938
-0.0317
4
0.1125
0.2887
5
0.1250
0.3616
2
0.1375
0.3999
6
0.1438
0.4016
7
0.1500
0.3967
8
0.1563
0.1276
1
0.1875
0.1054
3
Attribute
Performance
Benchmark
Evaluation
Noise Level
At109 dB, above
prescribed standard
89dB
Below standard
Operating Costs
$3100+ per year
$118+ per
year
Below Standard
Performance
209.76 CFM
1500 CFM
Below Standard
Longevity
Testing required
20 years
-
Safety
Testing required
-
-
Prototype 1: Velocity Profile
•Function/Performance
•Safety
•Reliability
•Quality
•Cost
•Noise
1.60
1.40
1.20
1.00
Prototype 2: Velocity Profile
0.80
1.20-1.40
1.60
1.00-1.20
0.80-1.00
0.40
0.60-0.80
0.20-0.40
0.20
11
0.00-0.20
9
7
1
2
5
3
4
5
6
7
8
3
9
10 11
12 13
14
1
1.40
1.30
1.20
1.10
1.50-1.60
1.40-1.50
1.30-1.40
1.00
1.20-1.30
1.10-1.20
1.00-1.10
0.90
0.90-1.00
0.80-0.90
11
0.70-0.80
0.80
9
7
0.70
1
2
Fluent Analysis
Cross Section
Final Prototype Drawing
Team Members
Economic Analysis
1.50
0.40-0.60
Prototype
Velocity Contour Plot
Static Pressure Contour Plot
0.1475’’ gap – mass flow rate = 0.40161803 kg/s
1.40-1.60
0.60
0.00
Front View
Final Recommendation
5
3
4
5
6
7
8
3
9
10 11
12
13
1
14
CFD software, Gambit and Fluent, were
utilized in the optimization of the nomoving-parts fan. Using the software
saved the design team a considerable
amount of time in the optimization process
due to the fact that it was possible to run
numerous tests with multiple compressed
air outlet gap sizes in a single day.
The economic analysis shows that for
the no-moving-parts fan, the
operating cost is 17 times more
expensive per year, than a regular
bladed ¾ hp explosion proof fan.
Over time, as the ¾ hp fan requires
maintenance, the operating cost gap
will narrow. However, even over 20
years the no-moving-parts-fan is still
7.4 times more expensive.
Engineering
Anthony Beal
L. Marie Verrier
Michael Lambert
Steven Yang
Marketing
Business Advisor
Dilip Thomas
Dr. Michael Lobbestael
Faculty Advisor
Industry Sponsor
Dr. Eann Patterson
Bob LaZebnik
Type of Fan
Purchase
Price
Operating cost per year (4380 hrs)
Maintenance Cost
per year
5 years
10 years
15 years
20 years
3/4hp Regular fan
$1,400.00
$183.73
$100
$2,818.96
$4,237.61
$7,056.26
$8,474.91
15 hp Compressor
$300.00
$3,124.53
$0.00
$15,922.65 $31,545.30 $47,167.90 $62,790.60