www.springerlink.com/content/1738-494x
DOI 10.1007/s12206-011-1030-7
(Manuscript Received December 8, 2010; Revised September 11, 2011; Accepted September 27, 2011)
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Abstract
The technique of inverse design problem (IDP) for optimizing the three-dimensional shape of an axial-flow fan blade based on the de-
sired airflow rate is presented in this work. The desired volume flow rate of air can be obtained from the airflow rate of the existing axial-
flow fan by multiplying it with a constant which is greater than unity. The geometry of the redesigned fan blade is generated using nu-
merous design variables, which enables the shape of the fan blade to be constructed completely; thus the technique of parameter estima-
tion for the inverse design problem can be used in this study. Results show that with the redesigned optimal fan blade, the airflow rate of
fan can be increased, thereby improving the performance of the axial-flow fan. Finally, to verify the validity of this work, the prototypes
of the original and optimal axial-flow fan blades are fabricated and fan performance tests are conducted with these blades on the basis of
the AMCA-210-99 standard. The algorithm used in the present study can be applied to the blade design problem in any propulsion and
power systems.
Keywords: Axial-flow fan; Fan blade design; Levenber-Marquardt method; Optimal design
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J [ ( Bj )] = {Q[ ( Bj )] }2 = UT U ; j = 1 to P . (5)
(a) Bj = B = {B1, B2, B3, B4, B5, B6, B7, B8, B9}
= { m, p, ta, , , Lr, Le, Hu, Hl} (6)
unknown design variables. If P design variables are used, Eq. under the present algorithm.
(5) is minimized with respect to the design variables Bj and then When the airflow rate is obtained the following equation
setting the resulting expression equal to zero. We thus found can be used to calculate the efficiency of fan blade
Ps Q
J [ ( Bj )] Q[ ( Bj )] = (16)
={ }[Q ]= 0 ; j = 1 to P . (9)
Bj Bj
where Ps represents static pressure, is the torque of blade,
Eq. (9) is linearized by expanding Q[(Bj) in Taylor series and denotes fan speed.
and retaining the first-order terms. Then a damping parameter
n is added to the resulting expression to improve conver-
6. Computation procedure
gence. This will finally lead to the Levenberg-Marquardt
method [12] and is given by The iterative computational procedure for the solution of
this inverse design problem using the Levenberg-Marquardt
(F + n I)B = D (10) method can be summarized as follows.
Choose an existing fan blade to start the computations; the
where design variables at the zeroth iteration, Bj0, can be obtained
from this blade and are used as the starting reference variables.
T The desired volume flow rate of air is also given in the very
F= , (11) beginning.
T
D = U, (12)
B = B n+1 B n (13) Step 1. Solve the direct problem by using CFD code to ob-
tain the estimated or computed volume flow rate of air,
where the superscripts n and T represent the iteration index Q[ ( Bj )] .
and transpose matrix, respectively, is the identity matrix, and Step 2. Check the stopping criterion; if not satisfied go to
denotes the Jacobian matrix defined as Step 3.
Step 3. Construct the Jacobian matrix in accordance with Eq
Q (14).
= . (14)
B T Step 4. Update B from Eq. (15), and compute the new fan
blade in accordance with the standard procedure stated in sec-
The Jacobian matrix defined by Eq. (14) is determined by tion 3. Go to Step 1 and iterate.
perturbing the unknown parameters Bj one at a time and com-
puting the resulting change in volume flow rate of air from the
7. The statistical analysis
solution of the direct problem.
Eq. (10) is now written in a form suitable for iterative calcu- Statistical analysis is important in determining the reliability
lation as of the estimated design variables. In this section the confi-
dence bounds analysis is developed for the estimated design
B n+1 = B n +(T + n I) 1T (Q ) . (15) variables, B, by assuming independent, constant-variance
errors. The variance-covariance matrix of the estimated design
When n = 0, Newton's method is obtained, as n , variables vector B is defined as [20]
the steepest-descent method is obtained. For fast convergence
the steepest-descent method is applied first, then the value of Var-cov(B) E[B E (B)][B E (B)]T (17)
n is decreased; finally, Newton's method is used to obtain the
inverse solution. The algorithm of choosing this damping where B = B() is the unknown design variables vector, is
value n is described in detail by Marquardt 12. the desired volume flow rate of air, E( ) denotes the statisti-
The bridge between CFD code and LMM is the cal expected value (averaging) operator, and superscript T
INPUT/OUTPUT files. The information from CFD code to refers to the transpose. Eq. (17) is a nonlinear system for the
LMM is the calculated volume flow rate of air and the Jaco- determination of the variance-covariance matrix
bian matrix, and the information from LMM to CFD code is The right hand side of Eq. (17) is then linearized by expand-
the new estimated shape for the fan blade. These files should ing B and E(B) in Taylor series and neglecting the higher-
be arranged such that their format can be recognized by both order terms. We thus obtain
CFD code and LMM. A sequence of forward fan blade prob-
lems is solved by CFD code in an effort to update the fan B BT
Var-cov ( B ) = T
E [ E ( )][ E ( ) ]T .
blade geometry by minimizing a residual measuring the dif-
ference between estimated and desired volume flow rate of air
(18)
C.-H. Huang and C.-W. Gau / Journal of Mechanical Science and Technology 26 (2) (2012) 427~436 431
For independent volume flow rate measurements with con- Table 1. The system variables for various fan blades considered in this
stant variance 2, we have 20 work.
Optimal Designed
Original Designed
E[[ E ( )][ E ( ) ]T ] = 2I . (19) fan blade
fan fan blade
fan blade #2
blade #1
NACA airfoil (mpta) 4609 5608 4506 4609
Introducing Eq. (19) into Eq. (18), the variance-covariance
Blade root chord (Lr, mm) 18.0 19.38 17.59 18.17
matrix becomes
Blade end chord (Le, mm) 33.0 37.86 30.64 34.18
Setting angle (,) 47 59 33.18 52.22
B BT
Var-cov ( B ) = 2 T . (20) Number of blades 7 7 7 7
Fan speed (, rpm) 2500 2500 2500 2500
Hub diameter (DHub, mm) 40.0 40.0 40.0 40.0
To express the right-hand side of Eq. (20) in terms of Jaco-
Fan diameter (D, mm) 110.0 110.0 110.0 110.0
bian, the chain-rule is applied and the high-order terms are
Hub height (Hu+Hl=H, mm) 15.0 15.0 15.0 15.0
neglected. After some length manipulations the following
equation is obtained: Fan gap (mm) 2.0 2.0 2.0 2.0
Air volume flow rate (Q, CFM) 78.19 88.84 63.0 83.0
1
Q T Q
Var-cov ( B ) = 2 T . (21)
B B This expression defines the approximate statistical confi-
dence bounds for the estimated design variables vector B, i.e.,
Here, the Jacobian matrix and its transpose are evaluated the estimated values of design variables are expected to lie
from the results of direct problem by perturbing the unknown between these two bounds with 99% confidence.
parameters.
If we assume independent errors, the nondiagonal elements 8. Experiments for fan blade performance testing
in the variance-covariance matrix vanish and can be written in
A fan performance test was conducted with the original and
explicit form as
optimal fan blades on the basis of the AMCA-210-99 standard.
This standard defines uniform methods for conducting labora-
B2 0 L 0
1 tory tests on house fans to determine airflow rate, pressure,
0 2
M power and efficiency at a given speed of rotation. The duct on
Var-cov ( B ) = B2
. (22)
O 0 the experiment is an outlet-side test duct of category B, and
M
0 pitot tubes (united sensor) were used as the pressure sensor.
L 0 B2 P
The air volume flow rate was measured using the Yokogawa
WT1600 power meter with an accuracy rating of 0.1%.
Then a comparison of Eqs. (21) and (22) gives the standard The purpose of the experiments is to test the accuracy of
deviation of the estimated parameters B as CFD code, i.e., to show that the numerical and experimental
airflow rates for fan blades are consistent under the specified
QT Q
1 operational and geometrical conditions. The measurement of
B = diag T (23) torque of blade is difficult in a fan blade experiment, so we
B B substituted the calculated numerical value of torque into the
fan efficiency equation, together with the measured air flow
where is the standard deviation of the measurements for the rate, static pressure and rotating frequency of fan blade, to
air flow rate. This result is identical to the one given by Ma- calculate the experimental fan efficiency.
niatty and Zabaras [21]. Based on Eq. (23), if the measure-
ment error is assumed normal distribution, it is quite intuitive
that the estimates are normal as well.
9. Results and discussion
Once the standard derivation of the estimated design vari- The system variables for the original fan blade are shown in
ables is obtained, it is natural that some confidence bounds are Table 1 and the shape of the fan blade can be constructed in
of interest. For this reason Flach and Ozisik [22] proposed the accordance with the technique stated in section 3, SHAPE
equation of the confidence bounds for the estimated quantities. GENERATION FOR FAN BLADE, and the grid system for
If we now assume a normal distribution for the measure- the fan blades and computational domain can be obtained
ment errors, the 99% confidence bounds are determined as 22 automatically by using CFD code. Fig. 2(a) shows the compu-
tational domain of the fan-duct system considered here. After
the fan blade grid systems are obtained, the volume flow rate
{B 2.576 B B mean B + 2.576 B } =99% . (24)
of air can be calculated using CFD code.
432 C.-H. Huang and C.-W. Gau / Journal of Mechanical Science and Technology 26 (2) (2012) 427~436
6
Table 3. The estimated standard deviation and 99% confidence
bounces for the design variables in optimal fan blade with = 0.0042.
Original fan (Experimental)
Lr Le m p ta
Original fan (Numerical)
B 0.00008 0.00019 0.00008 0.00021 0.00025 0.00012
Static pressure , Ps (mmAq)
2 80
Efficiency , (%)
0 20 40 60 80 60
Air volume flow rate , Q (CFM)
(a)
50
5
30
3
0 20 40 60 80
Air volume flow rate , Q (CFM)
(a)
2
80
0 60
Efficiency , (%)
0 20 40 60 80 100
Air volume flow rate , Q (CFM)
(b)
(a)
(a)
(b)
Fig. 5. The solid shapes for (a) original; (b) optimal fan blades.
(b)
Fig. 7. The experimental apparatus for the (a) entire fan test section;
(b) fan blade test section.
(a)
in reality that can be used in experiments. Figs. 6(a) and 6(b)
show the fabricated original and optimal fan blades, respectively.
The experimental apparatus for entire fan test section and
fan blade test section is given in Figs. 7(a) and 7(b), respec-
tively, and the operational conditions for fan blades testing
have been described in the preceding section. Figs. 8(a) and
8(b) indicate the experimental results for PsQ and rpmQ
curves for original and optimal fan blades, respectively. From
Fig. 8 it can be learned that the experiments performed quite
well since the fan speed keeps almost constant at = 2500
rpm for all the different testing cases considered here. The
trend of the Ps-Q curve for both fan blades is also reasonable.
The experimental results for original and optimal fans in
PsQ and Q curves are also shown in Figs. 3 and 4, respec-
(b)
tively. It can be seen from Fig. 3 that at the design point (Ps =
Fig. 6. The CNC machine fabricated (a) original and (b) optimal fan 0), the airflow rates for original and optimal fan blades are
blades. obtained as 77.595 CFM and 84.842 CFM, respectively. This
implies a 9.34% increase in the airflow rate. Although in nu-
For this reason the original and optimal fan blades must be merical simulations there is a 13.6% increase in the airflow rate
CNC fabricated in accordance with our design. Figs. 5(a) and for optimal fan blade, but still the design is effective since
5(b) indicate the solid shapes for the original and optimal fan 9.34% increase in the airflow rate is quite a significant number.
blades that were obtained from our numerical data. The numeri- However, at higher static pressure, the original fan blade has
cal data can be used in the CNC machine to fabricate fan blades better performance in airflow rate. This may be due to some
C.-H. Huang and C.-W. Gau / Journal of Mechanical Science and Technology 26 (2) (2012) 427~436 435
6 2540
original fan and is 29.5% for the optimal fan.
There always exists a discrepancy between experimental
2520 measurements and numerical simulation for any engineering
problems. It may be due to either simulation error or experimen-
Static pressure , Ps (mmAq)
4 tal error or both. In the present study the error at the design con-
2500
dition, Ps = 0, is very small, 0.77%, for the original fan and
4.7% for the optimal fan, but for the other operation conditions,
rpm
P-Q
rpm-Q 2480
larger error can be obtained but that is still acceptable for engi-
2 neering applications. From the above results it can be concluded
that the present numerical solutions for fan blade design prob-
2460 lems are reliable and the design of blades can be used in reality.
The comparisons of the numerical and experimental results
in Q curve for original and optimal fan blades are shown in
0 2440
0 20 40 60 80
Figs. 4(a) and 4(b), respectively. It is obvious from Fig. 4(b)
Air volume flow rate , Q (CFM) that the efficiency calculated by the numerical method is
(a) higher than that for the experimental result except for one
position for the original fan blade at low airflow rate. This
5 2540
may be due to the experimental error performed in fan testing.
P-Q
4
rpm-Q 2520
10. Conclusions
Static pressure , Ps (mmAq)