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Fan Optimization for Power Tools using Hyper Works

(Combination of Acusolve, HyperMorph, HyperStudy & SimLab)

by

Raúl Cano

Agenda

• Introduction (Company & Products)

• Hammer description

• Problem description

• Fan Optimization Process

• Results

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Introduction (Company & Products)

Stanley Black & Decker - DeWalt

DEWALT today is the leading brand of professional power tools in North America and

in the last 5 years the fastest growing power tool brand in the world.

Compact Hammers Mid Size Hammers Big Size Hammers

Agenda

• Introduction (Company & Products)

• Hammer description

• Problem description

• Fan Optimization Process

• Results

Hammer description

Agenda

• Introduction (Company & Products)

• Hammer description

• Problem description

• Fan Optimization Process

• Results

Problem description

Fan

Heat generating parts

Heat generating parts

All this heat generating parts must

be cool down by the air flow produced

by the fan inside the hammer

High resistance – small gaps

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Problem description

Volume Flow 4Kg. Hammer

Inlet

Outlet

Inlet FanOutlet Fan

InletOutlet

Inlet FanOutlet Fan

Inlet

Outlet

Inlet Fan

Outlet Fan

0

5

10

15

20

25

Fans

Vo

lum

e F

low

(l/

s)

Fan 1 Fan 2 Fan 3

Fan 1

Fan 2

Problem description

9

0,00

100,00

200,00

300,00

400,00

500,00

600,00

0,00 0,05 0,10 0,15 0,20 0,25 0,30 0,35 0,40 0,45 0,50

Po

wer

in [

W]

Torque in [Nm]

If the Air Flow Is increased,

the Power out, produced by the motor

could be also increased

Motor power out

for the Motor G59x30

480 W Power out

with low air flow

500 W Power out

with high air flow

Problem description

Motor power out

air flow power out influence

(Not a real case)

Agenda

• Introduction (Company & Products)

• Hammer description

• Problem description

• Fan Optimization Process

• Results

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Fan Optimization Process

Workflow optimization Process (Altair GmbH)

Fan Optimization Process

FEM Model for a

4 Kg Hammer

Inlet

Outlet

Baffle

Fan

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Fan Optimization Process

CAD Parts

CAE Parts

Baffle Fan

Fan

Simplified Baffle

Key Parts

Fan Optimization Process

Morph Volume & Handles

Morph Elements

Simplified symmetric model for the 4 Kg. Hammer

one fin model from 17 fins in total

16

Inlet Outlet

Fan Baffle

Angle Vertical

Fin Height

Curvature

Fin length

Fin Height 2

Curvature 2

Thickness

Fan Optimization Process

Simplified Model

Symmetric Model

for the 4 Kg Hammer.

Faster way

to evaluate the most

influence parameters.

Agenda

• Introduction (Company & Products)

• Hammer description

• Problem description

• Fan Optimization Process

• Results

Results

• Until now we got an increase of 10% in the

mass flow, it is possible to increase this

value.

• New process and understanding of

HyperMorph-Acusolve-HyperStudy

combination. New optimization parameters

are possible: Fan Torque optimization, fins

gearbox optimization, temperature

distribution.