Our client wanted to develop a new range of low noise, fan-based products to bring to market in short time scales, utilising existing tooling as much as possible.
We worked closely with senior executives, engineering managers and also with their supply chain, to meet their challenging product development cycles, using advanced analysis techniques to reduce the number of prototypes that needed to be designed and tested.
Our fluid dynamicists and noise and vibration experts developed a parametric model for designing the fan in the appliance, to achieve minimum noise levels for a defined performance. We developed the concept via computer-aided design (CAD) and fabricated a prototype fan within a short time frame.
Using Computational Fluid Dynamics (CFD) we generated 3D flow models of the overall appliance, including the fan, to understand the flow behaviours through the machine. This enabled us to suggest improvements to both the flow performance and the acoustic performance.
We used advanced measurement techniques, including laser vibrometry, to confirm the flow and acoustic performance of both a range of original appliances and our new prototype, validating our fluid dynamic and acoustic models.
We generated a second prototype in alternative materials to further optimise the acoustic performance, testing various additional noise reduction features. In addition to improving the fan flow and acoustic performance, we identified various relatively simple improvements to the other (non-fan) components of the appliance that could be incorporated into future product evolutions.