SBIR-STTR Award

Conventional Fans and radiator coolant systems for over the road and military applications have been a major source of inefficent engine and vehicle operations. The technology has been virtually unchanged for decades and is plaqued with warranty and service issues. As the engine manufactures move to a complete thermal managent system as a replacement to the current technology, a compact high efficency electric blower will be a major component. The goal of this project is to design,and demonstrate the feasibility of a compact high efficiency electric blower for primary cooling on military and commercial vehicles. This blower will be based on an existing blower developed by Engineered Machined Proucts (EMP) for use as a secondary cooling device. There are a number of advantages of the EMP blower over conventional fan technology. The primary benefit is the improved efficiency of this unit. Because this blower will be more efficient than current fan technologies, it should improve fuel economy as well as emissions. Fuel econnomy can also be improved by reducing parasitic losses because the blower will be controllable. The blowers unique design will allow for the use in a modular system. The same blower could be used across multiple engine platforms thus reducing inventories

The objective of this program is to define, develop and demonstrate the best methods for moving air for different vehicle systems. The work will begin with an evaluation of all traditional air moving devices and find possible ways to improve efficiency and performance. Air movement technologies, to be evaluated include axial fans and blowers, radial fans, mix-flow blowers, and centrifugal (squirrel cage) blowers. Advantages and disadvantages of each type of air moving device will be examined. A clear understanding of how any air movement device fits into the system will be developed. If the air movement device does not operate at its peak efficiency, the system as a whole does not operate as efficiently as it could. It is paramount that each component within a system be understood from the system’s perspective. Work will include the design and development of multiple air movement devices by a mathematical development process integrated with CFD analysis. Solid models of the finalized designs will be used to create working rapid prototype fans and blowers. Each prototype then will be performance tested. This will provide the measurable real world benefit of each design improvement. One or more of the prototype air moving devices will then be incorporated into other ongoing programs. The air moving device will be a part of an advanced fully controllable thermal management system. The system will be integrated into a vehicle platform yet to be determined, possible applications include the Humvee and FMTV. This vehicle will be fully tested to provide a comparison of the benefits of the advanced thermal system.

Benefits:
There are obvious benefits to high efficiency air moving devices. Improved efficiency leads to reduced power consumption and therefore improved engine performance. This of course means improved fuel economy. Improved controllability controls the engine temperature more tightly. Elimination of temperature fluctuations should then improve the performance of emission controls. In addition, there are also many 'trickle down' benefits of higher efficiency fans, such as the reduction of electrical component costs. In many cases, the controllers necessary to drive and control an electronic fan are more costly than the fans themselves. Reducing power draw by the fan will thus reduce the demands put on the controller and its components. Smaller and lower cost motors, controllers, and electrical components can then theoretically be used.. It is our intent to use this program to help bring an advanced coolant system to market for both the military and commercial industries. High efficiency air moving devices will be a critical part of this process. Expanding our market to include a thermal management system will not only expand our sales, but also help add U.S. jobs. With a current customer base that includes all the major U.S. diesel engine manufactures and some auto companies, EMP is well positioned to aggressively attack this market. Intellectual property will be an important part of moving forward. EMP has a tremendous amount of patents and applications in this field. EMP will continue to pursue patents where it is necessary to achieve a commercial advantage.

Keywords:
Air Pump, Fans, High Efficency Blower, Heat Exchanger, Compact Electric Blower, Heat Exchanger, Thermal Systems, Electric Blowers