ebm-papst Fans, Blowers and Technology

By Scott Beauchemin, Vice President – Engineering

In almost every development process, multiple design iterations are unavoidable. Optimizing an air flow system in a single iteration is rare. In fact, some projects require three or four design loops before the targeted air flow is met. In 2009, ebm-papst Inc. set out to find a way to minimize these steps and thus reduce development costs and get projects to market more quickly. The answer was Computational Fluid Dynamics (CFD) software.

Optimizing air flow systems during development can be challenging. Before ebm-papst introduced CFD to our development process, we would fabricate an initial prototype design using knowledge gained from previous projects. After testing it in the lab, we would compare the results against the air flow, efficiency and noise targets defined at the beginning of the project. In an ideal case, the results from the first prototype would meet or even exceed the targets defined for the project. But typically, the prototype would not exactly meet the targets, and we would move on to a second design. Each new iteration would require engineering time, material costs to fabricate another prototype and lab time to test the new version.  

Using CFD software has reduced the number of design iterations by allowing us to:

• Run numerical simulations of the flow field in a system using relatively basic CAD geometry to define the system. The software predicts the air flow through the system, determines the pressure drop, and helps identify problem areas in the flow field. It also looks at heat transfer to determine if critical components are being cooled adequately by the flow through the system.

• Simulate various designs to determine the optimal one for that specific system. CAD models for each design modification are created.

• Run those simulations simultaneously, often times after hours so the data is available the next morning. The various design options can be directly compared to determine which characteristics provide the best results.

CFD simulations don’t eliminate the need for experimental data. We still must build and test a prototype in the lab to verify that it meets the design targets. And we still use our knowledge from previous projects – but now, a characteristic can be simulated in the new system to see if it is beneficial. The simulations allow us to quickly narrow in on an optimized design.

The addition of CFD analysis to our capabilities has been a tremendous asset, and is just another example of how ebm-papst is constantly investigating and innovating to offer more efficient processes and solutions to our customers. To learn more, contact sales@us.ebmpapst.com.

By Scott Beauchemin, VP of Engineering, ebm-papst Inc.

Our company’s product portfolio has expanded into much larger sizes over the past decade. Ten years ago, a large ebm-papst fan was 500mm to 630mm in diameter. Now, we’re selling fans up to 1.5 meters in diameter that are used in large-scale refrigeration and ventilation applications.

Because importing such large products from our manufacturing counterparts in Germany posed logistics and warehousing challenges, we at ebm-papst U.S. decided to take advantage of our 25+ years of value-added experience to localize production here in the U.S.

The ebm-papst fans we purchase from Germany are now built into larger sheet metal assemblies designed to meet specific customer needs. The majority of this customization happens at our Farmington, Conn.-based U.S. headquarters.

We began by localizing production of our larger axial fans, which are typically used in condensers for the refrigeration market or in chillers in the HVAC market. These fans consist of a GreenTech EC motor, HyBlade® axial fan blades, grill guard and sheet metal venturi. Our U.S. facility now produces the sheet metal venturi and the final fan assembly.

As a result, motors, blades and grill guards are now shipped from Germany in more densely packed pallets, increasing the amount of components sent in one container and helping to reduce our environmental impact.

The next step in the process was to localize production of RadiPac assemblies. A RadiPac is a backward curved impeller, driven by a GreenTech EC motor, contained in a sheet metal enclosure. As energy efficiency has become a hot topic in the U.S. market, demand for energy-efficient backward curved impellers using a GreenTech EC motor has increased significantly. These products are typically used in rooftop air conditioning units, computer room air conditioning units and air-handling units, just to name a few applications.

RadiPac assembly

Localizing this production comes with many benefits. Three of the main ones include:

1. Products made to order

A major benefit to producing axial fans and RadiPacs locally is our ability to customize each product. Our sheet metal capabilities allow us to easily alter the venturi on an axial fan or the sheet metal enclosure surrounding a backward curved impeller. We have the ability to make specific mounting provisions for a customer. We can powder paint the venturi a customer-specified color. The end result is a product that exactly matches each customer’s requirement.

2. Quick turnaround

Beside allowing design flexibility, local production allows us to quickly react to customer demand. One example: We have several customers that use the same base fan in three different product variations. The differentiating factor is the sheet metal venturi. Without localization, we would have to import all three fan assemblies from Germany. Stocking the correct product mix would always be a challenge. By localizing production, we can stock the base components (motors and blades) and customize the sheet metal to each customer’s specs.

3. Reduced carbon footprint

By producing the sheet metal venturi and the final axial fan assembly, the motors, blades and grill guards are now shipped from Germany in more densely packed pallets, increasing the amount of components sent in one container and helping to reduce our environmental impact.

Localized production is a trend that makes sense on many levels: efficiency, customer service, development of skills and jobs in our communities. What other benefits do you see? What opportunities are still out there?

Share you thoughts below!

By Armin Hauer, Advanced Technology Manager 

Two weeks ago, I joined my German ebm-papst colleagues Katrin Schaake, Wolfgang Laufer and hundreds of scientists, researchers and engineers who swarmed San Antonio to attend three powerhouse events from June 3 - 7:     

• The Air Movement and Control Association International (AMCA) engineering conference    

• The International Gas Turbine Institute (IGTI)’s annual technical congress with several hundred papers and meetings of 20 committees

• The ASME International Gas Turbine Institute’s TurboExpo 2013, which hosted vendors from 12 countries 

As a longtime corporate member, ebm-papst has actively participated in AMCA’s events and worked on its committees. Because fans and turbomachinery play an important role in aircraft engines, power plant turbines and many other applications that would be discussed at IGTI and ASME, this year AMCA decided to co-locate and co-time its conference to allow cross-pollination of ideas and expertise with the other two events. 

The scope of fan sizes explored during the AMCA conference spanned 3.6  to 157 in., speeds from 750 to 10,500 rpm, and absorbed power from 30 W to 20 MW. We fan engineers loved it! 

The AMCA schedule included Wolfgang’s presentation, “Numerical Investigation of Axial Fans in Serial Connection,” that discussed his team’s research on two-stage setups of compact cooling fans, which are used widely in electronic telecom and computing equipment. These connected fans operate mostly at part load. If one fan fails, the remaining fan will speed up to avoid a local pressure drop or recirculation in the application. 

Using 3D numerical methods, the ebm-papst team of aerodynamics engineers, led by Wolfgang, studied various two-stage set-ups of axial fans with 85 mm impeller diameters. The goal was to measure and compare steady and unsteady calculations of different serial fan configurations and compare results. 

Our team proved how a proper arrangement of two axial fans will increase both fan pressure rise and flow rate. This type of arrangement would benefit air flow through the system & enhance cooling.

Dr. Michael Schmitz, manager of aerodynamics and simulation research and development at ebm-papst-St. Georgen, is a member of IGTI’s recently created Fans and Blowers Committee. The papers sponsored by this committee highlighted fan technologies in hovercrafts and fan sound reduction techniques for locomotives. One researcher provided bio mimetic studies involving fan blades with leading-edge bumps similar to the tubercles of humpback whales. Another analyzed the tip-clearance noise of axial fans, comparing experiments with numerical simulation. Another IGTI paper discussed inverse design methodology for fans and blowers driven by a genetic algorithm. 

Other topics presented at the conference included computational fan development, innovations such as a carbon-fiber bladed fan for abrasive air streams and a pair of fire-resistant, reversible tunnel ventilation fans. 

Presentations also addressed the all-important testing and certification of fans. In addition to electrical safety, air performance, sound, overspeed, balance and vibration requirements, some fans must undergo seismic pre-qualification or high-temperature stress testing. 

A talk about permanent magnet fan motors provided a welcome refresher. In 2004, ebm-papst Inc. won the AHR Expo Innovation Award for incorporating magnetic drive technology in fans up to 50 in. diameter and 12 kW electrical input, which expanded products to a wide variety of HVAC/R applications that can benefit from these advances.  The exhibition rounded off our days with hands-on demonstrations, follow-up discussions and networking opportunities. 

Next year’s Turboexpo takes place in Düsseldorf, Germany, and we’re already looking forward to participating. 

What innovations in fan technology are benefiting your business environment? What areas can be improved for your application’s air-moving requirements? We’d love to hear from you – leave a comment and message below.

ebm-papst engineers tell it from ‘the pits’: part 2

Part 1

Hogan Eng and Bill Aston talk about the two FIRST Robotics Competition teams that ebm-papst supports in Farmington and Woodbury, CT. 

Q: This year's FIRST Robotics Competition, Ultimate Ascent, game requires robots to fling plastic disks (Frisbees) and climb a metal pyramid. How did your teams approach this challenge as students conceived, designed and built your robots? 

Team Beta teacher-mentor Mike Murphy in the wrench costume - Richard Murkland Digital Photos

Hogan Eng: To help Team Beta understand the pros and cons of alternative strategies, we begin by simulating several rounds of the game. Students acted out behaviors of robots that would have certain characteristics, such as a long shooting robot, a climb-only robot or a defense-only robot. After discussions on what strategies could work, we brainstormed what kinds of mechanisms could be built for each strategy. We then voted on what approach was best given the six week time frame allowed to build the robot and the resources available. Our team worked in sub-groups responsible for developing the robot’s drive train, shooter, climber, programming elements and pit design. Each sub-group was composed of two mentors and a mix of veteran and new students. This provided the best support for new students while training our veteran students to be future mentors. 

Bill Aston: ebm-papst employee Matt Crossman, an alumnus of Farmington’s 2nd Law Enforcers, determined the team’s strategy for this year’s game. The team focused the robot on being able to effectively score points by throwing the discs. The robot’s design also had to allow it to climb the pyramid.  

Q: What, and how, did ebm-papst contribute to each team's robots in terms of design, engineering and production support?

Hogan Eng: While at the team meetings, I volunteered my experiences with program management and engineering design reviews. I also mentored the team’s shooter sub-group. When each group had robot parts that needed more sophisticated fabrication, I would bring the sketches to John DeMarco who would draw the part in CAD and tweak the design for better strength, manufacturability and aesthetics. The CAD information was then sent to   Bruce Thibodeau for programming the parts.  Tom Shimeld cut parts on the company’s laser machine. ebm-papst employee Mike Warner bent the parts. Employees on our production floor helped insert and paint components. 

In the meantime, another employee from ebm-papst Inc., T.J. Berti has come to our weekend meetings to train our students in TIG welding, making them quite accomplished welders! 

Q: The 2nd Law Enforcers have been around since 1997, and Team Beta's been around since 2009. How have each team's students evolved over these periods? How have they grown support from their schools and in their communities? 

Hogan Eng: Team Beta started out as a group of 12 sophomores at Nonnewaug High School. As the team's success grew in the school and in the surrounding community, we have grown to about 30 students and a dozen mentors. We’re now attracting students from other areas to Nonnewaug High who are joining our robotics team. During the team’s fund raising events, we displayed the robots and the students invite the community to ask questions. The team created the Connecticut Tech Fest, where we invite companies, other robot teams, universities, clubs and branches of our armed forces do display any really interesting mechanisms, inventions and products to the community. To promote careers in science and technology, the team actively engages other students.

Group of 2nd Law Enforcers sitting on the floor - Richard Murkland Digital Photos

Bill Aston: When I started as a mentor ten years ago, Farmington High School only recognized The 2nd Law Enforcers as a club. Now they are a team, with the same benefits as the school’s sports teams. Every year the older members of the team pass down what type of CAD files and geometry that we need to effectively produce parts off of our equipment. ebm-papst internal mentors Matt Crossman, Dale Watson, and TJ Swistro help with trouble shooting and working parts through production. ebm-papst continues to provide materials, our shop equipment time and the resources of our people.

Q: Why do you continue to dedicate your expertise and support to these teams?

Hogan Eng: I really believe in the ideals of FIRST, which encourages students to go into technical fields where they can have the opportunity to improve their lives, our communities, the country and the world. FIRST Robotics believes that our young people have a much better chance of becoming an engineer and making something useful as opposed to becoming a pro athlete. I have loved science even as a child and have become successful as an engineer, so this is my way of giving back to the community, sharing and teaching what I know to students who may have the same kinds of interests.

Bill Aston: My focus has shifted slightly; most mentor expertise comes from Matt Crossman, who is an alumnus of Team 178 and now manages most of the team’s activities for me.

Q: What would you say is one major way the students' robots have evolved since you became involved with the FIRST Robotics Competition?

Hogan Eng: I originally helped start a different robotics team in Woodbury back in 1997. That program focused on a mechanical design challenge with some basic program writing to customize how the robot is controlled. Being an electrical engineer, I commented that there wasn't enough of an electrical component for the kids who may have more advanced interests in electronics. Well, 16 years later, I am amazed at the level of sophistication of the robots and the skills of the students in C++ programming of gyros, accelerometers, visual image recognition, target tracking and more! As the technical world gets more complicated, these students have risen to the challenge. FIRST Robotics has provided an accelerated path to lead them there.

Q: Tell us about one moment or experience associated with CT FIRST that is either your favorite and/or one you know you will never forget.

Hogan Eng: It was 2009, our team’s rookie year. We had built a beautiful robot and headed to our first competition in Hartford. We won the Rookie All Stars award for our presence as a unified team, our robot design, and how well the students presented to the judges. Other teams thought we were a veteran team! We were thrilled. We realized this is not all about building a robot. It’s really about what the team had achieved over the six weeks in technical, organizational, interpersonal, and social and communication skills. We had formed a tightly knit group that was more like a family.

Bill Aston: One of my first years I showed a sophomore female student how to use an ordinary drill. She ended up being a leader in the engineering/build department of the team by the time she was a senior. 

For additional information about CT FIRST programs, visit ctfirst.org. For additional information about FIRST, visit usfirst.org.

ebm-papst engineers tell it from ‘the pits’: Part 1

ebm-papst believes that experience-based learning is the best way to get our kids excited about science and technology…and have a blast along the way. Every year, our company and its employees devote time, resources and expertise to turning this belief into reality.
 
Along with like-minded organizations including United Technologies, General Dynamics-Electric Boat, Northeast Utilities and our state’s leading universities, we support high-school level FIRST Robotics Competition (FRC) teams as they conceive, design, build, program and test robots that compete regionally and nationally.
 
FIRST stands for “For Inspiration and Recognition of Science and Technology.” This year’s FIRST Robotics Competition Connecticut Regional, sponsored by UTC, was held March 29 and 30 at the Connecticut Convention Center.  

To get ready for the competition, ebm-papst manager Hogan Eng devoted nights and weekends to helping Woodbury’s FIRST Robotics Competition (FRC) Team 2836, Team Beta at Nonnewaug High School.

Photo of Team Beta with Hogan Eng getting ready for battle - David Everett Photography

Meanwhile, manager Bill Aston mentored Farmington High School’s FRC Team 178, the 2^nd Law Enforcers.

2nd Law Enforcers team members wheeling their 'bot onto the field - Richard Murkland Digital Photos

Hogan and Bill’s involvement with the two FRC Teams is backed by employees Matt Crossman, Dale Watson, TJ Swistro, John DMarco, Bruce Thibodeau, Tom Shimeld and Mike Warner who each contribute their engineering and manufacturing expertise to the two teams’ robots.
 
Together, ebm-papst’s engineering and manufacturing experts help students on the two teams master science and technology concepts while gaining valuable career and life skills that are carrying them to higher education and STEM-based careers.
 So how did the two teams fare at the CT Regional?

• FRC Team 2836, Team Beta, received the Excellence in Engineering Award sponsored by Delphi

• Rebecca DiSarro, a member of Team Beta, was named Connecticut’s finalist for the FIRST Dean’s List.

• FRC Team 178, the 2nd Law Enforcers, received the CT Regional Competition’s Engineering Inspiration Award.

• Tim Barron, lead mentor for Team 178, received the Woodie Flowers Finalist Award for Connecticut.

Stay tuned for our next blog, where we catch up with Hogan, Bill and the ebm-papst team as they talk in depth about this year’s competition, the game, Team Beta and the 2nd Law Enforcers.

by Lou Moffa, Market Manager - Refrigeration

Take a walk outdoors in any suburban area and it is difficult to avoid the sounds created by the mechanical inventions in our modern society.  The drone of an aircraft passing overhead, the rush of vehicles from a busy street or the buzz of a lawnmower in the neighbor's yard create a measurable soundtrack to our daily activities.  Most of us are pleasantly surprised by just how quiet it becomes when these sounds suddenly stop and we are exposed to the underlying level of quiet that is present.  We cannot eliminate these noises entirely, but by applying our GreenTech philosophy of continuous design improvement during our product development, ebm-papst can again help engineers create air moving systems that are found outdoors that we can comfortably live with. 

In congested cities, with living spaces adjacent to supermarkets and small industry, the need for quiet operation is not just desired, it is mandatory by local codes.   Fans that are used to move large amounts of air to cool our mechanical equipment or keep our refrigeration systems running are necessary components in the systems that are placed on rooftops and the outside of our buildings.  Engineers and designers work very hard to meet the strict guidelines that are put in place to limit noise but these restrictions can negatively affect their final designs.

To lower noise in these applications, there are standard "fixes" that the designer can call upon to help meet the required noise and performance levels.  With axial fans, the common fix is to reduce the motor RPM and increase the number of fans to handle the air performance needs and or increase the blade size.  These solutions can lead to a reduction in system performance, add components increase the system footprint and increase energy consumption.   Not an appealing solution with today's high electrical costs, small installation areas and increased refrigeration costs.  Even worse, in many cases, these changes are not always effective and further fixes must be done on site where additional changes are even more costly. 

AxiTop from ebm-papst, a leader in air moving technology, offers a groundbreaking solution.  We have combined our high efficiency AC and EC axial fans with a passive diffuser assembled in one complete package to help simplify installations.  Our optimized AxiTop design has been shown to reduce noise lower energy consumption when installed in typical applications.  Integration of this assembly is simple.  The fan and diffuser are delivered as a complete assembly that can easily be integrated into an existing design using our standard square wall plate.  Or custom wall plates are available so that the AxiTop fan assembly can be integrated seamlessly into your air handling system.  

AxiTop is currently available worldwide in 800 and 910mm diameter axial fans.  These popular sizes are perfectly suited for use on rooftop condensers, fluid coolers, and agricultural ventilation applications.

If you need a real solution to meet applications with low noise requirements and at the same time reduce total cost of ownership and simplify your design, our AxiTop product line provides an answer! 

Please visit us at booth #2967 at the upcoming AHR Expo in Dallas, TX, to see the AxiTop units on display and for a complete overview of this exciting new product. Or contact us at sales@us.ebmpapst.com to review the benefits of using AxiTop. 

by Scott Beauchemin, Vice President - Engineering

ebm-papst’s success in the market can partially be attributed to our dedication to maintaining engineering resources to support customer projects.  Our local technical expertise allows us to provide a level of support that most competitors aren’t able to provide.  We have several engineering departments within the organization that help make that possible.

The Applications Engineering department has the highest head count of the various engineering groups at ebm-papst.  Applications Engineers are responsible for providing technical support to all customers within an assigned geographic region. Technical support can range from helping the customer select the proper air mover for their equipment to answering basic technical questions about ebm-papst product.  Applications Engineers work with customers from various market segments including HVAC, medical, industrial, IT/ telecom, etc. The diversity of our customer base gives the engineering group an opportunity to learn about various types of equipment.  Applications Engineers also spend part of their time working in our engineering lab which consists of several air flow chambers and a semi-anechoic sound room.  Customers send their equipment to our lab for baseline testing and optimization.  The Applications Engineers coordinate this effort, help perform the tests and report the results back to the customer.  The knowledge of ebm-papst product and customer’s applications gives Applications Engineers an opportunity to advance within the company if they perform well.  The educational background for an Applications Engineer is typically a Bachelor’s of Science in Mechanical Engineering.  Since our product is very much electro-mechanical, an educational background in Electrical Engineering can also be attractive. 

A portion of ebm-papst’s business is producing value-added assemblies for customers.  A value-added assembly can come in different configurations but it generally involves packaging a fan or multiple fans within a sheet metal assembly.  The assembly can include various other components such as connectors, filters and specific control boards.  While Applications Engineers serve as the project manager for these projects, there are three additional engineering groups that have direct responsibilities for these projects. 

The Design Engineering group is responsible for developing the value added assembly in Pro-Engineer and creating Bills of Material.  They are directly involved in working with the production floor regarding their designs.  The Design Engineer will often be seen building prototypes and working with their hands. Design Engineers will also conduct air flow modeling using Computational Fluid Dynamics software.  The goal is to optimize the air flow path in simulation so we only make sheet metal one time.  Design Engineers typically have a Bachelor’s of Science in Mechanical Engineering.  

The Electrical Engineering group is tasked with developing control boards that are used in conjunction with ebm-papst fans.  Members of the Electrical Engineering group will design the circuits, lay out the PCB so it can be fabricated, write software, build and test prototypes.  The controllers developed by this group are most often installed into a value added assembly but can be sold as a separate component on occasion. Members of the Electrical Engineering group generally have a Bachelor’s of Science in Electrical Engineering.

The last link in the value added chain is the Manufacturing Engineering group.  Manufacturing Engineers are tasked with supporting the production floor with work instructions, developing processes for manufactured parts and creating new tooling.  We are constantly expanding our manufacturing capabilities so the Manufacturing Engineers keep busy introducing new technology to the floor.  The Manufacturing Engineers work side by side with the Design Engineering group to bring a new product into production.  Manufacturing Engineers typically have a Bachelor’s of Science in Mechanical or Industrial Engineering.