Fan Optimization for Power Tools using Hyper Works(The combination of Acusolve, HyperMorph & HyperStudy)

The development of modern electric power tools for professional applications requires special attention to be simultaneously paid to the two main groups of characteristics: those which take into consideration the efficiency and user comfort of the tool, and those which determine the robustness and durability of the devices. For the fulfillment of these two groups of attributes, computer-aided simulations using the finite element software Acusolve® in combination with HyperMorph® and HyperStudy® has become central to the development process of Stanley Black & Decker Deutschland GmbH. The computer aided simulations are used throughout the development cycle - from the pre-development phase, right up to testing near-series prototypes and beyond to improving design based upon product-failure returns.

From the point of view of the performance and durability of our machines, it is our goal to design products to ever higher standards. To achieve and surpass the exacting requirements of our professional customers, one key factor is the cooling inside the machine. There are many factors which together contribute to achieve the best cooling: e.g. the position of the openings for air ingress and egress; the geometry of the housing; the geometry and fins of the gear housing; and of course the fan. The latter is naturally of paramount importance because, depending of its position in the machine, the geometry of the fan’s fins and their  position relative to the baffle could result in an increase or decrease of the air flow, the noise-level, and the overall cooling effect. To understand and optimize these factors, Acusolve® has been successfully used to determinate the amount of air flow; furthermore, in combination with HyperStudy® and HyperMorph® it is also possible to evaluate a huge number of designs – the results of which are used to assist the design engineers at Stanley Black & Decker to determinate the key parameters that yield the best performance for cooling down the components inside the machine without wasting too much power from the motor.


The Author

Raúl Cano
Stanley Black & Decker Deutschland GmbH