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DESIGN AND OPTIMIZATION OF CENTRIFUGAL

BLOWERS

Submitted by

ARUN A R (19M607)
SUNDAR JACOB R (19M639)
SRIRAM A (19M647)
THIYAGARAJAN P (19M649)

Dissertation submitted in partial fulfillment of the requirements of the degree of

BACHELOR OF ENGINEERING MECHANICAL


ENGINEERING (SANDWICH)

November 2021

DEPARTMENT OF MECHANICAL ENGINEERING


PSG COLLEGE OF TECHNOLOGY
(Autonomous Institution)

COIMBATORE – 641 004


PSG COLLEGE OF TECHNOLOGY
(Autonomous Institution)

COIMBATORE – 641 004

DESIGN AND OPTIMIZATION OF CENTRIFUGAL


BLOWERS

Bonafide record of work done by

ARUN A R (19M607)
SUNDAR JACOB R (19M639)
SRIRAM A (19M647)
THIYAGARAJAN P (19M649)

Dissertation submitted in partial fulfillment of the requirements of the degree of

BACHELOR OF ENGINEERING MECHANICAL


ENGINEERING (SANDWICH)

…………………………. …………………………
Dr.T.Prabu Dr.K.Mayilsamy
Faculty guide Programme Coordinator

Certified that the candidate was examined in the viva voice examination held on

……………….. ………………..
(Internal Examiner) (External Examiner)
Acknowledgement

ACKNOWLEDGEMENT

The completion of this project would not have been possible without the
guidance and support of many people. We would like to express our sincere
gratitude to Dr.K.Prakasam, the Principal, PSG College of Technology for
providing us with the necessary facilities for the project work.

We express our heartfelt gratitude to Dr.P.R.Thyla, the Head of


Department, Department of Mechanical Engineering, PSG College of
Technology, for providing us the opportunity to carry out this project work and
for her constant support and encouragement throughout the project.

We would like to thank Dr.K.Mayilsamy, Professor, Programme


Coordinator, Department of Mechanical Engineering, PSG College of
Technology, for providing us with an opportunity to do this project and make use
of the facilities.

Our sincere thanks to our tutor Mr.N.Mathimurugan, Assistant


Professor, Department of Mechanical Engineering, PSG College of Technology,
for his constant support and guidance.

We extend our sincere thanks to Dr.T.Prabu, Assistant Professor,


Department of Mechanical Engineering, PSG College of Technology for sharing
their knowledge and expertise and for guiding us throughout the project work.

We like to express our thanks to all teaching and non-teaching staff


members in the Department of Mechanical Engineering, for their direct and
indirect support.

i
Abstract

ABSTRACT

Blower is used to deliver the air or gas with an appreciable rise in pressure again
the flow resistance. It is an important role in various industries for air-conditioning
systems, furnaces and dust or fume extraction systems especially in textile
industries where raw cotton is transformed into a fabricated thread like structure
which is later used for various purposes. Based on the input data the design
calculations have been carried out and modelled using CF Turbo and
SOLIDWORKS. The cleanup and meshing are carried out in CFD Analysis. The
Main Aim Behind these Project for increase energy efficiency & constant air flow
delivery that enable them generate energy of increased efficiency. Done the CFD
investigation for getting improved parameter blend utilizing prepare. This will
provide optimised design of centrifugal blower. This paper gives the solution to
above problems by optimization of centrifugal blower impeller.

ii
Table of Contents

TABLE OF CONTENTS
Page No.

ABSTRACT..........................................................................................................ii

TABLE OF CONTENTS.......................................................................................iv

LIST OF FIGURES.............................................................................................vi

LIST OF TABLES..............................................................................................viii

CHAPTER 1 – INTRODUCTION........................................................................1

CHAPTER 2 - LITERATURE REVIEW..............................................................3

2.1 Introduction..............................................................................................3

2.2 Types of PAM’s.......................................................................................3

2.3 Applications in material handling............................................................5

2.4 Rehabilitation applications.......................................................................6

2.5 Control strategies followed....................................................................12

2.6 Summary................................................................................................15

CHAPTER 3 - METHODOLOGY AND OBJECTIVE......................................16

3.1 Methodology..........................................................................................16

CHAPTER 4 - DESIGN STUDY........................................................................18

4.1 Introduction............................................................................................18

4.2 Study of human gait and lower limb anthropometry..............................18

4.2.1 Assessment and monitoring of growth............................................18

4.2.2 Measuring stature............................................................................19

4.2.3 Lower limb movements...................................................................20

4.3 Force calculation and sizing of suitable actuator....................................20

4.4 Proposed mechanisms and motion analysis...........................................24

iii
Table of Contents

CHAPTER 5 - CONCLUSION...........................................................................30

BIBLIOGRAPHY...............................................................................................31

iv
List of Figures

LIST OF FIGURES
Page No.

Figure 1 Normal and contracted muscle...................................................................3


Figure 2 Textile PAM under actuation.....................................................................4
Figure 3 (a) Holding cylindrical bottle to check power grasp (b) Holding tennis ball
shows the precision grasp.........................................................................................5
Figure 4 Air muscle actuated humanoid hand holding a bottle.................................6
Figure 5 (a) Extensor actuators; (b) Circular Pneumatic Muscle Actuator...............6
Figure 6 Proposed wrist joint rehabilitation system..................................................7
Figure 7 (a) Movements of the fishtail and the palm; (b) Construction of the
rehabilitation equipment...........................................................................................8
Figure 8 Soft glove grasping various objects............................................................9
Figure 9 Observing the performance of the glove when pressurized at 200 kPa. (a)
Raising the weight with the help of flexing the wrist, (b)Raising the dumbbell with
an extension of the wrist (c) holding capacity of the finger, (d) squeezing power of
the thumb................................................................................................................10
Figure 10 Proposed ankle rehabilitation system.....................................................10
Figure 11 Proposed pneumatic artificial muscle actuated above-knee prosthesis...11
Figure 12 Connection diagram of the PAM [24]....................................................13
Figure 13 Methodology..........................................................................................17
Figure 14 Human lower limb anthropometry [34]..................................................19
Figure 15 Lower limb movements [35]..................................................................20
Figure 16 Lower limb weight distribution..............................................................21
Figure 17 PAM Working [36]................................................................................22
Figure 18 Working range graph of 20 mm fluidic muscle from Festo....................23
Figure 19 Festo product catalogue..........................................................................24
Figure 20 Proposed motion analysis for knee rotation...........................................26
Figure 21 Proposed sketch of lambda mechanism..................................................27

v
List of Figures

Figure 22 Lambda mechanism motion analysis......................................................27


Figure 23 Hip, Knee and ankle joint angles during a gait cycle.............................28
Figure 24 Hip angle measurement..........................................................................28
Figure 25 Ankle angle measurement......................................................................28
Figure 26 Knee angle measurement.......................................................................29
Figure 27 Working mode for a 2-DOF 3-parallelogram PP....................................29

vi
List of Tables

LIST OF TABLES
Page No.

Table 1 Types of motions used for rehabilitation...................................................25

viiIII
Chapter 1 Introduction

CHAPTER 1 – INTRODUCTION
Centrifugal blowers are widely used in different industrial applications,
which are proficient of as long as restrained to high-pressure rise and flow rates.
Centrifugal blowers are mainly two main parts, namely, the casing and the
impeller. The impeller is often considered an integral part of the suction motor
since its housings and the motor are assembled as a unit. The impeller, driven by
the blower shaft adds the velocity component to the fluid by centrifugally casting
the fluid away from the impeller vane tips. The key idea here is that the energy
created is kinetic energy. The amount of energy given to the fluid corresponds to
the velocity at the edge or vane tip of the impeller. Addison (1995) established that
the faster the impeller revolves or the bigger the impeller is, the higher will be the
velocity of the fluid at the vane tip and the greater the energy imparted to the fluid.

The principle involved in the design of a blower is similar in virtually every


important aspect as that of a centrifugal pump except for the fact that the term
“centrifugal pump” is often associated with liquid as its working fluid while the
blower is meant to work on air (Edward, H.S. 1995). The effects of centrifugal
force acting upon the spinning air within the impeller create the suction. As the
impeller rotates, the spinning air moves outward away from the hub, creating a
partial vacuum which causes more air to flow into the impeller. Air enters the
impeller axially through the inlet nozzle which provides slight acceleration to the
air before its entry to the impeller. The action of the impeller swings the air from a
smaller to a larger radius and delivers the air at a high pressure and velocity to the
casing. The centrifugal energy also contributes to the stage pressure rise. The flow
from the impeller blades is collected by a spirally-shaped casing known as scroll or
volute. It delivers the air to the exit of the blower. The scroll casing can further
increase the static pressure of air. The outlet passage after the scroll can also take
the form of a conical diffuser.

Impeller is the most important part of the blower components because of the
fact that its performance inadvertently determines the blower’s performance. An
impeller is essentially a disk-shaped structure with vanes that create the actual
1
Chapter 1 Introduction

suction in a blower. The impeller is always placed directly onto the shaft of the
electric motor so that it spins at a very high speed. The effects of centrifugal force
acting upon the spinning air within the impeller create the suction.

The design of centrifugal blower involves a large number of interdependent


variables so there are several possible designs for the same duty. To calculate the
power input, flow rate and total adiabatic head must be known. As a result, to
provide a certain amount of power to the air a larger amount of power must be
provided to the blower shaft. This power is called brake horsepower.

2
Chapter 2 Literature review

CHAPTER 2 - LITERATURE REVIEW

The performance of the fan obtained by different fan laws. Hence lot of emphasis
is given to understand the basic theory of fans, their types and their working. The
selection of critical parameters is very essential and determining the performance
of the fans. The basic equations mainly continuity equation, momentum
equations and energy equations need to be considered while following the
computational fluid dynamics approach. While considering any practical problem
the best turbulence model and order of accuracy needs to be selected for good
results. When carrying out the design optimization of centrifugal fans, centrifugal
blower where the mass flow variation is controlled by mobile ante rotor and not
by speed variation of the electrical motor. For vibration analysis of blower need
to know the parameters which cause vibration and also the method to measure
vibration with proper setup arrangements. Due to vibration the life of bearing of
blower is reduced. The life of bearing can be improved by carrying corrective
actions on blower & modifying its accessories like Plumber block to prevent
bearing failure.

3
Chapter 2 Literature review

CHAPTER 3 - METHODOLOGY AND OBJECTIVE


3.1 Methodology
The methodology to meet the objectives is mentioned in Figure 1 which
starts with a study of existing lower limb rehabilitation robots. The proposed
passive lower limb orthosis limb support or kind of exoskeleton-based system
design is a key part of the rehabilitation robotic system. The workspace of the
proposed system is studied to select a suitable manipulator for covering the
required clinical workspace region based on the available clinical data set.
Further, the best possible manipulator configurations are studied and their
performances need to be investigated to provide the required or desired motions
of the lower limb or orthosis system based on the given clinical gait data Set. The
best-suited manipulator configuration has to be simulated for understanding its
motion capabilities and the motion controller is designed using its dynamic
model. Further, the functional design of the proposed rehabilitation robot along
with the detailed mechanical design needs to be done. Based on functional and
detailed designs, a scaled in-house experimental prototype has to be fabricated
and tested its motion capabilities in real-time without a motion controller.
Further, the fabricated prototype has to be controlled in real-time with the
proposed motion control scheme for exhibiting its therapeutic capabilities and
feasibilities during the passive range of motion therapies. The controller design
optimization and detailed performance investigations need to be performed in
this phase which includes repeatability, resolution, and motion accuracy tests.
The clinically obtained gait data set has been provided to the proposed system to
perform a passive range of motion and verify the feasibility of the proposed
rehabilitation robotic system.

4
Chapter 2 Literature review

Figure 1 Methodology

5
Chapter 4 Design

CHAPTER 4 - DESIGN STUDY

4.1 Phase I – Blower types

The centrifugal fan uses the centrifugal power generated from the rotation of
impellers to increase the pressure of air/gases. It may be classified into three basic
types according to blade configuration: forward curve, backward inclined, and
radial or straight blades [1]. Because of its high static pressure and capability of
handling airstreams containing a high level of particulate, radial blade is suitable
for the application of dust laden. The open wheel or paddle wheel is the most
common of the radial blade impellers. Air wheel and radial tip impeller are the
other variants of radial impellers ideal for contaminated airstreams but neither is
intended for bulk material handling
4.2 Phase II – Parametric study on blowers
The critical parameters of the centrifugal fan impeller is found out which
highly affect the performance characteristics are impeller outlet width, impeller
outlet diameter, blade thickness, impeller blade outlet angle, and number of blades.
comparisons are conducted between the fan with original impeller and two larger
impellers with the increments in impeller outlet diameter of 5% and 10%
respectively in the numerical and experimental investigations. Experiment results
show that the flow rate, total pressure rise, shaft power and sound pressure level
have increased, while the efficiency have decreased when the fan operates with
larger impeller. The tip clearance (i.e., distance of the blade with top of the casing)
has been deduced that the impeller with backward-curved blades was very
sensitive, whereas the other two types were not. The impeller with radial tipped
blades showed a weak dependency on tip clearance. However, for the case of fully
radial blades, it has been observed that the fan is almost insensitive to the tip
clearance. The inlet radius has major impact on the flow rate of the centrifugal
blower. Too small or too large of a radius will result in a noticeable loss in the flow
rate. Too small of a radius will have negative impact on flow rate. Anyway, it's
best to have the bell mouth radius ratio at the value around 9%.

4.3Phase III – CFD Analysis.


Computational Fluid Dynamics usually abbreviated as CFD, is a branch of
fluid mechanics uses numerical methods and algorithms to solve and analyze
problems that involve fluid flow . The CFD part is used for improving the results
of static pressure generated at the entry to the impeller, static efficiency. The MRF
(moving reference frame) applied in the CFD analysis of centrifugal fan as a
rotating region around the impeller and component of the impeller stationary . A
250mm backward curved blower impeller in a shroud was tested and modeled in
two CFD scenarios: one which resolves the impeller and shroud geometry and one
which requires knowledge of the pressure versus flow curve and models only the
shroud geometry. Comparing with the test data MRF models predict the flow fields
much better than the lumped compact models using the P-Q curves.

6
Chapter 4 Design

4.4Phase IV – Design of Experiments.


Design of experiments (DOE) or experimental design is the design of any
information-gathering exercises where variation is present, whether under the full
control of the experimenter or not. The blower housing was optimized using a
Design of Experiments (DOE) technique where the geometry of housing was
varied in a structured manner to capture expected sound order behavior.

CHAPTER 5 - ANALYSIS OF
CENTRIFUGAL BLOWER.
The 3D modeling of the blowers are created using SOLIDWORKS. The major
parts of the blowers are fan inner diameter, fan outer diameter, blade inlet width,
blade outlet width, number of blades, blade thickness, and volute casing.

Front and Side View of the Blower.

The geometry of the blade depends on fan diameters and blade angle. For each
number of experiments, the blade profile varies which could be constructed using
tangent circular arc method.

The air flow inside a blower is high turbulent flow. Therefore, this study simulates
the complex flow patterns inside the centrifugal blower by using the commercial
computational fluid dynamics software Fluent to solve the fully three-dimensional
incompressible Navier–Stokes equations by the standard k- ε turbulence model.
The steady k-ε simulation is performed with the moving reference frame (MRF)
model to deal with the rotating fluid inside a centrifugal blower. The projected total
pressures with the various airflow rates on operating points can be used to
determine the performance curve. Based on the calculated torque it is then possible
to calculate the blower efficiency for the entire performance curve.
7
Chapter 4 Design

CHAPTER – 6. CFD ANALYSIS.


Computational Fluid Dynamics (CFD) approach is the effective method of solving
non-linear partial differential equations that governs fluid flow, heat transfer and
turbulence of flow. In this present study, CFD FLUENT is used to solve the flow
inside the centrifugal blowers. Moving Reference Frame (MRF) method is
adaptable for the condition where fluid rotates. A separate cell zone has to be
mentioned for MRF method, the second cell zone condition in our study was
considered as MRF zone. The assumptions made for this study are, i. Steady state
air flow ii. Implicit solver iii. Standard wall function iv. Second order upwind
scheme.
Works to be completed

 Optimizing the final dimensions of the Parallelogram manipulator and


arriving at a suitable driving mechanism for lower limb rehabilitation.

 Kinematic and Dynamic analysis of proposed motion control system to


validate the assumptions.

 Development of robust control systems for the proposed lower limb


rehabilitation system.

8
Chapter 5 Conclusion

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Chapter 5 Conclusion

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Chapter 5 Conclusion

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Chapter 5 Conclusion

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