Tong Chi Automobile-Moving head light cooling fan noise reduction proposal

According to customer feedback, the company’s product 400W moving head light uses a total of 6 cooling fans: 6020 fan 2pcs, 8025 fan 2pcs, 5020 fan 2pcs, the noise is too high when the prototype is running, our Ru0026D director went to the customer company to combine the wind tunnel instrument Test data and physical analysis of equipment give substantial suggestions for optimization and installation methods: u003cbru003e u003cbru003e u003cbru003e 1. Optimize fan selection: u003cbru003e u003cbru003e u003cbru003e 1. Air volume calculation of base fan u003cbru003e u003cbru003e u003cbru003e 【Composition】6020 x2 u003cbru003e u003cbru003e u003cbru003e [Confirm heat consumption] Input the maximum power of 520W, and calculate the heat consumption according to the power efficiency of 80%. Wu003d520*0.2u003d104W u003cbru003e u003cbru003e u003cbru003e [Design temperature rise] The maximum working temperature is 45 degrees, and the maximum temperature rise is 60 degrees. u003cbru003e u003cbru003e u003cbru003e ⊿ Tu003d 60-45u003d15 degrees u003cbru003e u003cbru003e u003cbru003e [Calculate the movement air volume] u003cbru003e u003cbru003e u003cbru003e 104/(20*15)u003d0.35m^3/mmu003d12.43CFM u003cbru003e u003cbru003e u003cbru003e 【Estimated Air Volume】 u003cbru003e u003cbru003e u003cbru003e The coefficient is 2 that is: Q*2u003d25CFM u003cbru003e u003cbru003e u003cbru003e 【Result】 u003cbru003e u003cbru003e u003cbru003e A single fan is 12.5CFM. 6020 fan 3000RPM can reach this air volume. u003cbru003e u003cbru003e u003cbru003e u003cbru003e u003cbru003e u003cbru003e u003cbru003e 2. Light source fan u003cbru003e u003cbru003e u003cbru003e [Composition] 5020x1 8025x2 u003cbru003e u003cbru003e u003cbru003e [Explanation] The light source has special requirements for the blower 5020 that blows directly, and the fans on both sides have no special requirements. u003cbru003e u003cbru003e u003cbru003e [Model selection] (1) 5020 blower is unchanged according to the original air volume and pressure parameters: 7CFM /21Pa. u003cbru003e u003cbru003e u003cbru003e (2) 8025 fan chooses low-speed static fan. Change the original speed from 4000RPM to 2500RPM. u003cbru003e u003cbru003e u003cbru003e (3) The light-changing film blower and the light source blower share the same specification. u003cbru003e u003cbru003e u003cbru003e (4) The ambient temperature of the light source is relatively high, and the working environment temperature of the fan is about 80. The electronic components and bearings of the fan must be made of high temperature resistant materials. u003cbru003e u003cbru003e u003cbru003e [Verification and Confirmation] Provide samples to install and confirm the lamp bulb and tube temperature by the light source FAE. (Tested and passed) u003cbru003e u003cbru003e u003cbru003e u003cbru003e u003cbru003e u003cbru003e u003cbru003e Two, combined with physical analysis of installation impact u003cbru003e u003cbru003e u003cbru003e 【Main Noise Confirmation】 u003cbru003e u003cbru003e u003cbru003e Power on each fan to test separately to confirm the noise. The noise generated by the base and arm lights is similar. u003cbru003e u003cbru003e u003cbru003e [Recommendation for base optimization] u003cbru003e u003cbru003e u003cbru003e 1. There are obstacle pairs at the entrance of the two fans of the base, which has a greater noise impact. The fan at the power supply is installed on the side or a thinner fan. u003cbru003e u003cbru003e u003cbru003e 2. The original use of 6020 4000RPM changed to 3000RPM, the fan can be reduced by about 7db. Or change to 8015 2000RPM. u003cbru003e u003cbru003e u003cbru003e [Verification] Working at the maximum ambient temperature of 45 degrees, the measured power supply MOS tube, rectifier output tube, transformer, and temperature do not exceed the maximum temperature stress of 110 degrees, and the fan may be adjusted according to the situation. u003cbru003e u003cbru003e u003cbru003e 【Optimization Suggestions for Arm Lights】 u003cbru003e u003cbru003e u003cbru003e 1. The product is a public model, and the mold cannot be changed. As far as the light source is required, the speed of the 8025 fans on both sides can only be reduced to achieve noise reduction, from 4000RPM to 2800PRM. The fan can be reduced by about 8dB. u003cbru003e u003cbru003e u003cbru003e Through optimization, the noise is reduced by about half, basically meeting customer requirements. u003cbru003e u003cbru003e u003cbru003e [Light source actual measurement confirmation] The light source FAE test temperature rise is within the allowable range. u003cbru003e u003cbru003e u003cbru003e u003cbru003e u003cbru003e u003cbru003e u003cbru003e The rocker lamp mechanism is a male model, and the installation method of the fan has a great impact on noise. u003cbru003e u003cbru003e u003cbru003e 1. The air inlet of the base fan does not leave a safe distance, and the noise is louder. u003cbru003e u003cbru003e u003cbru003e 2. The base does not consider the reasonable ventilation required for air cooling. u003cbru003e u003cbru003e u003cbru003e 3. 8025 on both sides of the light source on the arm lamp, the fan is recommended to be directly mounted on the shell side to better form air convection. u003cbru003e u003cbru003e u003cbru003e 4. The opening area of u200bu200bthe fan inlet/outlet of the enclosure is too small and needs to be optimized. u003cbru003e u003cbru003e u003cbru003e For the above problems, special attention should be paid to fan assembly and air duct optimization when opening private molds. For 400W rocker lights, it is easy to achieve heat dissipation and noise reduction. u003cbru003e u003cbru003e u003cbru003e u003cbru003e u003cbru003e u003cbru003e u003cbru003e Thank you for your reading. Tongchi Automobile is a professional manufacturer of cooling fans, specializing in the development and production of cooling fans, DC fans, centrifugal fans, and blower cooling fans. It has its own Ru0026D team and is the agent of Japan’s SANYO DENKI cooling fans. JAMICON Kaimei cooling fan, Taiwan AVC fan, welcome to consult, thank you!