Efficient Fan Design Using Propellers for Fan Array Wind Tunnels

Abstract

The operation of unmanned aerial vehicles (UAVs) in adverse environments requires the ability for repeatable testing of complex, turbulent conditions. Traditional methods such as field studies and wind tunnels often lack the controllability and spatial flexibility required to simulate realistic, time-varying wind profiles, respectively. An alternative testing facility is a modular, open-concept fan array wind tunnel that utilizes independent fan “pixels” to arbitrary wind conditions. However, current fan pixels are standard computer server fans, which consume significant energy in off-design conditions. We investigate the replacement of these units with UAV motors and UAV-like propellers to improve the thrust-to-electric power ratio. This includes the overall increase in the diameter of the fan. We explore the design parameters space of a number of blades, pitch, twist, and sectional chord length and shape by employing blade element momentum (BEM) theory. Based on aerodynamic principles, it is expected that optimizing the blade geometry will significantly reduce energy consumption while maintaining the high thrust levels required for simulated flight conditions. Ultimately, this design study will lead to a printable fan design that will be used experimentally tested in the laboratory.

Publication Title

Regional Student Conferences 2026

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