Mahle has invented a bionic radial blower for automotive air-conditioning systems to improve efficiency while significantly reducing noise levels. The aerodynamic shape of the fan blades is inspired by the fins of a penguin, and the system has been designed for vehicles with challenging installation space.
“Evolution has equipped the penguin with fins that allow it to glide through the water with minimal resistance and, therefore, ultra-high efficiency. The fin shape served as a model in the optimization process of the impeller of our radial blower,” said Dr Uli Christian Blessing, vice president of R&D thermal and fluid systems at Mahle.
The bionic fan is said to be 4dB or 60% quieter than similar components and around 15% more efficient because the motor requires less energy. The system can be used in all passenger car classes, as well as in light- and heavy-duty commercial vehicles.
AI-supported design
“The application of artificial intelligence has been enormously useful in the optimization of the bionic radial blower,” Blessing reported. “Our engineers guided the AI and provided it with data and information, enabling it to create more than 30 million virtual designs in a very short time. Internally, we are referring to this as superhuman engineering.” The Mahle engineers used AI to find the ideal shape and positioning of the fan blades and quickly produce prototypes.
The system sits in front of the evaporator and makes the design of the air-conditioner symmetrical and narrow. This creates more space for other components.
The technology group is currently presenting the system at the Auto Shanghai trade fair in China.
