Tech Corner 5: Lift FansGiven the conversations about lift fans I thought it might be interesting to discuss the basics of how a lift fan works, and how it interacts with the cushion, and lastly what effect ducts and lift holes have.
Lift system requirementsIts worth just thinking for a moment about the lift system and what it has to do. This is two things:
- Create enough cushion pressure to overcome the craft weight
- Provide enough lift air flow to make up for the loss of lift air through the airgap under the skirt
First liftAs the fan spins, if there is no air flow (ie the craft has not lifted and the skirt is sealing against the ground) it creates a pressure increase from inlet to outlet. The faster the fan goes, the greater pressure it will create. At low revs there is not enough pressure increase to cause the craft to lift, and nothing happens other than the skirts begin to fill out a bit. At a certain speed, the fan can create enough pressure to lift the craft. This is called
first lift, and is the point at which the craft just begins to lift off the ground.
With the fan operating at first lift speed, all the fan can do is create the pressure. There is no power left over to provide any flow, and the fan will be operating in pressure mode only, there will be no flow to lubricate the cushion and the craft isn't really hovering properly.
Design liftOnce the fan speeds up beyond design lift, it is capable of creating more pressure than is needed for the cushion. However, if the cushin pressure rises any, it just lifts the craft up and opens up an airgap under the skirt, allowing this "extra" pressure to leak away. This regulates the pressure under the craft, and the extra power that the fan has goes to creat flow instead of pressure. Once this extra flow is enough to create a big enough air gap, that is to lubricate the skirt well, the craft is hovering properly. We call this
design lift.
Design lift is the most important parameter in the lift system. On a very smooth surface, this might be achieved at lower revs and on a rough surface or scrubby vegetation it may be achieved at higher revs. When we calculate design lift, we make an assumption about "average" conditions and apply a safety factor to allow for non-ideal conditions. The assumption boils down to a 20mm air gap, with the safety factor normally taken as about 1.5-1.8. This is what you see in the performance calculator.
The two stage lift conceptWhat this means is that there are two distinct stages in the lift process to understand
- Pressure mode: Create pressure in the lift system until first lift is achieved. There is no (significant) flow in this stage
- Flow mode: Create flow through the lift system until there is enough clear air gap to reduce friction and allow the craft to move - design lift.
Below first lift the fan is in pressure mode, above first lift it moves into flow mode.
Upstream of the fanSo its now obvious that the create design lift, we have to have an airflow through the fan. To get this, the fan must be operating above a critical speed (first lift) AND it must be able to get enough air in. Sounds obvious really! But there are some key bits that are often overlooked.
The air that goes through the fan is literally "sucked" in by the fan. Air can only move from a high pressure to a low pressure EXCEPT immediately across the fan. So the pressure immediately in front of the fan is at a lower pressure than atmospere, and thats why the air in front of the fan rushes towards the fan. Its just pressure. Remember that at a given speed, the fan can only create a given pressure rise - and this INCLUDES the suction part at the front. So, if your fan has to suck air through slots or ducts, the suction effectively comes off the pressure that can be raised on the high pressure side. If you fan has to suck hard to gets its air, its output pressure is reduced.
So its not that a fan cannot work when "buried" in bodywork BBV style, its just that it will work with reduced efficiency. Take the bonnet off a BBV3 and see how much the lift improves - its very significant.
For efficient fan operation. make sure that the upstream air inlet path is always of increasing area when compared to the fan - it must never be less area than the fan. Ideally, the inlet path area should be at least 50% greater than the fan area by a distance of 1 fan diameter in front of the fan.
Downstream of the fanOnce the fan has created some pressure, and assuming that we're above first lift and there is some flow, then that air has to move from the fan into the cushion. Remember that air only moves from high pressure to low pressure -if air is to travel through the duct, the air downstrea (in the cusion) must be lower than the pressure upstream (just behind the fan). This is wasted pressure, and wasted power.
If the air has to go through complex ducting and small lift holes, then the restriction is high and the pressure wastage is also high. On the other hand, if the ducting is short and of large size, the pressure wastage is low. A typical integrated craft with a plenum ducting air into the cushion via many small holes wastes about half the lift air pressure at design lift, in contrast delivering the air directly into the cushion wastes almost no pressure.
Ideally all the lift air should be delivered immediately and directly into the cushion.
Is there a best place to feed air into the cushion?Some people will say that the lift air should be introduced to the cushion at the front of the craft. Reasons given for this are usually something to do with reducing plough-in or something vague about "track laying with air". Thats all just hogwash. It doesn't matter where the air is put into the cushion, it will distribute itself equally through the cushion immediately once in there. The only exception to this is when a compartmented cushion system is used to ensure pitch stability, when the air should be delivered to each compartment in accordance with the design of the system. The Sev system, for example, requires that the air is delivered to the rear compartment first, but the antil-plough flap requires that air is delivered to both compartments at the same time for reasons beyond the scope of this article.
Twin fansSo what if twin fans are used? Will they fight each other?
If the two fans are identical and run at the same speed, they will both have the same first lift and transition from pressure mode to flow mode at the same time. In this case, the twin fans will have exactly the same first lift as a single fan, but above first lift they will create twice the flow, provided the upstream inlet area is big enough and not cluttered. To work out the approach area, think of each fan as having a solid wall between it and its partner fan.
If the two fans are not identical or run at different speeds, they will not achieve first lift at the same revs. In this case, the one that achieves first lift first will alway dominate, and the subordinate fan will always work at low efficiency. At the worst case, the subordinate fan may actually reverse flow. Its not that they are fighting each other as such, its just that they are not matched.
Matching the fans means not only the same fan, but the same upstream and downstream areas.
Further workTheres a lot more to lift fans than I've discussed here, such as what is the optimum blade angle and why, fan stalling, etc. But that will have to wait for another installment, we can talk about this part first then go onto the more advanced stuff.
Ian