Case Study: Flexxaire Variable Airflow Fan for High-Performance Applications
The Challenge
Farmers rely on high-performance equipment to get through narrow harvesting windows efficiently. Standard fixed-pitch fans continuously draw power from the engine, even when full airflow isn’t required. To address this inefficiency, a real-world test was conducted on a Claas Jaguar 930 forage harvester to compare the performance and fuel consumption of a traditional OEM fixed-pitch fan with a Flexxaire variable-pitch fan.
Test Setup
The test was designed to capture real operational data during active harvesting:
- Duration: 19 days during the first cut of haylage
- Machine: Claas Jaguar 930 with a Mercedes-Benz OM 460LA 4i engine
- Fan Type: OEM sucker fan, diameter 1168 mm
- Instrumentation: A standalone datalogger was installed to monitor fan performance and fuel consumption
- Goal: Measure the potential power and fuel savings delivered by Flexxaire’s IVP (Infinite Variable Pitch) fan
Results: Real Power, Real Savings
After 79 hours of harvesting, the results spoke for themselves:
- Average power savings: 11.2 HP (8.4 kW)
- Fuel saved per hour: 1.8 litres
- Projected annual savings (600 hrs/year): 1,080 litres of diesel
These savings mean lower operating costs, reduced environmental impact, and more efficient use of engine power for the task at hand.
Reaffirmation with KULI
Beyond field testing, Flexxaire partnered with Magna to model the fan integration in KULI, a thermal management simulation tool, to validate performance:
- Simulated blade pitch angles: 0° to 25°
- Modelled system included: Radiator, oil cooler, and charge air cooler
- Inputs considered: Coolant and charge air temperature, dynamic thermal inertia, and system latency
- Goal: Ensure stable fan behaviour and optimal temperature control without oscillation
The modelling confirmed that the Flexxaire system could dynamically respond to real-time temperature inputs while optimizing energy usage throughout a full operating cycle.
Conclusion
The data confirms that Flexxaire’s variable pitch fans are effective. In this case, over 1,000 litres of fuel could be saved annually while maintaining optimal cooling performance, thanks to reduced fan load and dynamic control.
Flexxaire’s solutions are engineered to meet the demands of high-performance agricultural equipment, supporting operators with cleaner radiators, improved fuel efficiency, and less maintenance downtime.
Let’s Start the Conversation
Our engineers are ready to discuss your cooling challenges, learn about your application, and explore how Flexxaire can support your design goals.