A Case Study in Cooling Fan Testing for LED Projection Equipment
1. The Challenge: Unexpected Noise and Poor Airflow
A customer in the LED lighting industry was developing projection light equipment for building illumination.
Their initial design used three large 172 mm cooling fans.
After calculating airflow requirements, the customer’s engineer was confident the design would meet performance targets.
However, during prototype testing, two major problems appeared:
- Noise levels were much higher than expected.
- Actual airflow was lower than the engineer’s calculations.
2. Our Technical Lab Approach
To investigate, we invited the customer to bring their chassis to our Technical Center in Torrance, CA.
Our application engineers performed controlled airflow and acoustic testing using:
- Airflow chamber for airflow measurement and operating point analysis
- Soundproof room for analysis of sound and vibration
- Simulated load and ducting setups to replicate real-world conditions
3. The Root Cause: Fan Placement Interference
Testing revealed that fan placement, not fan performance, was the main issue.
Because the three 172 mm fans were mounted too close to one another, the airflow from one fan disrupted the intake of the fan next to it.
This interference reduced total airflow and increased noise level.
4. The Solution: Fewer Fans, Better Results
Our engineers recommended a redesign:
- Reduce the number of fans from 3 to 2.
- Increase spacing between the two fans to avoid airflow interference.
After adjustments:
- Airflow met the required performance target.
- Noise levels dropped significantly.
- The system ran more efficiently.
Even though SANYO DENKI AMERICA sold fewer fans (from 3 to 2), the priority was delivering the best solution for the customer—reliable performance, lower noise, and long-term satisfaction.
5. Why Partner with SANYO DENKI AMERICA
Our Technical Center services go beyond supplying fans, we help customers optimize designs, troubleshoot issues, and ensure the best real-world performance. Whether it’s airflow testing, noise reduction, or thermal optimization, our engineering team is here to help.
Recommended read for fan placement in chassis: What to consider when designing fans in parallel
About SANYO DENKI
SANYO DENKI has been a trusted provider of cooling solutions for various industries, with fans being a crucial component in many advanced devices. Contact us for a quote, or to discuss your device’s customization requirements.
Our experienced application engineers and field engineers will provide support on the customization or any other technical support for your equipment. Contact our representatives or distributors to start discussing your next project.
