Automated control of complex aerodynamic flows generated by Windshaper fan arrays

Windshapers, also known as fan-array wind generators, offer a high degree of control over complex aerodynamic flows thanks to the independent control of their thousands of small fans. But the process of setting up, measuring, and validating these flow profiles for aerodynamic tests can be time-consuming and cumbersome. In this study, a novel and intuitive approach is presented, making this process less tedious. An optically tracked 5-hole probe was developed to collect and process three-dimensional flow data in real-time. The flow data is used in a feedback loop to precisely control each and every fan of the Windshaper to generate the desired flow profile in the test area. A 3D graphical interface allows users to set-up the flow easily and visualize how the generated flow profile might deviate from the setpoint in every area of the test section. The present study is divided in two parts. First, we evaluated the accuracy and frequency response of the probe’s flow measurement capabilities. Then, we tested the effectiveness of the flow control setup with a series of wind profiles. The results obtained demonstrate that this approach can significantly reduce the time and effort required to generate and control complex flows for aerodynamic testing. Specifically, our tests showed that the real-time flow control method allowed to generate the desired flow profile in the test area with sufficient precision and with a short setup time. The 3D graphical interface provides an intuitive and easy-to-use platform for setting up the flow and visualizing any deviations from the setpoint. Finally, the probe’s performance is up to industry standards and exceeds the requirements for precise flow control of a Windshaper. Overall, our results suggest that this novel method provides an innovative and effective solution for generating and controlling complex aerodynamic flows, with potential applications in a range of industries including aerospace, automotive engineering, and wind energy.