Off-statistics input data sets are common in axial-flow fans design and may easily result in some violation of the requirements of a good aerodynamic blade design. In order to circumvent this problem, in the present paper, a solution to the radial equilibrium equation is found which minimizes the outlet kinetic energy and fulfills the aerodynamic constraints, thus ensuring that the resulting blade has acceptable aerodynamic performance. The presented method is based on the optimization of a three-parameters vortex law and of the meridional channel size. The aerodynamic quantities to be employed as constraints are individuated and their suitable ranges of variation are proposed. The method is validated by means of a design with critical input data values and CFD analysis. Then, by means of systematic computations with different input data sets, some correlations and charts are obtained which are analogous to classic correlations based on statistical investigations on existing machines. Such new correlations help size a fan of given characteristics as well as study the feasibility of a given design.
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