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Thank you for taking the time to find out more about our company, our services and the benifits we can provide for your company. MechCal is an internationally recognised technology service provider and manufacturer of advanced carbon composite fans.
We can provide custom design and analysis for each individual solution you require, no job is too big or too small.
Our unique and technologically superior products have attracted the interest of several Original Equipment Manufacturers (OEM's) in this market segment. Combined with our design advantage, the use of composite materials allows us to easily tailor solutions to clients' needs.
Should you require additional information, please do not hesitate to contact us as we look forward to being of service to you.
MechCaL Composite Fan Technology Video >>>
Axial Pressure Distribution cut >>>
The MechCaL Difference
Why switch to a composite Fan?
This design is verified and optimised using computational fluid dynamics modeling. A finite element analysis of the structural design of the optimised fan is conducted before a prototype is builtur design advantage, the use of composite materials allows us to easily tailor solutions to clients' needs. Read More >>>
The following video focuses on MechCaL's corporate profile, customer relationships and overview of the company.
MechCaL has developed a range of fans for a niche market sector through making use of proprietary technology developed over the last several years by its principals.
The company has experienced steady growth in its customer base and has expanded to become an internationally recognised technology service provider and manufacturer of advanced composite fans.
Velocity cross section plots
By focusing on crucial design aspects including noise reduction, aerodynamic efficiency and mass, MechCaL has developed products that exceed client expectations. MechCaL's clients have performed noise and performance tests at their own facilities and verified the significant improvements delivered by MechCaL designs
Download MechCaL Carbon Composite Fan Technology Brochure
MechCaLCompositeFanTechnology(2).pdf
Key Features
We focus on these crucial
design aspects in all of our
products:
NOISE REDUCTION
AERODYNAMICS
PERFORMANCE EFFICIENCY
MASS SAVINGS
Contact Us
Please contact us for more information about our products.
Contact Us >>>
MechCaL centrifugal fans are designed and manufactured for specific client applications to satisfy targeted performance goals. All Centrifugal designs undergo comprehensive mechanical and aero designing. After the prototype is manufactured, the fan is dynamically balanced and finally experimentally tested using BS848 ducting to verify performance figures. read more>>>
MechCaL Jet Fans have been designed to increase the total "Jet Throw" while maintaining the same flow rate and pressure as well as reducing the total power consumed. This unique patented design produces up to 60% increased "Jet Throw" over and above the other advantages.
MechCaL Axial Flow Fans are designed to meet client specific operating point in an attempt to reduce power consumption and generated noise. MechCaL Axial Flow Fans have been independently tested and verified by clients for specific applications and have shown to reduce power consumed by up to 25% for the same flow rate and pressure developed. read more>>
Mixed Flow Fans are designed and built in an attempt to satisfy unique client applications to have high pressure and high flow rates in a single installation. Prototypes have been shown to adequately satisfy these unique applications.
Prototype fans undergo performance testing according to British Standard 848 before going into production. Each production MechCaL fan is dynamically balanced and spun at high speed before delivery to the client.
CASE STUDY 1 | CASE STUDY 2
Original Metal Fan:
MechCaL Composite Fan:
- Mass: 16kg
- Premature bearing failure
- Aerodynamic performance less than optimal
- Mass: 6kg (60% weight reduction)
- Cost: less than the OEM replacement steel fan
- Bearing failure problem solved
- Aerodynamic performance improved by 15%
- Hub attachment improved (quicker fitment)
MAIN MENU PRODUCTS FEATURES CONTACT US
Mass: 80kg
Catastrophic failure, causing extensive damage downstream and considerable downtime
Mass: 26kg
Cost: less than the OEM replacement steel fan Weld fatigue problem eliminated
853mm Fan Performance Comparison
MechCaL's 850mm Mark 1 fan was designed to be a composite replacement for the existing steel unit - no aerodynamic or acoustic changes were made to the straight bladed fan. The Mark 1 is geometrically (and hence aerodynamically and acoustically) identical to the original steel fan and was designed purely as a light-weight composite replacement to eliminate the weld fatigue problem experienced with the heavy steel fans. The MechCaL 850mm Mark 2 fan is completely re-designed fan, optimised for the same application as the Mark 1 fan and is a backward curved radial fan with 11 airfoil profiled blades. The fan is designed to be a drop-in replacement for Mark 1 or steel unit and utilises the existing inlet and scroll. Performance testing shows that the fan meets the Mark 1 2250rpm performance at 1900 rpm yet is 7dB(A) quieter. At 2250 rpm (Mark 1 operating speed), the Mark 2 fan produces ~40% more static pressure for a given volume flow. Structurally, the Mark 2 is stronger than the Mark 1 due to the thickness of the airfoil profiled blades. The Mark 2 fan mass ~20kg compared to the ~80kg of the original steel fan and its inertia is consequently significantly lower resulting in lower start-up, vibrational and gyroscopic loads on the drive and support systems
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Intrinsically safe - no sparking
Fail safe and reduced consequential damage in the unlikely event of a failure no shrapnel
Chemically resistant - can be tailored for specific applications
Drastic reduction in fan weight, thereby extending the life of the mechanical drive system and making handling and
fitting much easier
Optimal aerodynamic design to provide higher performance / efficiency for any specific application
No rusting/corrosion
Tailored erosion resistance for abrasive environments
Lower drive motor rating and lighter bearing system
Lower power consumption
Uniform dimensions and consistent quality
Lower flow noise and mechanical noise level
Longer life due to improved mechanical strength
Custom design at no extra cost - no fan is too big or too small
The MechCaL factory has been designed specifically for composite manufacturing and is separated into 4 discrete areas. Each area is associated with a specific task and is hermetically isolated from the others to avoid dust and particulate contamination, ensuring process and product quality. The areas include a room for cutting composite cloth materials, a room to blend resins and apply the layups and a general sanding room. The remaining part of the facility is used as a general preparation and assembly area where the majority of the larger machines such as the milling machine, CNC Router and large lathe are placed.
Within the facility, MechCaL has developed various proprietary processes to ensure that all products that are manufactured are of a high quality. A plethora of jigs and moulds have been designed and manufactured. As part of the assembly and curing process for manufacturing composite components, MechCaL has developed various procedures that are part of its intellectual property and unique to MechCaL fans.
Centrifugal scroll
The feature common to all polymeric composite processes is the combining of a resin, a curing agent, some type of reinforcing fibre, and in some cases a solvent. Typically, heat and pressure are used to shape and "cure" the mixture into a finished part. In composites, the resin acts to hold the fibres together and protect them, and to transfer the load to the fibres in the fabricated composite part. The curing agent, also known as hardener, acts as a catalyst and helps in curing the resin to a hard plastic. The reinforcing fibre imparts strength and other required properties to the composite.
Baseplate for centrifugal fan being machined using a CNC router.
Engineering Design & Analysis Read More >>>
Noise & Vibration Services Read More >>>
Fluid Dynamics & Aeronautics Read More >>>
Axial pressure distribution cut animation >>>
Engineering Design & Analysis
Services
Although specialised in high performance fan design and manufacture, MechCaL also offers aeronautical and mechanical engineering consultation services that include design, optimisation, analysis, machining / manufacturing and testing.
MechCaL's integrated service results in efficient designs that are simultaneously optimised for function and noise (if required).
Examples include:
Fans, impellers and wind turbines
Prototypes/Models Shafts and beams
Fatigue and stress Calculations
Composite design and manufacture
Masts / antennae / towers Pump, motor and gearbox selection
Failure analysis Finite Element Modelling (FEM)
Bearing, weld fastener selection etc.
Capabilities
Design optimisation
Mechanical Engineering Design
Analysis Manufacturing / Machining
Product Design, Development and Testing
Noise & Vibration Services
With over 12 years' experience in noise measurement, noise analysis and noise abatement, MechCaL's founding member is one of the country's leading acoustics experts.
MechCaL focuses on technical solution of a wide range of noise problems:
- Noise "hot spot" location and reduction(for example in vehicle cabins).
- Environmental noise measurement abatement (for example industrial
noise propagating to suburbs).
- Abrasive environments
- Solution of specific problems (for example pumps, fans, compressors etc).
- Class 1 noise measurements for Environmental Impact Assessments (EIA).
Noise & Vibration analysis
Noise & Vibration measurement
Noise & Vibration prediction
Noise & Vibration abatement
Custom Hardware & Software Development
Fluid Dynamics & Aeronautics
MechCaL's access to wind tunnels and CFD (computational fluid dynamics), combined with top aeronautical engineering capability make it one of only a few independent sources of fluid dynamic and aeronautical expertise.
- From aircraft design to industrial flow problems, MechCaL can help.
- Aerodynamic analyses of aircraft and aircraft stores / pods / antennae etc.
- Aerodynamic design and optimisation, for example wings, propellers, race cars, vehicles, wind turbines.
- Solution of specific fluid dynamic problems (e.g. pumps, fans, valves, ducts).
- Hydrodynamics.
- Product development, including aerodynamic design, manufacture and testing.
Wind Tunnel Testing
Aeronautical Engineering
Computational Fluid Dynamics
Design Optimisation
Product Design, Development, Manufacture and Testing
Name and Surname:
Company:
Email Address:
Enquiry:
South Africa
Gavin Ratner
Gavin_MechCaL.co.za
+27 83 352 0306
MechCaL Contact Details
Physical address: 328 Price Street, Despatch, Pretoria
Postal address: PO Box 1866, Silverton 0127, Pretoria, South Africa
Phone: (012) 755 8304, Fax: 086 548 8183
E-mail: info_mechcal.co.za
Main Menu
About us
Products
* Case study 1
* Case study 2
Features
The Manufacturing Process
MechCaL Capabilities
* Engineering Design & Analysis
* Noise & Vibration Services
* Fluid Dynamics & Aeronautics
Latest News
MechCaL Composite Fan Technology Video
Axial Pressure Distribution cut
MechCaL winner of the
Technology top 100
