How to Scientifically Select Cooling Fans for the Era of High Thermal Density in Humanoid Robots-Capital-Cooling fan manufacturer

Humanoid robots are entering an era of high thermal density, making the scientific selection of cooling fans a systematic engineering task that cannot be decided arbitrarily.

The core idea is to move the selection process forward to the early design phase and follow a rigorous procedure.

Against the backdrop of the rapid development of the humanoid robot industry, thermal design has evolved from an "auxiliary function" to a "core reliability indicator."

Phase 1: Early Intervention and Thermal Simulation Modeling

In the initial design phase, thermal simulation should be used to accurately calculate cooling requirements, avoiding errors from experience-based selection.

1.Modeling: Use professional software (such as ANSYS, Flotherm, SolidWorks Flow Simulation, etc.) to build a 3D model of the robot, inputting key parameters including:

▶Power distribution of heat sources (e.g., CPU, GPU, servo drives, etc.)

▶Physical dimensions and materials of the device

▶Expected ambient temperature

2.Simulation Analysis: Run the simulation to obtain key data:

▶Target Airflow (CFM): Determine how much airflow is needed to keep core components within a safe temperature threshold (e.g., chip temperature ≤ safety limit).

▶Static Pressure Requirement (Pa): Evaluate how much "penetration power" the airflow needs to effectively pass through heat sink fins, filters, or complex internal air ducts.

Phase 2: Matching Core Performance Parameters

Airflow determines the upper limit, static pressure determines success, and structure determines efficiency.

Based on the simulation results, precisely match the core performance parameters of the fan.

The key here is understanding the "golden balance" between airflow and static pressure, rather than blindly pursuing a single metric.

☛Airflow: Determines "cooling coverage." Typically, for every 100W of cooling power, 10-15 cubic meters/hour of airflow is recommended, with a 20% increase suggested for high-temperature environments.

☛Static Pressure: Determines "air penetration." If the robot's internal structure is compact, with dense heat sinks or long air ducts, a high-static-pressure fan must be selected (e.g., static pressure ≥ 50Pa) to ensure airflow reaches critical heat-generating areas.

Fan Size Selection Guide for Different Scenarios

Fan size directly affects airflow, static pressure, and noise. Below is a size selection guide for different load scenarios:

Fan Size (mm)	Airflow (CFM)	Application Scenario	Typical Application
40-60	5-15	Home/Education	Education companion robots, desktop interactive robots
60-80	15-35	Commercial Service Robots	Hotel greeters, mall guide robots
80-120	30-70	Industrial/Medical Collaborative Robots	Surgical assistance, industrial assembly cobots
120+	50+	High-load Research Robots	Laboratory humanoid robots, research test platforms

Phase 3: Environmental and Reliability Selection

The working environment of humanoid robots is complex and changeable, so the following factors must be considered to ensure the long-term reliability of the fan.

1.High-Temperature Resistance

◆Motor: Copper wire motors are preferred for their superior thermal conductivity and stability.

◆Insulation Grade: An insulation grade of at least Class B (withstands 130℃) is recommended for industrial scenarios.

◆Bearings: Ordinary oil-impregnated bearings are prone to failure at high temperatures. Double ball bearings (withstand up to 120℃, long life) or oil-impregnated bearings filled with high-temperature grease are recommended.

◆Blade Material: Avoid ordinary ABS plastic that deforms easily above 60℃. Choose modified materials like PPS (Polyphenylene Sulfide) blades that can withstand 150℃.

2.Ingress Protection (IP) Rating

Select based on the dust, oil, and moisture conditions of the robot's environment. For example, IP55 protects against splashing water, while IP67 protects against rain and short-term water jet impacts.

3.Noise Control

Service and home robots have high requirements for silence. Low-noise fans should be prioritized while meeting cooling requirements.

Phase 4: Functional and Installation Adaptation

Finally, determine the fan's functions and installation details based on actual integration needs.

Function Selection:

✔FG (Speed Signal): Used to monitor fan speed in real-time.

✔RD (Alarm Signal): Issues an alarm when the fan fails.

✔PWM (Speed Control): Dynamically adjusts fan speed based on temperature to achieve energy saving and noise reduction.

Installation Considerations:

☢Space Constraints: Precisely measure the installation space's height and planar dimensions to ensure the fan can be installed smoothly.

☢Layout Planning: Plan the fan layout reasonably (e.g., front-in rear-out, side-blow + top-exhaust, etc.) to avoid air short-circuiting or mutual interference.

☢Connection Method: Confirm that voltage (12V, 24V, etc.), lead length, terminal type, etc., meet design requirements.

Cooling Fan Selection Recommendations

☑Brand: San Ace (Japan)
☑Recommendation Reason: If your robot is positioned for high-end scientific research, medical surgical assistance, or extreme reliability scenarios, San Ace is the industry's "all-rounder."

Core Advantages:

☑Ultra-long Life: Products like the 60L series can last over 100,000 hours at 60℃, with strong high-temperature resistance and oxidation resistance.

☑Dual Reverse Rotation Technology: Unique technology that effectively copes with complex airflow resistance, ensuring airflow penetration under high loads.

☑Industry Recognition: It is a "pre-approved" benchmark in medical and high-end industrial equipment, with extremely high consistency.

Below is a model recommendation list organized by performance characteristics and application scenarios to facilitate your selection.

Model	Size (mm)	Voltage	Airflow (CFM)	Static Pressure (Pa)	Core Features
172 ST1-109-314	Φ172×51	AC 115V	226.1	196	Airflow king, high-performance AC fan
60L 9CRLB...	60×60×76	12V	84.8	1500	Static pressure king, dual reverse rotation, ultra-long life
120AD 9ADA...	120×120×38	100-240V	135.3	170	Wide voltage, high static pressure
60 9G0624...	60×60×25	24V	42.7	224	Small size high static pressure, supports PWM
120 9RA1212...	120×120×25	12V	130	120	Balanced performance, low noise

High-Performance Core Cooling (Suitable for Torso/Computing Module)

For core computing modules like CPU/GPU, strong cooling with high static pressure and large airflow is required.

1.San Ace 172 ST1-109-314 (AC Axial Fan)

Features: This is San Ace's high-performance AC fan with extremely strong cooling capacity.
Key Parameters:

Airflow: Up to 226.1 CFM

Static Pressure: Up to 196 Pa

Size: Φ172 × 51 mm

Advantages: Outstanding performance in both airflow and static pressure, suitable for occasions with dense heat sources and heat sink fins requiring strong penetration.
Application: Core torso of humanoid robots, high-density power modules, communication base stations.

2.San Ace 120AD 9ADA1201G1002 (AC/DC Fan)

Features: Wide voltage input, strong adaptability, and excellent static pressure performance.
Key Parameters:

Static Pressure: 170 Pa

Airflow: 3.9 m³/min

Voltage: 100 ~ 240 V (Wide voltage)

Size: 120×120×38 mm

Advantages: Supports global wide voltage input and can provide stable airflow while overcoming significant duct resistance.
Application: Industrial equipment with voltage compatibility requirements, UPS uninterruptible power supplies, robot joint drives.

High Static Pressure/High Speed (Suitable for Compact Spaces)

For parts with limited space but high heat generation, such as robot joints and servo drives, small-size, high-static-pressure models are required.

1.San Ace 60L Series (Dual Reverse Rotation Fan)

Features: Designed for high static pressure, its unique dual reverse rotation technology allows it to generate extremely strong airflow penetration even in confined spaces.
Key Models:

9CRLB0612P0G001: Airflow 84.8 CFM, static pressure up to 1500 Pa, speed 19700 RPM

9CRLA0612P0G001: Airflow 74.1 CFM, static pressure 1400 Pa, speed 16500 RPM

Size: 60×60×76 mm

Advantages: Extremely high static pressure, with a lifespan of up to 100,000 hours (at 60℃ environment). It is a powerful tool for solving heat dissipation bottlenecks in compact spaces.
Application: Robot joints, high-load servers, high-power power supply modules.

2.San Ace 60 9G0624P4H001 (DC Fan)

Features: High-speed, high-static-pressure fan in a 60mm size.
Key Parameters:

Static Pressure: 224 Pa

Airflow: 42.7 CFM

Speed: 9500 RPM

Size: 60×60×25 mm

Advantages: Outstanding static pressure performance among similar 60mm fans, supports PWM speed control, and has a high energy efficiency ratio.
Application: Industrial automation equipment, inverters, space-constrained robot components.

Conventional Efficient Cooling (Suitable for General Modules)

For control boards, sensor modules, etc., general models with balanced performance can be selected.

San Ace 120 9RA1212P4G001 (DC Fan)
Features: A classic 120mm fan with balanced performance and excellent noise control.
Key Parameters:

Airflow: 130 CFM

Static Pressure: 120 Pa

Noise: 47 dB(A)

Size: 120×120×25 mm

Advantages: Achieves a good balance between airflow, static pressure, and noise, with a lifespan of up to 60,000 hours (at 60℃ environment).
Application: Servers, communication equipment, medical instruments, general control cabins of robots.

Selection Summary

Space Constraints: For extremely limited space (e.g., joints), the 60L series is preferred for its high static pressure to penetrate dense components.

Power Consumption: For high-power core modules above 300W, large-size, high-airflow models like the 172mm or 120AD are recommended.

Control Requirements: For intelligent speed control and noise reduction, models with PWM functionality (e.g., 9RA1212P4G001, 9G0624P4H001) must be selected.

Capital Technology Co., Limited is the chief agent of SANYO DENKI, one of the leading enterprises of the cooling fan industry.

We are a factory who also have our own independent brand CAPITAL product series.

The main products are cooling fan, DC/AC fan, radiator, filter, reactor etc.

We can provide customer with the most professional and perfect technical support, welcome to contact me at anytime at rainlee@szcpt.com.

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