Open Source Electric Supercharger

[Matt@Cosworth]

for example this TD04 compressor map

looks quite promising so with a 62mm compressor you can get 25lbs/ min at 46K rpm?

[al3k]

Originally Posted by Matt@Cosworth

for example this TD04 compressor map

looks quite promising so with a 62mm compressor you can get 25lbs/ min at 46K rpm?

Thats a Garrett T04B 62 trim compressor map, the wheel is 70mm / 55.3mm (exducer/inducer).
I see it as the higher the lb/min number the higher is the needed shaft power.
Here is also a chart from a EFR7064 for a 2l, you can see the turbo shaft hp requirement at the bottom and target boost and rpm at top and other paramters like flow lb/min in the middle.

[al3k]

Here is one for a 0.5bar/7.5psi target:

[KroozX]

After some further technical optimisations made another test with my ESC, now at 22V power voltage. It produces about 0,18 Bar of max pressure at about 75kg/hr airflow. Not really much, however it consumes only about 600-700W.


[ame]https://www.youtube.com/watch?v=xNZSJ4k0G8k[/ame]

[Matt@Cosworth]

how come its less airflow despite the voltage increase and presumably more rpm?

[KroozX]

There voltage was actually higher in the first test, so everything is correct - less airflow and less pressure.

[al3k]

Nice! what type of optimisations was done?

I have recceived my turbo now and have taken it apart and have started some CAD work to experiment and simulate how to mount the motor. I will 3d print some parts to check fitment, not 100% sure how I will do the mouting but I will try to make a adapter first, I dont want to drill through the backplate incase I wanna test different motors.
Compressor inducer /exducer on my ebay turbo meassured at 52.76 / 75.98, which should equal a 47 or 48 trim.
Made the motor with detachable shaft so I can test different lengths and currently working on the adapter plate.
Ive talked to the guy at Alien Power System and he confirmed that he can make a custom shaft like this which is awesome, just need to figure out the meassurements so I can order.

[KroozX]

Originally Posted by al3k

what type of optimisations was done?

The motor controller is mounted properly now, so it's much handy to use now:

Originally Posted by al3k

Ive talked to the guy at Alien Power System and he confirmed that he can make a custom shaft like this which is awesome, just need to figure out the meassurements so I can order.

Really useful option, saves time and work.

[al3k]

Originally Posted by KroozX

The motor controller is mounted properly now, so it's much handy to use now:




Really useful option, saves time and work.

wow it looks really good!

Are you skilled with electronics?
I wonder if using super capacitors for example 12x2.7v in series to get 30-32v, can I then just use a DC to DC converter to step up the 12v start battery and set output to 30v using the highest amp rated module I can find to charge the supercaps?
Im not sure if its practical since the voltage can drop alot, but I guess the run time will only be <5sec for each run.
Or maybe if there exsist some kind of circuit that can make it possible to switch on and off wires to charge in parallell and discharge in series, then use 2x 6x2.7v banks.

[KroozX]

Originally Posted by al3k

wow it looks really good!

Thanks! The motor controller was designed specially for this supercharger application, it has very quick response, very efficient and has a proper construction and cooling (way better than used in normal RC grade motor controllers).

Originally Posted by al3k

I wonder if using super capacitors for example 12x2.7v in series

Not really sure that capacitors are a good idea for such setup. Depends of what should be achieved there. What is actually your supposed usage case, if you think about supercaps?

[Matt@Cosworth]

As I understand it using super-caps are there to give a buffer and so cope with the massive in-rush current and spool the motor as quick as possible


on a seperate topic can you share what compressor you're running

[al3k]

I got this one https://www.ebay.com/itm/T04E-T3-T4-...72.m2749.l2649


But the item spec they provide is not correct its a 48trim comp. wheel (52.76 / 75.98mm) .
Some progress on the esc mockup.

[WNDSRFR]

What kind of material is the motor shaft made of? It looks like some kind of plastic. Is it going to withstand the instant 0-50,000 RPM torque it's going to be subjected to?
I ask because my first ESC broke it's shaft because of just that. Rob replaced it with the V2 which has the two stage switch to reduce the torgue shock.
I wonder if anyone else had a shaft problem on the V1.

[al3k]

Originally Posted by WNDSRFR

What kind of material is the motor shaft made of? It looks like some kind of plastic. Is it going to withstand the instant 0-50,000 RPM torque it's going to be subjected to?
I ask because my first ESC broke it's shaft because of just that. Rob replaced it with the V2 which has the two stage switch to reduce the torgue shock.
I wonder if anyone else had a shaft problem on the V1.

Its just protyping/testing/mockup to see how the fitment is before i order the real parts, the motor, adapter and shaft is 3dprinted PLA plastic.