Open Source Electric Supercharger

[BlueDubbinTDI]

Good lord the engineering going on in this thread. Glad to see progress happening I'm exited to see the final product down the road!

[neutron256]

For simplicity sake I've decide my first prototype will be a 12V system. I'm also going back to one of my earlier designs because fitting the compressor wheel directly to the motor shaft was proving to very problematic.

I got my motor today so I got busy in CAD on designing all the parts.

Parts for test fitting are hot off the 3D printer (3D printing is awesome!). All the parts fit great so I'll be ordering all the off-the-shelf hardware bits & metal to machine tomorrow.

The parts:
-Backplate (3D Printed White)
-Bearing (3D Printed Clear)
-Shaft (3D Printed Blue)
-Spacers (3D Printed Red) x4
-Screws & Washers x 4
-Compressor Wheel & Nut
-12V Brushless Motor
-Compressor Housing
-O-Ring (Missing)



The bearing is pressed into the backplate. An O-Ring would also be added in the notch but I don't have one yet.



The shaft goes through the bearing



The screws with washers are placed through the backplate and spacers are added to form the motor mount



The motor is attached, and the compressor wheel is then placed on the shaft. A nut on the end of the shaft is tightened with one wrench while a second wrench is used to hold the shaft



The assembly is then placed in the compressor housing and secured with a snap ring

[SloS14]

Drooool

[rusty959]

Nice, looking good.
What are the specs on the bearing you are using?
The motor change is due to running 12v, correct? What are the specs of this new motor? I don't think I have seen yet.

[neutron256]

Originally Posted by rusty959

Nice, looking good.
What are the specs on the bearing you are using?
The motor change is due to running 12v, correct? What are the specs of this new motor? I don't think I have seen yet.

Yep this is the twelve volt setup. I'm going to be testing two motors. One with higher torque, the other with higher RPMs.

SkyRC Toro SCT 4600Kv
Max Power: 2000w
Max Voltage: 18v
Max current: 180a
Brushless KV: 4600
Resistance: .005ohm
Poles: 4
Weight:220g

SkyRC X8 2650Kv
Max Power: 2200w
Max. Voltage: 17V
Max. Current: 129A
Brushless KV: 4600
Resistance: 0.0062ohm
Poles: 6
Weight: 375g

I'm not expecting the kind of PSI the Phantom SC is seeing from this 12V setup but I figured this is a good start, and it will be a much simpler system system on the battery/charging side of things.

[rusty959]

Originally Posted by neutron256

Yep this is the twelve volt setup. I'm going to be testing two motors. One with higher torque, the other with higher RPMs.

SkyRC Toro SCT 4600Kv
Max Power: 2000w
Max Voltage: 18v
Max current: 180a
Brushless KV: 4600
Resistance: .005ohm
Poles: 4
Weight:220g

SkyRC X8 2650Kv
Max Power: 2200w
Max. Voltage: 17V
Max. Current: 129A
Brushless KV: 4600
Resistance: 0.0062ohm
Poles: 6
Weight: 375g

I'm not expecting the kind of PSI the Phantom SC is seeing from this 12V setup but I figured this is a good start, and it will be a much simpler system system on the battery/charging side of things.

Interesting. I'm curious to see what happens with them. What are the specs on the bearing you are using?

[neutron256]

Originally Posted by rusty959

Interesting. I'm curious to see what happens with them. What are the specs on the bearing you are using?

I'll be using ceramic bearings from Boca Bearings rated up to 65K RPM. Boca is a great source for just about any bearing you might need.

[rusty959]

Nice, Boca is definitely the best place I've found so far for looking at bearings. I've found some that look like they will work for me that are rated just shy of 100k. But thats still guessing on size since I haven't started purchasing things yet.

[ciro]

Thats looking pretty good. Let me know when you want to do direct metal printing.

[neutron256]

Originally Posted by ciro

Thats looking pretty good. Let me know when you want to do direct metal printing.

I'm just waiting on some parts so I can do a final fit test with the O-Ring.

Whats the accuracy and finish of the direct metal printing? I was planning on just milling it but if you're offering...

The shaft will have to be turned on the lathe to get the strength and accuracy needed.

[Grantmac]

Do you intend on isolating the 12v drive battery so that it's not charged when the ESC is powered?

-Grant

[neutron256]

Originally Posted by Grantmac

Do you intend on isolating the 12v drive battery so that it's not charged when the ESC is powered?

-Grant

I'm still deciding on how I want to configure it, but yes most likely I will have a relay that opens separating the positive poles of the batteries when the ESC is active.

[rusty959]

Originally Posted by Grantmac

Do you intend on isolating the 12v drive battery so that it's not charged when the ESC is powered?

-Grant

This may not have been directed at me, but I'm not planning on isolating the 12v battery even when its part of my 24v system. Not worth the added complexity/resistance/money.

[Grantmac]

Originally Posted by rusty959

This may not have been directed at me, but I'm not planning on isolating the 12v battery even when its part of my 24v system. Not worth the added complexity/resistance/money.

Are you going to run a 12v parallel to 24v series set-up like I posted? I'm seriously in favor of that option personally. Although I believe a small 12v battery might be required to run the car electronics while the system is in 24v mode.

-Grant