Open Source Electric Supercharger

[neutron256]

Since there has been much interest in the Phantom electric supercharger, and many people throwing around ideas oh how it could be improved I'm starting this thread for interested tinkerers like myself to share information and brainstorm designs and improvements.

Important things to keep in mind
1. Safety First
Electricity can be cause damage to your car, and more importantly to you. Experiment at your own risk.
2. All ideas are welcome
Feel free to contribute but at the same time make sure you've read the whole thread and are not just rehashing something that's already been brought up.
3. Be Respectful
People have different skill/knowledge levels. Don't make someone else feel dumb just because they asked an honest question.
4. This is open source only
The goal is to share information, not create a commercial product.

Parts

-MAP sensor connector: Sumitomo HX 040 3-way (need to verify)
-Throttle Position Sensor Connector: Yazaki 6-Way (need to verify)
-Crank Position Sensor Connector: NipponDenso 2-way (need to verify)
-MAF Sensor Connector: TS 025 5-way (need to verify)

Useful Links

Phantom Superchargers
http://www.phantomsuperchargers.com/
@fenton 's Phantom Supercharger Build
http://www.ft86club.com/forums/showthread.php?t=39719
EFI connection (excellent source for automotive electrical connectors)
http://www.eficonnection.com/
Kinugawa Turbo (for compressor housing/wheel parts)
http://kinugawaturbo.com
An interesting papaer on electric supercharging
http://www.movingmagnet.com/medias/d.../m12-12-16.pdf
A large collection of compressor maps
http://www.not2fast.com/turbo/maps/all.html

[SloS14]

Here's what I've got so far..It's not much.
[ame="http://www.youtube.com/watch?v=b2UH8CMC780"]At dunno motor 1 - YouTube[/ame]

[neutron256]

Relevant Skills:
-Basic Electronics (including some experience with micro controllers)
-Hobby Machinist
-CAD (preferred program RhinoCAD)
-Hobby Mechanic

Speciality Tools:
-Benchtop CNC Mill
-Benchtop Lathe
-3D Printer
-Assorted Shop Tools
-Limited access to a full Machine Shop

My Build

Compressor
-TD05/06 Compressor Housing (ordered)
-20G Compressor Wheel (ordered)

I may have to switch to a 25G wheel and housing but I will see how the 20G performs first.

I'll have to custom machine the backplate for the housing to serve as a mount for the motor.

Some sort of adapter will need to be created to mount the compressor wheel directly to the motor shat

Motor
Turnigy SK3 (3968-1500KV)

Kv (rpm/v) 1500 (theoretical top speed 45K RPM)
Weight (g) 363
Max Current (A) 110
Resistance (mh) 0
Max Voltage (V) 30
Power(W) 3000
Shaft A (mm) 8
Length B (mm) 68
Diameter C (mm) 39
Can Length D (mm) 68
Total Length E (mm) 92

Speed Controler
Turnigy dlux 120A HV Brushless Speed Controller

Spec.
Max Cont Current: 120A
Max Burst Current: 140A
BEC: N/A
LiPo: 6~12S
NiMH: 16~36cells
Weight: 129grams
Max RPM (2-pole): 200,000rpm
Size: 60 x 33 x 23mm
Motor Plug: Female 4mm bullet Connector
Battery Plug: Nil
Features: Spark Eliminator Lead with 2mm Plug

Controller
-Microcontroller (haven't decided but I favor the PICaxe because its cheap and simple)
-Display (I really just want a simple LED Bar display to show charge)
-Inputs
Tap into the throttle position sensor
Boost sensor
Battery Charge
Power Switch
Arm Switch

Battery
-Testing
Turnigy nano-tech A-SPEC 4000mah 10S 65~130C Lipo Pack (This will be charged outside the car. Test setup will not include a charging system)

-End Goal
Still Researching

General Concept

The boost sensor will allow the Micro Controller to keep the compressor running at a speed to match atmospheric pressure reducing intake restriction when the system is in standby. When the system is active the Micro Controller can use the boost sensor to match the amount of boost to a given throttle position.

Other Thoughts

It might be nice to have selectable recharge rates to allow the driver to choose how much and when the extra load of the battery charging happens.

[DAEMANO]

Great idea, subscribed.

[Calum]

x2

[s2d4]

Originally Posted by SloS14

Here's what I've got so far..It's not much.

Cool coool, funky that you are typing the %? as you go
Write a simple simulation function to do 5% increments with 100-500ms as well as simple print instructions per each step probably would help later for testing purposes too.

[SloS14]

Here are some potential high rpm motors: http://www.neumotors.com/Site/1500_series.html

I'd like to go all out and build a GUI showing:
turbo power %
TPS %
MAP in/hg
TPS change in % over past x ms

[neutron256]

For you programmers out there, how hard do,you think it would be to adjust the speed of the motor in a liner way to match a target boost pressure?

[SloS14]

Originally Posted by neutron256

For you programmers out there, how hard do,you think it would be to adjust the speed of the motor in a liner way to match a target boost pressure?

I'm not a programmer, but I play one on TV. To do it VERY WELL, it would be similar logic to how a balance bot works, but instead of aiming for "straight up an down", you'd be aiming for "this much MAP voltage"

is that what you mean?

It's definitely one of the more (if not the) most challenging aspect. Very similar to "gain" on an EBC. "Gain" could be done with a pot.
I don't translate my thoughts to words well most of the time. This is no exception.

[s2d4]

Originally Posted by SloS14

Here are some potential high rpm motors: http://www.neumotors.com/Site/1500_series.html

I'd like to go all out and build a GUI showing:
turbo power %
TPS %
MAP in/hg
TPS change in % over past x ms

GUI on what platform? Mobile?

[jamesm]

We should start a github repo for the controller code, models, etc.

[pheoxs]

Originally Posted by neutron256

For you programmers out there, how hard do,you think it would be to adjust the speed of the motor in a liner way to match a target boost pressure?

Fairly easy using a brushless motor, you basically just need six mosfets and switch them on off in the right order. But its easier to buy an inverter package and tie your controller into it

I built one in Univ for fun for ~80$ I think. Used an arduino controller to convert a 0 to 5V signal from the pedal (or in this case you'd use the throttle body signal) and change it to a PWM to pulse the mosfets on and off which controls how much power you send, then during all that you alternate which mosfets you are driving to charge the right windings and push the motor forward. I think what I built was good for 48V / 30A. I used a inverter IC package since they frowned upon building something for that much power myself O.o

Obviously with something for a car it has to be more robust / withstand heat, but its not hard.

The coding was simple, like 15-20 minutes probably depending on how fancy you wanted it. Obviously with a GUI / other external stuff its different, but for just a basically throttle to output its a simple loop to build.

[jamesm]

Originally Posted by SloS14

I'm not a programmer, but I play one on TV. To do it VERY WELL, it would be similar logic to how a balance bot works, but instead of aiming for "straight up an down", you'd be aiming for "this much MAP voltage"

is that what you mean?

It's definitely one of the more (if not the) most challenging aspect. Very similar to "gain" on an EBC. "Gain" could be done with a pot.
I don't translate my thoughts to words well most of the time. This is no exception.

The easiest way would be a closed loop system using the map sensor. It's fairly simple, in terms of logic.

[SloS14]

Now with completely unrealistic accelerator and engine sounds (impossible to hear over the motor). Currently it's a 1:1 of accelerator to motor with no RPM, MAP inputs.

[ame="http://www.youtube.com/watch?v=LstTJbAI95M"]Arduino electric supercharger 2 - YouTube[/ame]