(non-Ebay) Electric Turbocharger (Supercharger?)

[teknicalissue]

Thought I'd update you guys!

As mentioned before; I'm going with a 20g. I got the dimensions for the motor that the company is going to send me (ignore the top part where the nut threads in.. it's too small because it broke ) which will now put me in the test fitment test of this whole project. with a 3d printed version of the motor; an ebay 20g compressor housing and 20g 6 blade compressor wheel; I can now start printing the central cover to hold everything together.

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[jim95redgsx]

Well, it looks like things are coming together nicely.

I'm curious as to how you're planning to attach your motor mount to the compressor housing. The stock 20G seems to have the compressor housing backplate as part of the CHRA and is sealed with an O-ring and held in place with that big snap ring.

I'm not sure if your printed ABS plastic will hold up (in both strength and temperature) in this application. That thin flange with the O-ring groove may not be strong enough in ABS plastic.

Compressed air temps in the compressor housing can reach temps of over 300*F. ABS melts at 221*F. I don't know if it softens at all before it melts. I'd hate to see you ruin your compressor wheel and housing by having the wheel and housing come into contact with each other.

Jim

 

[teknicalissue]

Well, it looks like things are coming together nicely.

I'm curious as to how you're planning to attach your motor mount to the compressor housing. The stock 20G seems to have the compressor housing backplate as part of the CHRA and is sealed with an O-ring and held in place with that big snap ring.

I'm not sure if your printed ABS plastic will hold up (in both strength and temperature) in this application. That thin flange with the O-ring groove may not be strong enough in ABS plastic.

Compressed air temps in the compressor housing can reach temps of over 300*F. ABS melts at 221*F. I don't know if it softens at all before it melts. I'd hate to see you ruin your compressor wheel and housing by having the wheel and housing come into contact with each other.

Jim

I've been thinking about that and I'm on the fence on either trying to strengthen the ABS in some shape or form (I'd test it against heat in an oven set at 400*) or just using the 3d prints as a way of prototyping the test fitment and getting the plate made at a machine shop. For the first option; I was thinking of using some heat resistant paint on top of a layer of clear JB weld Epoxy which should give it strength. But again.. I'm a bit weary.

I might just get it all done at a machine shop now that I think of it... it sounds safer and more reliable. I'll probably consider 3d prints with other filaments such as carbon fiber or nylon once I get another printer that can handle that type of filament just to experiment. I'd hate to see the compressor and wheel destroyed too

and ABS does soften before it melts which would make one heck of a metal light show if the back plate warped to the side by 1mm . heck with the amount of air being compressed and ABS softening; it would create a bubble, destroy the wheel and housing as well as shoot my motor out.

Yea... machine shop sounds like an excellent idea! haha I'll just use 3D prints to test the fitment.

 

[teknicalissue]

While I wait for the motor to be built, I am starting to work on the casing of the board controlling all of the logic... Here she is!

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[Chumpaumpalumpa]

Glad to see this is still coming along nicely

 

[teknicalissue]

Glad to see this is still coming along nicely

Indeed! I'm still waiting on the Electric Turbo company for the motor. I hate waiting

 

[jim95redgsx]

Have you done anything with the adapter plate between the compressor housing and the electric motor? Or are you waiting until the motor comes in?

There is a guy on the ECMLink forums who was looking to make small aluminum parts for DSMer's. He has a small CNC milling machine. If you are interested, and don't have access to the ECMLink forums, I can try to get some contact information for you. Let me know.

I have no idea if your 3D printer files can be converted for use on a CNC machine.

Jim

 

[teknicalissue]

Hey Jim!

I would love to get in contact with him! the adapter shouldn't be too complex but I'm sure there is a way of converting gcode to a CNC machine. Shoot me over his contact info and we can get the communication started!

I am also waiting on the motor. The casing is custom and I have to make sure the 3D prints fit before I send it off to get made.

All in all though; There has been decent progress!

 

[Chumpaumpalumpa]

Hey Jim!

I would love to get in contact with him! the adapter shouldn't be too complex but I'm sure there is a way of converting gcode to a CNC machine. Shoot me over his contact info and we can get the communication started!

I am also waiting on the motor. The casing is custom and I have to make sure the 3D prints fit before I send it off to get made.

All in all though; There has been decent progress!

So what are you printing the final stuff in, 50 microns?

 

[teknicalissue]

So what are you printing the final stuff in, 50 microns?

100 microns. I was going to go to shapeways and have them print the final parts in steel; but If I could get someone to do it on a CNC machine; That'd be awesome!

Until I get the motor in my hands; I can't verify how well the part I made fit so that motor is my current road block in to moving forward.

As a side note.. I bought a used Audi S6 with the V10 engine! haha Great car but I'm starting to dislike the audi community. I presented the electric supercharger idea to them and It's been flame after flame on that thread. There's nothing like DSM peeps that's for sure!

my misery
http://www.audizine.com/forum/showt...-in-electric-supercharger-for-the-S6-5-2L-V10

 

[o0GuitarKid0o]

100 microns. I was going to go to shapeways and have them print the final parts in steel; but If I could get someone to do it on a CNC machine; That'd be awesome!

Until I get the motor in my hands; I can't verify how well the part I made fit so that motor is my current road block in to moving forward.

As a side note.. I bought a used Audi S6 with the V10 engine! haha Great car but I'm starting to dislike the audi community. I presented the electric supercharger idea to them and It's been flame after flame on that thread. There's nothing like DSM peeps that's for sure!

my misery
http://www.audizine.com/forum/showt...-in-electric-supercharger-for-the-S6-5-2L-V10

Wow I guess it's true what they say about audi owners hah ,they just complained the whole time and added nothing of value.

Youv come to far to stop now! Very interesting topic

 

[teknicalissue]

Wow I guess it's true what they say about audi owners hah ,they just complained the whole time and added nothing of value.

Youv come to far to stop now! Very interesting topic

I know right! I was hoping for feedback like I got in this group but the entire thing has been such a headache. What's worse is that their home page is featuring the concept of a new Audi with an..... Electric turbo

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I feel as though I should make it and make it incompatible with Audi vehicles except for mine!

I guess I never realized how much I love the DSM community

 

[o0GuitarKid0o]

I know right! I was hoping for feedback like I got in this group but the entire thing has been such a headache. What's worse is that their home page is featuring the concept of a new Audi with an..... Electric turbo

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I feel as though I should make it and make it incompatible with Audi vehicles except for mine!

I guess I never realized how much I love the DSM community

Lmao this forum is great , ever go read the honda forums? Youl cringe hah ,

And do it be like you need this special adapter to use the turbo with those crazy audi headers with 3 inch pipes no cat that appearntly add more hp than your turbo pushing 18 psi rolls eyes some people just don't want instant boost I guess

 

[teknicalissue]

Lmao this forum is great , ever go read the honda forums? Youl cringe hah ,

And do it be like you need this special adapter to use the turbo with those crazy audi headers with 3 inch pipes no cat that appearntly add more hp than your turbo pushing 18 psi rolls eyes some people just don't want instant boost I guess

I Swear this will be the last bashing comment but.... You literally have to remove the engine to replace the headers in comparison to our turbo which is a drop and go solution... no engine removal required. You'd think I'd get smiles

 

[o0GuitarKid0o]

I Swear this will be the last bashing comment but.... You literally have to remove the engine to replace the headers where my turbo is a drop and go solution... no engine removal required. You'd think I'd get smiles

Lmao I guess it's they way she goes , I wouldn't mind a low psi elextric turbo for my laser thats been swapped to nt it wouldn't least make it kinda stick again

When's the motor coming in?

 

[teknicalissue]

Lmao I guess it's they way she goes , I wouldn't mind a low psi elextric turbo for my laser thats been swapped to nt it wouldn't least make it kinda stick again

When's the motor coming in?

Sometime next month! The original lead time was 1.5 months but the scope changed when they had to change the casing for the motor to allow the larger angular contact bearings as well as a custom water jacket for the custom casing. They are also going to run some tests on the motor as well to make sure it is functioning per spec.

Once I get the motor in, I'll order the controller; attach it to the Arduino board and make sure I can communicate without issues. Then I'll finish the design on the back plate for the comp housing and lastly! Put it all together for a desk test. Once the desk test passes; I'll do some testing on my end and then pass it around to you guys for testing and feedback.

Would also need help from you guys to determine the airflow of the turbo on X RPM's and what not. We have a long way to go but I think it'll be worth it in the end.

 

[o0GuitarKid0o]

Cool man can't wait to see how it turns out!

 

[Chumpaumpalumpa]

What bearings did you end up going with?

 

[teknicalissue]

http://nhbb.com/files/catalog_pages/new-16.pdf

SSMER-2280SD502

Angular contact bearings capable of 250,000 RPM and 300lbs of Axial load

Max operating temp is 250*F

 

[Chumpaumpalumpa]

Awesome sounds perfect. What about for lubrication of the gears?

 

[teknicalissue]

Awesome sounds perfect. What about for lubrication of the gears?

No gears, The custom motor I'm making will be able to directly spin the compressor wheel @ 115k RPM which is why we went with the 20g route

 

[Chumpaumpalumpa]

No gears, The custom motor I'm making will be able to directly spin the compressor wheel @ 115k RPM which is why we went with the 20g route

Ah, thats right its been a while haha Have you calculated expected output yet?

 

[jim95redgsx]

I've been trying send you the e-mail address of the guy with the CNC machine. His name is Trevor. He replied "Sure I'd love to".

I can't start a private Conversation with you. I keep getting this error message...
"You can't start a conversation with tecknicalissue because of his or her privacy settings".

I'm not sure if he wants me to post his e-mail address on the open forum. Please change your privacy settings, at least temporarily.

Jim

 

[jim95redgsx]

Yeah, He doesn't want me to post his e-mail address on here. You'll have to change your privacy settings or maybe try to start a private conversation with me.

Jim

 

[teknicalissue]

Ah, thats right its been a while haha Have you calculated expected output yet?

I've been trying send you the e-mail address of the guy with the CNC machine. His name is Trevor. He replied "Sure I'd love to".

I can't start a private Conversation with you. I keep getting this error message...
"You can't start a conversation with tecknicalissue because of his or her privacy settings".

I'm not sure if he wants me to post his e-mail address on the open forum. Please change your privacy settings, at least temporarily.

Jim

Yeah, He doesn't want me to post his e-mail address on here. You'll have to change your privacy settings or maybe try to start a private conversation with me.

Jim

Here is my "spam" email. I'll keep a look out for his name somewhere: [email protected]

I had the same issue with @Chumpaumpalumpa... Nothing I did in my settings

On a side note... I'm debating on wether I should include a water to air intercooler to the kit or not:

http://www.frozenboost.com/liquid-air-intercooler/water-to-air-intercooler-p-1034.html

Thoughts?

I figured that should help some with temperature associated with compressing air