Controller active fan/filter cooling

I

itchynackers

100 kW
Joined
Dec 27, 2009
Messages
1,088
Location
Janesville, WI
I'm thinking of putting this... http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=300435337322&viewitem=&sspagename=STRK%3AMEWAX%3AIT

and this... http://www.amazon.com/IMC-Micro-Boxer-60mm-25mm/dp/B0008IV4LS

on each end of my Lyen 12fet. It's not really overheating, but I plan on some winter system upgrades in case I go to more power. Can anyone see any pitfalls I may run into? I just want to put the filter on the upstream case end of my controller, and the fan on the downstream case end to pull the air through. I'll probably strap a 12v rechargeable nicad somewhere on the bike with a toggle switch.

Thanks,
Adam
 
Nice little filter, but I don't know if that fan would move any air with that restriction. I think a centrifugal fan from something like a server cooler would be more effective, and also easier to design in a hood or vent system to exclude rain and snow.
41Vtn+yNlaL._SL250_.jpg
http://compenet.com/Nidec-Gamma-30-Gamma30-Centrifugal-Fan/M/B0025VJEL8.htm
 
i like the air filter principle.
instead of using your 60mm fan i use a 40mm which also is slightly thicker.
This will fit better at the end of the 12FET controller.

I glued it with a 2 component epoxy on the side. (i will post picture later)

this is the fan i used.

998643_RB_00_FB.EPS.jpg
 
+1 for 'laminar flow' blows like the one Rebel Pilot recommended. They are very efficient at moving air. Blade fans are easier to install but chop up the air a lot more. Either way you'll be in good shape adding a bit of active cooling.
 
If you want to go all the way on air filtering you can copy what is used on modern locomotives. First, use inertial filters to remove large particles from the air. Use a small "dust bin" blower to remove the particles from the filter.

http://www.camfilfarrrailroad.com/Monoclone.htm

Then use an element based filter to remove the small particles.
 
Don't want to go too crazy. Just want a simple setup that may do some good.
 
You definitely want a centrifugal fan, not the typical bladed fan because they simply won't pull much air through any restriction. I did exactly what you plan though I didn't filter it, and successfully ran a controller that was always hot at stock power to far cooler at double the power. See my thread http://endless-sphere.com/forums/viewtopic.php?f=2&t=20359&hilit=active+controller+ventilation

It worked great until the day I forgot to turn the fan on and blew the controller on the first hill I encountered, so the approach works. Next time I'd do some kind of auto-on arrangement when I turn my bike on.

The fan I used was smaller than the fan rebelpilot linked, so his fan would do very well pulling through a filter and move a lot of air. If you don't have that much height available, you might want to try a computer slot fan.

John
 
You guys have me convinced with the centrifugal fan, but I'd like one thats on the small side. Maybe one that is roughly 2"x2" so that it doesn't extend past the controller too much. Anyone know where to find a smaller one?
 
Is that the one listed as 3.83" wide? I'd like one a bit smaller.
 
itchynackers said:
Is that the one listed as 3.83" wide? I'd like one a bit smaller.
Click to expand...

No, the height in the orientation in the pic is 2". That controller is the typical 1.75" high controller case. I got that from a cannibalized Bosch charger, so I have no idea where you would buy one.
 
one example from ebay;
1pc Brushless DC Cooling Blower Fan 5V 12V 24V 50x15mm $2.75 + $2.70 shipping
- Ultra quiet MID speed brushless DC Blower
- Size: 50mm (Diameter) x 15mm (H)
- Blade Material :thermoplastic UL94V-0 PBT
- Housing Material i: thermoplastic UL PBT
- Operating Temperature: -10 Celsius degree to +60 Celsius degree
- Life Expectancy at 40 Celsius degree: 40000 hours
- Speed: 3800 RPM
- Airfow: 15-30 CFM
- Noise: 29-25 dBA
- Rating: DC 5V/12V/ 24V 0.14A-0.5A
- Sleeve-bearing
http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=180506549021
 
This is the one i used for cooling.

IMG_0001-1.jpg

IMG_0004-2.jpg
 
rebelpilot said:
one example from ebay;
1pc Brushless DC Cooling Blower Fan 5V 12V 24V 50x15mm $2.75 + $2.70 shipping
- Ultra quiet MID speed brushless DC Blower
- Size: 50mm (Diameter) x 15mm (H)
- Blade Material :thermoplastic UL94V-0 PBT
- Housing Material i: thermoplastic UL PBT
- Operating Temperature: -10 Celsius degree to +60 Celsius degree
- Life Expectancy at 40 Celsius degree: 40000 hours
- Speed: 3800 RPM
- Airfow: 15-30 CFM
- Noise: 29-25 dBA
- Rating: DC 5V/12V/ 24V 0.14A-0.5A
- Sleeve-bearing
http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=180506549021
Click to expand...

Thanks for the find Rebepilot, I'm going to pick up some of those.


MrKang,
Do yourself a favor and run some tests with just small amounts of restriction to see how much flow is affected with those types of fans. Axial fans are widely used because they are quiet, but when you really need to move air and there's a degree of restriction to the flow, then centrifugal fans dominate. Low power axial fans can't create the pressure differential required for these purposes. Check the air flow throughput, not near the fan, because it can be misleading since they'll throw air off the tips of the blades and suck air in near the center, and not really moving air through the pathway, just churning air outside.
 
at the other side of the controller i have 2 holes. If i put my finger on it i can feel the air sucked in.
This airflow is what i think blown over the FET's. I also see it on my temp meter which is inside the controller on the FETs
when i turn the fan on arround 52 celcius...the temperature is cooled of to a 35 celcius
So i think it's woring flawlessly
 
MrKang said:
at the other side of the controller i have 2 holes. If i put my finger on it i can feel the air sucked in.
This airflow is what i think blown over the FET's. I also see it on my temp meter which is inside the controller on the FETs
when i turn the fan on arround 52 celcius...the temperature is cooled of to a 35 celcius
So i think it's woring flawlessly
Click to expand...

If it's moving air the it's working, which is all that matters. Maybe those fat fans work better to pull or push a pressure differential. I'll have to get one and try it. I had a wide variety of the more typical fans, and none moved much air even through a 1" diameter hole a the other end of the container with no screen or filter. With the little centrifugal fan, it blows well as little as 2 pieces of 3/8ths tubing as the intake.

John
 
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