3D printed 400mm EDF project

Things that fly
SkyersJet   10 mW

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Re: 3D printed 400mm EDF project

Post by SkyersJet » Aug 04 2021 4:52pm

Hi thanks, it looks exactly like the cutaway in the blue diagram. It's just a simple single speed gearbox.

sprocati   1 µW

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Re: 3D printed 400mm EDF project

Post by sprocati » Sep 02 2021 7:03am

Very nice project.
Could you provide information about the BLDC motor?
Who manufacturer it?
Which ESC have you used?

Regards

SkyersJet   10 mW

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Re: 3D printed 400mm EDF project

Post by SkyersJet » Oct 12 2021 5:14pm

Thanks. It's a TP 5870 inrunner. I am running it with a Hobbywing 14s ESC. I previously used a Castle Edge HV 12s ESC

SkyersJet   10 mW

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Re: 3D printed 400mm EDF project

Post by SkyersJet » Oct 12 2021 5:18pm

New Prototype
  • Wider shaft to prevent flexing
    Drive shaft secured at both ends to prevent vibration
    Washout added to blades
    Duct lengthened to allow air to accelerate
    Thinner walls and shorter screws to save weight
    Narrower gearbox to not obstruct air
    Stators are now aerofoil sections
    Nylon blades
Attachments
Screenshot 2021-10-12 at 12.12.03 pm.jpg
Screenshot 2021-10-12 at 12.12.03 pm.jpg (139.01 KiB) Viewed 1012 times

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nicobie   1.21 GW

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Re: 3D printed 400mm EDF project

Post by nicobie » Oct 12 2021 8:41pm

Nice.

Can't wait to see the test results.
Ask for it by name.

my eTownie build thread: http://endless-sphere.com/forums/viewto ... =6&t=23701
Magazine article https://www.electricbike.com/nicks-etownie/

BalorNG   1 kW

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Re: 3D printed 400mm EDF project

Post by BalorNG » Oct 21 2021 2:54am

SkyersJet wrote:
Oct 12 2021 5:18pm
New Prototype
  • Wider shaft to prevent flexing
    Drive shaft secured at both ends to prevent vibration
    Washout added to blades
    Duct lengthened to allow air to accelerate
    Thinner walls and shorter screws to save weight
    Narrower gearbox to not obstruct air
    Stators are now aerofoil sections
    Nylon blades
Seriously impressive project, might as well use it to propel a bike :)
But unless your nylon is higly CF/GF-filled, it is not that much stiffer than petg in my experience, so you'll still have problems with blades contacting the shroud at high RPMs I suspect. They might *survive* it though, but this is still not very nice...
Using CF/GF filled filament (not nessesarily nylon, CF petg works well according to my tests, to promote epoxy adhesion) and carefully gluing strips of uni CF to stiffen the construction over it will work, but balancing it would be a nightmare (I think it was already suggested).

SkyersJet   10 mW

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Re: 3D printed 400mm EDF project

Post by SkyersJet » Dec 05 2021 8:40am

These blades are actually PLA.


SkyersJet   10 mW

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Re: 3D printed 400mm EDF project

Post by SkyersJet » Dec 05 2021 8:41am

Can people see the video? I just see a blank.

SlowCo   10 MW

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Re: 3D printed 400mm EDF project

Post by SlowCo » Dec 05 2021 8:52am

Yes I can see/view the video.
Did you also have a thrust measurement in place (suitcase weighting scale) to see the amount and difference in thrust?

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fechter   100 GW

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Re: 3D printed 400mm EDF project

Post by fechter » Dec 05 2021 11:39am

I could see the video too. At least it held together this time. Which one gave the most thrust?
"One test is worth a thousand opinions"

SkyersJet   10 mW

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Re: 3D printed 400mm EDF project

Post by SkyersJet » Dec 05 2021 3:49pm

Hmm must be my browser.

circular intake gave 5.7kg @1492W and the elliptical one gave 5.8kg @1439W

SkyersJet   10 mW

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Re: 3D printed 400mm EDF project

Post by SkyersJet » Dec 12 2021 3:53pm



I think I might consider switching to direct drive. The gearbox is still vibrating too much.

SkyersJet   10 mW

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Re: 3D printed 400mm EDF project

Post by SkyersJet » Jan 30 2022 5:14pm


mechhead   10 W

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Re: 3D printed 400mm EDF project

Post by mechhead » Feb 22 2022 4:37am

Hi, nice work.

you are likely loosing a lot of thrust because your diffuser thrust straightening fins are not angled and are likely in a stall. you might study pictures of ones off actual aircraft. the air coming out the back of the fan is turning about the aixs and this needs to be caught with angled fins that cancel the rotational moment of the airstream, a lot of the thrust is made by streightening the flow with angled stator blades that also have an optimal spiral twist to them and the duct nozzle is non parallel in most ducted fans also to enhance thrust .

keep up the experiments you may also like to try a pancake style drone motor that is made for the slower rpm of the big fan instead of a lossy gearbox an 80 or100mm dia one can be had inthe same power level as the motor your using

SkyersJet   10 mW

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Re: 3D printed 400mm EDF project

Post by SkyersJet » Feb 26 2022 2:53pm

I tried angled fins, it was a flop https://twitter.com/SkyersJet/status/14 ... 0553483269

If you mean an outrunner the problem is torque, not power hence the gearbox.

SkyersJet   10 mW

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Re: 3D printed 400mm EDF project

Post by SkyersJet » Feb 27 2022 5:11pm


I blame the heavy steel ring on the duct for this. The test trolley has got to go as well, too wobbly.

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nicobie   1.21 GW

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Re: 3D printed 400mm EDF project

Post by nicobie » Feb 27 2022 7:24pm

Is that strain gauge reading lbs.? If so 161 lbs is great!
Ask for it by name.

my eTownie build thread: http://endless-sphere.com/forums/viewto ... =6&t=23701
Magazine article https://www.electricbike.com/nicks-etownie/

SkyersJet   10 mW

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Re: 3D printed 400mm EDF project

Post by SkyersJet » Feb 27 2022 8:21pm

17.2 kg

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nicobie   1.21 GW

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Re: 3D printed 400mm EDF project

Post by nicobie » Feb 27 2022 8:46pm

That's still respectable! I was having trouble believing it could pull 161 lbs. 8)
Ask for it by name.

my eTownie build thread: http://endless-sphere.com/forums/viewto ... =6&t=23701
Magazine article https://www.electricbike.com/nicks-etownie/

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