Otis Singleton
Building an electric supercharger at home is a challenging endeavour that requires careful planning and technical expertise. It involves using a high output motor, such as a 50,000 RPM 40 KW motor, and a dedicated high-voltage battery system, which can be expensive. The project also demands a thorough understanding of turbochargers, battery management, and electronic speed controllers. While similar technology exists in F1 cars, it is often proprietary and combined with conventional turbos for optimal performance. Enthusiasts have shared their experiences and insights on forums, offering glimpses into the complexities and costs of such DIY projects. Before embarking on this project, it is essential to evaluate the potential gains, costs, and time investments required to achieve desired results.
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Sourcing parts
- Electric Motor: The electric motor is a crucial component of your supercharger, and you will need a high-output motor capable of delivering significant power. You can consider using a high-RPM, high-KW motor similar to those used in high-end radio-controlled models. These motors can be sourced from hobby shops or online retailers specialising in remote-controlled vehicles. Alternatively, you may want to explore options such as the torqamp, which has been mentioned by DIY enthusiasts.
- Battery System: The battery system is another essential part of your setup. You will require a dedicated battery system capable of delivering high voltage, such as 48 volts. Lithium-polymer batteries, similar to those used in electric cars, can be considered. These batteries can be charged slowly from the car's electrical system, minimising the load on the engine. Keep in mind that batteries can be expensive, so it is important to carefully evaluate your options and consider the cost-benefit ratio. Alibaba has been suggested as a possible source for batteries and other electronic components.
- Electronic Speed Controller (ESC): The ESC is responsible for regulating the speed of your electric supercharger. It is a critical component that ensures the safe and efficient operation of your setup. The ESC should be compatible with your chosen motor and battery system. When sourcing an ESC, pay attention to its specifications, such as voltage and current handling capabilities, to ensure it can handle the demands of your supercharger.
- Compressor: The compressor is the heart of your supercharger, responsible for pressurising the air entering the engine. You can explore options such as the PanDair General Supercharger, which is a turbocharger turbo remanufacturing kit compatible with various engine sizes. Alternatively, you can consider using the compressor side of a vortec supercharger, as mentioned by some DIY enthusiasts.
- Adapters and Connectors: Depending on the specific vehicle you are working with, you may need adapters and connectors to interface your supercharger with the engine. For example, if you are working with a Tesla, you may require specific adapters to integrate your supercharger effectively. Ensure that you research the specific requirements of your vehicle and source the necessary adapters to ensure a seamless installation.
It is important to note that building a homemade electric supercharger can be a complex and costly endeavour. Always prioritise safety and consult with experts or online communities with experience in this field to ensure that your setup is safe and reliable.
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Battery power
A battery dedicated to powering the supercharger is required for a DIY electric supercharger. The battery's voltage should be high, with one source recommending 48 volts. The battery system should be able to charge when the car is idling or cruising.
A small 1.5 kg lithium polymer battery can be used to power a 3D-printed electric centrifugal supercharger. This battery can be slow-charged via a low-current regulator from the car's electrical system, ensuring an insignificant load on the engine.
The cost of batteries is a significant consideration, as they can be expensive. One source estimates that a DIY supercharger setup capable of providing 100 kW of power daily would require tens of thousands of dollars in solar panels and battery storage.
The battery management system (BMS) is also important, as it regulates the charging and discharging of the batteries. Some DIY builders have experienced issues with their BMS, resulting in unbalanced batteries and reduced performance.
It is recommended to keep the charge rate around 500 watts to avoid overloading the system.
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Motor output
One approach is to use a high output motor, such as a 50,000 RPM 40 KW motor, as seen in some YouTube videos and forum discussions. This type of motor can provide significant boosts in torque and power, but it requires a dedicated high-voltage battery and motor controller system. The high-voltage battery, for example, a 48-volt battery, plays a crucial role in delivering the necessary power to the motor.
Alternatively, some enthusiasts have designed and tested 3D-printable electric centrifugal superchargers that pull about 4 kW of power and boost to 5 psi. These designs utilise small lithium-polymer batteries that can be slowly charged from the car's electrical system, minimising load on the engine. While this approach may not provide the same level of boost as a high output motor, it showcases the potential for 3D printing in creating customised supercharger components.
It's important to note that the cost of high-performance motors and batteries can be significant. The electronic speed controller, or ESC, is another critical and costly component. When planning a homemade electric supercharger project, it's essential to evaluate the desired power gains, cost constraints, and technical challenges associated with each component.
Additionally, safety considerations, such as the inclusion of an intercooler to prevent debris from an exploding supercharger from entering the engine, should not be overlooked. The motor output, battery specifications, and associated electronics all contribute to a complex system that requires careful design and testing to ensure optimal performance and safety.
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Intercoolers
An intercooler is an important component of a supercharger system, helping to maintain optimal performance and protect the engine. Intercoolers are typically found between the supercharger and the engine's intake manifold, and they work by transferring the heat from the compressed air charge to the atmosphere. This helps to prevent the supercharger from producing too much heat, which can be detrimental to the engine and its parts.
There are different types of intercoolers available, such as air-to-water intercoolers, which function as an additional self-contained cooling system for the engine. These intercoolers have radiators with fins and tubes that allow ambient air to pass through, facilitating heat transfer. A small electric pump circulates the coolant within the system.
When designing a homemade electric supercharger, it is essential to consider the placement of the intercooler's heat exchanger. It should be positioned in the path of fresh air and in a location that is relatively easy to mount. Alternatively, it can be mounted out of position and electric fans can be used to compensate.
The intercooler also serves a critical safety function by preventing debris from an exploding supercharger from entering the engine. This protective feature underscores the importance of including an intercooler in any supercharger setup, especially when experimenting with homemade or modified systems.
Overall, intercoolers play a crucial role in the performance and longevity of a supercharged engine. By regulating the temperature and mitigating the risks associated with excess heat and debris, intercoolers ensure that the engine can operate within safe parameters. This, in turn, allows enthusiasts to explore performance enhancements while maintaining the integrity of their vehicles.
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Design and testing
The design and testing of a homemade electric supercharger require careful consideration of various components and their interactions. Here is a step-by-step guide to designing and testing such a system:
Step 1: Understanding the Basics
Begin by understanding the principles behind electric superchargers and the desired outcome. Electric superchargers use an electric motor to drive the compressor, providing additional air pressure to the engine, resulting in increased power output.
Step 2: Component Selection
Select the appropriate components for your setup. This includes choosing a high-output electric motor, such as a 50,000 RPM 40 KW motor, a dedicated battery system (e.g., 48 volts), an Electronic Speed Controller (ESC), and a compressor. Consider the power requirements and compatibility of each component.
Step 3: 3D Printing and Prototyping
Design a 3D printable electric centrifugal supercharger. This allows for customisation and easy modifications. Test the design using 3D printing technology, ensuring that the supercharger can handle the desired boost levels and air density.
Step 4: Battery Configuration
Configure the battery system to provide sufficient power to the electric motor. Consider using a lithium polymer battery that can be slow-charged from the car's electrical system via a low-current regulator. This ensures that the supercharger operates without placing a significant load on the engine.
Step 5: Intercooler and Safety Considerations
Incorporate an intercooler into the design to prevent debris from an exploding supercharger from entering the engine. Additionally, perform tension tests to ensure the system can handle the boost pressures and RPMs safely.
Step 6: Activation and Control
Determine whether the supercharger will be manually activated by the driver or automatically engaged based on the engine's needs. Consider using an Electronic Speed Controller (ESC) and a Battery Management System (BMS) to monitor and control the supercharger's performance.
Step 7: Testing and Refinement
Test the supercharger on a vehicle, monitoring its performance and impact on the engine. Make adjustments as needed, such as modifying the throttle position or using fuel injection to add fuel under boost. Ensure that the supercharger provides the desired boost without negatively affecting the vehicle's performance or safety.
Step 8: Comparison and Optimisation
Compare the performance of your homemade electric supercharger to commercially available options. Evaluate the cost, power output, spool-up time, and torque boost to determine if your design is competitive. Optimise your design based on these comparisons to improve performance and efficiency.
Building a homemade electric supercharger is a complex task that requires mechanical and electrical expertise. It is important to thoroughly test and refine the design to ensure safety and performance. While it may be challenging, the reward of a successful, high-performance electric supercharger can be well worth the effort.
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Frequently asked questions
The advantages of an e-turbo include nearly instant spool-up time, a lower-end torque boost, and a high-end power boost with a super flat curve.
You will need an AC to DC converter, a load manager, a battery power source, and an adapter for your car. You will also need to consider the cost of the batteries and motor, as these can be expensive.
One example is a 3D-printable electric centrifugal supercharger, which pulls about 4 kW of power and boosts to 5 psi. Another example is the PanDair General Supercharger, a car SUV aluminum Cherokee Roots supercharger compressor blower that can be purchased online.
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