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Frequent flyer Gold
Posts: 286
  
Location: Russia, Perm | Therefore, the continuation of part 1. I bought a new 9G. As you remember, at the compressor destroyed belts at full load. I decided to create a new supercharger. To do this, I turned to one-mechanical plant. I talked with the designers and engineers. And has agreed to help in the production of. First, there was developed a concept and drawings. The first option was.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | In the concept, I refused to belt in principle. This will gear reducer. |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | In the manufacturing process it became clear that the gear housing is easier to make a round. New drawings.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | As you can see, it has to be a two-stage gear box. For that you need two-stage gearbox? The gear transmission are changing the direction of rotation. Two-stage gear box does not change the rotation. However, the price of the production was very high. So decided to make one-stage gear box and change the rotation of the impeller and the snail. |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | I bought a new snail and the fan with the right rotation.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Development of drawings and calculations took 2 months. The first thing made gears. On a sheet of written dimensions, confirmation of quality, hardness Brunel (lower picture)
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | The next step production of shafts. There were made two shaft. High-speed and low-speed. Shafts are made of steel. -Hardened high-frequency currents. Balancing
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | This picture I made for the understanding of how it looks in assembled form.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Further made cover. For the connection of actuator and snails.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Manufacturing of a case goes in several stages. First, divide the lathe work.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Further milling and holes.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | In the housing made two holes for plugs. However, you can also set the nozzle for oil supply. |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | This picture I made for the understanding of how it will look supercharger.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | The next step is making holes for the shafts. This work is not completed yet. This is done to coordinate the machine. I will make in the near future. |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Initially, I only wanted to install a supercharger. However, in the course of the project, it was found out, that there are very many people who want to install a package. I understood that I can give it to people. Therefore, the project was at a military factory. At this point in the development of 2 variants of the compressor. 1) For engines up to 2.7 liters. 2) For engines up to 5 liters. The options have in the same gear, but the different size of the snail and the impeller. I will show you the difference between the snails. |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Option snail 1, you saw in the previous photo. I want to tell about the snail for the variant №2. The turbocharger is selected in size and is calculated according to the formula of air flow. I need this charger. For the first sample I took the used snail from the turbocharger. To use it is necessary to spend tuning.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | First, increased the center hole of the input. Now it is 3.5" (89.5 mm) For the new impeller. Hole output 2" (50 mm). The entire enclosure is processed by the sand of the jet machine. Here is a picture for comparison. To the left version for engine 2.7 litres. On the right side for 5 liter engine
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | As you can see in the photo, in 5 litre version, there are studs. It is necessary to make the transition to the pipe. I will tell you how it is done. First is worked out the piece of steel. The second part of the standard pipe transition with a diameter of 52 mm to 70 mm.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | On the reverse side parts made recessing for the rubber ring. Just set the diameter of the holes.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Next, hold the welding works, using argon.The result was a metallic glass.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | A further step, polishing machine. After 30 minutes the glass looks like this.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | That's all for now. Watch out for the continuation of the project... |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | A small bar to the product. With the help of a laser.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | To Continue. Before the New year, managed to finish the work on the coordinate milling machine. Made holes in the hull and mounted bearings.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | In aluminium housing should not be put bearings. First set of steel bushings, and in them shall be established by the bearings.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Wanted to check, how are the gears and shafts. A very tight fit. Now we need to gather all.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | I want to tell You continued. All parts are made and you can begin to build. So begin the assembly. I laid out the parts on the table. Details are processed skimmed
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | The next step, insert the high-speed shaft and put the key. And put the gear.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Now does sealant, you can connect the housing and cover. Tighten the bolts and remove the sealant.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | You can mount the shafts. Make sure you use a lock thread. Delaying high-speed and low-speed shaft
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | On the reverse side there is recessing for sealant. Apply sealant and install the cap. Also installs the cuffs high-speed shaft.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Now you can install the impeller. In this connection there is a tension. Therefore, the first impeller is heated in boiling water. The impeller is expanding and freely installed on the shaft and secured nut. The gap is 0.5 mm. It says about the correctness of the assembly
Edited by stayer 19/2/2012 17:18
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Now close the front cover of the high-speed shaft and install the cuffs of the low-speed shaft. Install a snail and check the gap. All well-0.5 mm
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Now I have a compressor. The installation will begin when it becomes warmer. Now in Russia the winter. On the street -35C.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | I started to do brackets for mounting the supercharger. I decided to abandon the long-intermediate shaft. The compressor is placed next to the drive belt. Brackets as temporary. We have to understand the kinematics and mounting. So they look as ugly. Sometimes you have to do 3 - 4 times, and different designs. The second bracket also did, but I got the phone and I have not made the photos. From here there are 2 problems. To do degree outlet by 90 degrees. And yet the incoming air is next to the hot collector. I think to find the right solution.
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | resolution is too big stayer...
try 1280x1024 |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | The next step processing bracket
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Painting powder paint and polymerization in the heat chamber
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | I got rid of the pins and installed the compressor.
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | beautiful job....very professional.
But how will the belt loop around? |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Administrator - 6/3/2012 04:21
resolution is too big stayer...
try 1280x1024 Yes, I have long wanted to ask, how to do it? Watch the big picture uncomfortable. Tell me how can I fix it? Can I fix photos that have already been put up? |
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | stayer...here is a small program for free.
it is english so good luck
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Thank You. Corrected all the photos. Now look more convenient. |
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | stayer - 7/3/2012 21:54
Thank You. Corrected all the photos. Now look more convenient.
Photos look great.
thank you for posting them. |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Administrator - 6/3/2012 19:40
But how will the belt loop around? It is quite simple. I first make part (see photo). This part should be set instead of screw alternator. At the other end of the details need to install a stray pulley. Earlier it was so - belt is on the generator. Now the drive belt is on the compressor pulley, returns to stray pulley and goes to the generator.
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | Nice work. |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | I want to tell you how to make an additional pulley. It is necessary in order to remove the belt. First I bought a pulley. You must install the bearings.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Pulley steel, made a robot, accuracy is not bad. The first thing to do, sharpening hub of steel 40H (Russian standard). The hub on a hot pressing inside the pulley. Internal diameter of the sleeve is made under the bearings. On the reverse side of the pulley cut off the bottom. Now make a yoke under timing belt. Inside the sleeve is made recessing a snap ring and Burt at the end of the sleeve.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Set bearings and produced axis to a pulley.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Then all set to the motor.
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Oh, it's noisy. A very powerful stream of air. Now I want to drive 2-3 weeks with no load. This lapping of details
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Frequent flyer Silver
Posts: 51
Location: Australia | nice development work
any new developments? |
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Frequent flyer Bronze
Posts: 45
Location: Perth, WA | Any updates on this Stayer? |
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