DSC06687 Picture showing the Aluminum chill plate version 1.0 after the majority of the CNC work had been completed.
DSC06686 During fabrication a small layer of Aluminum was left on the bottom of the plate which when eventually removed provided a brilliant smooth surface on both the top and bottom faces of the plate.
The final chiller plate dimensions match the controller base dimensions and they are described in the previous post.
DSC06602 The 1.25" wide channels allow for good flow and contact surface. The final weight of chill plate version 1.0 was 708.23 grams.
DSC06627 Showing the internal view of the 0.125" NPT inlet and outlet ports on the side of the chiller plate. updated 2/7/2020 Pilot holes drilled with 0.332" (Q) drill ($7.19) and tapped with 1/8-27 NPT tap ($6.19). updated 3/18/21 The center to center spacing was initially 38.1mm, but later chill plate version 2.2 provided an increased center to center distance of 50.8 mm to accommodate larger footprint 90 degree elbow fittings. updated 9/7/21
updated 3/18/21
DSC06628 Gasket adhesive that was used to secure the Chiller Plate to the base of the controller. One source is Advanced Auto Parts part number 22072 at $4.49. EVWest indicates that white silicone should not be used as it degrades over time.
To mount the chiller plate to the controller, the bottom surface of the controller and the top surface of the chiller plate are cleaned (brake cleaner or solvent) and then Gasket Maker is applied to the top surface of the chiller plate. The bolt holes are aligned and the two parts are clamped together for curing for 24 hours. Any excess silicone can then be trimmed from the sides. During fabrication of the chiller plate, if a small beveled edge is machined onto one of the top outer edges of the chiller plate, the bevel can allow for insertion of a chisel so that a mallet can then be used to separate the two parts later if needed.
Alternative Chill Plate Design - Faster Flow Design
The inlet inner diameter of a 1/8" NPT hose nipple is 0.307" (thin wall schedule 10) and 0.269" (standard wall schedule 40). Thus for a schedule 40 pipe fitting, the cross sectional area is 0.227 square inches. This cross sectional area will define the flow rate at a given inlet pressure. Once the cooling fluid enters the plate, the larger cross sectional area (rectangle 1.25" wide and 0.50" tall, 0.625 square inches ) results in a flow rate that is only 36.3% of the inlet flow. It is not known how much heat must be removed from the controller when it is under full load. It is possible that a different design with only 0.75" channel width and the same 0.50" depth, will not have any material impact upon performance, but we will make one and test it. This design is much simpler, although tedious to fabricate, when manually operating a Bridgeport.
DSC06698 Showing the smaller 0.75" width channels in an alternate design chill plate version 2.0. The final weight of this design is 708.41 grams.
DSC06697 Edge on view showing the input and output NPT threaded holes for version 2.0 at the far side and on this plate the addition of two extra threaded ports holes at the front edge for optional sensors.
updated 2/7/2020
updated 9/7/21
DSC06782 Edge on view showing placement of 0.125" brass plugs installed into sensor ports of version 2.0 with sensor.
To mount the chiller plate to the controller, the bottom surface of the controller and the top surface of the chiller plate are cleaned (brake cleaner or solvent) and then Gasket Maker is applied to the top surface of the chiller plate. The bolt holes are aligned and the two parts are clamped together for curing for 24 hours. Any excess silicone can then be trimmed from the sides. During fabrication of the chiller plate, if a small beveled edge is machined onto one of the top outer edges of the chiller plate, the bevel can allow for insertion of a chisel so that a mallet can then be used to separate the two parts later if needed.
Alternative Chill Plate Design - Faster Flow Design
The inlet inner diameter of a 1/8" NPT hose nipple is 0.307" (thin wall schedule 10) and 0.269" (standard wall schedule 40). Thus for a schedule 40 pipe fitting, the cross sectional area is 0.227 square inches. This cross sectional area will define the flow rate at a given inlet pressure. Once the cooling fluid enters the plate, the larger cross sectional area (rectangle 1.25" wide and 0.50" tall, 0.625 square inches ) results in a flow rate that is only 36.3% of the inlet flow. It is not known how much heat must be removed from the controller when it is under full load. It is possible that a different design with only 0.75" channel width and the same 0.50" depth, will not have any material impact upon performance, but we will make one and test it. This design is much simpler, although tedious to fabricate, when manually operating a Bridgeport.
DSC06698 Showing the smaller 0.75" width channels in an alternate design chill plate version 2.0. The final weight of this design is 708.41 grams.
DSC06697 Edge on view showing the input and output NPT threaded holes for version 2.0 at the far side and on this plate the addition of two extra threaded ports holes at the front edge for optional sensors.
updated 2/7/2020
updated 9/7/21
DSC06782 Edge on view showing placement of 0.125" brass plugs installed into sensor ports of version 2.0 with sensor.
updated 9/7/21
DSC06795 Multiple copies of these plates version 2.0 were fabricated and they are available to others by contacting William at sales@narchem.com .
updated 2/19/2020
DSC06792 Picture of McMaster Carr (part 5346K13, $1.19 ea.) straight brass barbed for 1/4" hose ID that was used when the center to center holes was only 1.0" (chill plate version 2.0). The ID of the straight fitting is 0.18".
DSC06795 Multiple copies of these plates version 2.0 were fabricated and they are available to others by contacting William at sales@narchem.com .
updated 2/19/2020
DSC06792 Picture of McMaster Carr (part 5346K13, $1.19 ea.) straight brass barbed for 1/4" hose ID that was used when the center to center holes was only 1.0" (chill plate version 2.0). The ID of the straight fitting is 0.18".
updated 9/7/21
DSC06794 Picture of McMaster Carr (part 53525K11, $2.67 ea) of the 90 degree elbow brass barbed for 1/4" hose ID that was used when the center to center holes was 1.50" (chill plate version 2.1) and there was additional space for rotation of the fitting during installation. The ID of the 90 degree elbow is 0.18".
updated 9/7/21
Hi Wiliam, thanks for sharing your project.
ReplyDeleteI am also working on a project using the Hyper 9HV motor and would like to know if you have already selected a cooling pump ?
Best regards, Arnold.
Dear Arnold:
DeleteSome are using PC gaming liquid cooling systems (pump, coolant reservoir, and fans) to cool the Hyper9 controllers. In the next few weeks I will post information about cooling but in the meantime I am focused upon the XSPC D5 cooling systems that can be found here:
http://www.xs-pc.com/water-pumps/d5-photon-170-reservoirpump-combo-v2
William
William, did you ever get around to finalizing your cooling system? Thanks for pointing me in the right direction with the Dorman fuel connector
DeleteThanks William, so a flow rate of 1200 lph (20 lpm) should be sufficient ? My project is converting an outboard marine motor and i intend to use an electric impeller pump and seawater/ freshwater to cool the controller.
ReplyDelete/Arnold.