1100 Fan Conversion Kit


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Thread: 1100 Fan Conversion Kit

  1. #1
    Registered nitewatchman's Avatar
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    Default 1100 Fan Conversion Kit

    So for the last year or so I have followed the issues discussed about fan balance on the 1100 in particular and the potential vibrations that could result. I didn't think that my machine was particularly noise or out of balance so I just rocked along with the stock fan, A previous post got my interest up over the holidays and I decided to put something together to address the issue.

    I installed the first version of the fan kit and the difference in sound and vibration is huge. The only sound now even at 5140rpms is the whine of he VFD. There is a very slight vibration but this I believe is coming from the unbalanced Spindle pulley.

    I modeled a replacement for the motor end bell keeping the same general configuration and mounting points. To this new end bell I spliced a housing to integrate a 120mm fan. I used a Noctua Industrial 12VDC fan since I already had 12VDC available in the mill headstock. I used the Austrian Noctua fan because of its reliability. I have replaced a lot of fans, but I have never replaced a Noctua fan.

    The model was the converted to an .stl file and printed on my Rostock Max V2. The fan and grill were installed in the new printed motor end bell and the entire assembly fixed to the motor using the same mounting with longer screws. The end bell consumes about .5+kg of filament and takes about 15 hours to print

    The airflow over the motor is continuous and runs anytime the machine is powered. The volume of air produced is ample and seems to keep the motor very cool. I cycled the motor from low to high speed and back down continuously for about 5 minutes. This essentially keeps the horsepower meter in the yellow all the time and there was no perceptible warming of the motor.

    I am quite happy with way this all turned out and looking back I should have done it long ago. There are some small changes that I will make to the model like adding extended bosses below the flange mounting bolts but all in all the fit was quite good with sufficient clearance between the end bell top and the door switch to slide into place without removing the door switch, I also intend to take some Flir photos of the motor to judge the cooling efficiency during a long term run just to be sure.

    I have also considered offering the kit or kit components for sale if there is an interest.

    gary

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    Last edited by nitewatchman; 01-06-2017 at 03:49 AM.


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    Default Re: 1100 Fan Conversion Kit

    Nice job Gary, BTW I always enjoy your postings....

    Robert



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    Default Re: 1100 Fan Conversion Kit

    Very nice!

    Sent from my SM-G900V using Tapatalk



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    Default Re: 1100 Fan Conversion Kit

    I would be very interested in a kit like this. I have the 770 though...I'm assuming motor size differences would leave me out.



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    Default Re: 1100 Fan Conversion Kit

    Quote Originally Posted by nitewatchman View Post
    So for the last year or so I have followed the issues discussed about fan balance on the 1100 in particular and the potential vibrations that could result. I didn't think that my machine was particularly noise or out of balance so I just rocked along with the stock fan, A previous post got my interest up over the holidays and I decided to put something together to address the issue.

    I installed the first version of the fan kit and the difference in sound and vibration is huge. The only sound now even at 5140rpms is the whine of he VFD. There is a very slight vibration but this I believe is coming from the unbalanced Spindle pulley.

    I modeled a replacement for the motor end bell keeping the same general configuration and mounting points. To this new end bell I spliced a housing to integrate a 120mm fan. I used a Noctua Industrial 12VDC fan since I already had 12VDC available in the mill headstock. I used the Austrian Noctua fan because of its reliability. I have replaced a lot of fans, but I have never replaced a Noctua fan.

    The model was the converted to an .stl file and printed on my Rostock Max V2. The fan and grill were installed in the new printed motor end bell and the entire assembly fixed to the motor using the same mounting with longer screws. The end bell consumes about .5+kg of filament and takes about 15 hours to print

    The airflow over the motor is continuous and runs anytime the machine is powered. The volume of air produced is ample and seems to keep the motor very cool. I cycled the motor from low to high speed and back down continuously for about 5 minutes. This essentially keeps the horsepower meter in the yellow all the time and there was no perceptible warming of the motor.

    I am quite happy with way this all turned out and looking back I should have done it long ago. There are some small changes that I will make to the model like adding extended bosses below the flange mounting bolts but all in all the fit was quite good with sufficient clearance between the end bell top and the door switch to slide into place without removing the door switch, I also intend to take some Flir photos of the motor to judge the cooling efficiency during a long term run just to be sure.

    I have also considered offering the kit or kit components for sale if there is an interest.

    gary
    Gary thats a super nice looking fan shroud!!


    That motor fan on mine was the biggest cause of vibration, the belt was second.

    You could make a bit of improvement by balancing the PDB nut if its an older machine, in the last photo it appears to be off center somewhat with the spindle, my machine is an early 2012 version and the PDB nut thread was about a class 4 fit to the spindle thread, and there was a lot of vibration from it.

    the new machine I had the priveledge of looking at the local HS didnt vibrate much at all, but they didnt have the sheetmetal splash guard installed yet, and it had a 2 bolt fan on it.

    again nice work on the shroud!

    mike sr


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    Default Re: 1100 Fan Conversion Kit

    That's rather inspirational!



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    Default Re: 1100 Fan Conversion Kit

    Gary-

    You should send those pictures to Tormach and offer them for sale through them (that where the enclosure and ATC and PDB came about).

    I would buy one... beautiful work.

    Time to buy a 3d printer, I guess...

    Tim
    Tormach 1100-3 mill, Grizzly G0709 lathe, PM935 mill, SolidWorks, HSMWorks.


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    Default Re: 1100 Fan Conversion Kit

    It looks like a good 3D CAM project!

    Sent from my SM-G900V using Tapatalk



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    Default Re: 1100 Fan Conversion Kit

    A that is why a 3D printer is so handy at times, Very nices

    http://danielscnc.webs.com/

    being disabled is not a hindrance it gives you attitude


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    Default Re: 1100 Fan Conversion Kit

    Super nice job, I like the solution a lot!!!

    I would be interested in buying the finished product or the cad files or the STL files at a reasonable price to avoid having to measure and cad it up myself - hope you will make it available

    Thanks

    Learning to use a Tormach Series 3


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    Default Re: 1100 Fan Conversion Kit

    Gary,

    Very nice. I too am very interested in acquiring the shroud. BTW, is that a Fenner belt and if so, was it helpful in reducing vibration at higher RPMs?



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    Default Re: 1100 Fan Conversion Kit

    Looking online at the Noctua fans, some have 3-pin connectors and others have 4-pin with PWM control. Do all of these run at full speed with just power input on two pins or do I need something fancier to control them? What did you use for a power supply?



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