Portable Airflow Companion

http://www.instructables.com/id/Portable-Airflow-Companion/

Food Living Outside Play Technology Workshop

Fan Powered by any Heat Sourceby Joohansson on February 27, 2015

Table of Contents

Fan Powered by any Heat Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intro: Fan Powered by any Heat Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 1: Materials and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Step 2: Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 3: 3D Printing (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 4: Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Step 5: Self-regulating CPU Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Author:Joohansson My SiteI like to design, construct and experiment with both old and new technology, especially when it includes mechatronics. I'm also devoted to photography,computers, programming and technology in general.

Intro: Fan Powered by any Heat SourceHow to build your own portable thermoelectric device with a quadcopter motor.

This project might not have an electrifying impact to the world but its a baby brother to my first instructable (Thermoelectric Fan) and just had to be built. Its muchsmaller than most similar projects and the top power device can be detached from the lower heat source base and be used as experiment in other areas. What does itdo? It converts heat energy into kinetic energy, looks nice and sounds awesome!

Concept:

It uses a thermoelectric generator module (TEG) to power a motor with a fan. The heat source (candle) heat up the lower aluminium plate => creates a temperaturedifference over the module => generates electricity to the motor => increases air flow through heat sink => increases temperature difference => more power. Without thefan it would eventually stop generating power since the heat sink would get almost same temperature as the plate.

Experimental Areas:

Almost any heat source with enough temperature can be used to power the motor and this makes this small device easy and fun to experiment with. Its very sensitive totemperature differences. I could run it on water with only 20C difference (23C air temp and 43C water temp). As seen in the video its powered from fire, hot water, food,and even used to cool a computer processor. The latter is an idea I had when i created my first build in 2013 and people said to me it cannot be done. It can and itsstable for normal use but with further optimizations it could probably be even better. I don't think it can replace a regular CPU cooler but as it uses no electricity from thecomputer its somewhat environmental friendly. More information on last page.

Specifications:

Size base: 56x64x40mmSize power device: 56x56x40mm (including fan)Size total: 64x64x79mmWeight base: 27gWeight power device: 85gWeight 3D print: 2.7gWeight total:114.7gCost: ~12$

Construction

It require few parts, easy to build and you do not need any knowledge about electronics. You just need some mechanical tools for cutting, drilling and polishing thealuminium. If you want to build it, please read further.

If you like my projects and want to contribute for future instructables, feel free to use this bitcoin address (or QR code image):1BouwowuprgQrtUYgyzYnNvHyRYbLceqHg

file:/member/Joohansson/file:/member/Joohansson/http://www.davit.sehttp://www.instructables.com/id/Thermoelectric-Fan-Driven-by-a-Candle/


Step 1: Materials and ToolsI think you can find everything on Ebay. Prices are estimated. Aluminium and bolts not included in price since its basically scrap metal.

1x Motor: Hubsan x4 20x8mm (20x7mm also works) [$3]1x Propeller: Hubsan x4 propeller [$1]1x TEG: 40x40x4mm (My module is same as used in Powerpot5, but most TEG or TEC will work) [$4]1x Heatsink: 43x43x16.5mm (ICK PGA 17X17 8.6C/W by Fischer Electrinics) [$4]1x Aluminium sheet: 56x56x3mm1x Aluminum sheet: 75x65x3mm3x Bolts: M4x40mm2x Bolts: M3x15mm1x Wire: 0.5x150mm1x shrink tube: 30mm (optional)1x CPU thermal paste (optional for better heat transfer, I highly suggest it): For example Keratherm KP 92

Tools:

HacksawFilePliersScrew driverDrills: 2.5mm, 3.3mm, 4mm & 7 or 8mm depending on motorScrew taps: M3, M4 (optional for better stability)Soldering iron (optional)Sandpaper: Different types from 100-1500 grit for smooth surfaces (optional for nice finish)3D printer with T-glase filament: For my special design part (optional)


Step 2: ConstructionWire (Used for fixating the heat sink)

Fixate the two M3 bolts (CC=50mm) to use as template1.Bend the wire around the bolts and twist the ends2.

Heat SinkIf you use a 8mm motor you will need a 8mm centered hole in the heat sink.

Use pliers to cut the middle parts of the heat sink if possibleDrill a 8mm hole (not all way through the bottom)Check that motor fits into the hole (wire goes beneath the motor if possible)

Bottom Aluminium Sheet

Use hacksaw and file to make it nice 75x65mm1.Wait to cut it triangular to make easier to fixate in machines2.Draw edge lines (red) and mark up for three M4 holes, see image for measurements3.Drill three holes with 3.3mm drill if you want to use M4 threads, or 4mm if no threads4.[Optional] Create M4 threads with thread tap5.Cut the edge with hacksaw to get the triangle6.

Top Aluminium Sheet

Use hacksaw and file to make it nice square 56x56mm1.Use the bottom sheet as template and mark up same three holes, see image for measurements2.Drill three 4mm holes (half way through), we use no threads here to make it easy to attach/detach3.Use the heat sink as template or my measurements to mark up the two M3 holes4.Create M3 threads with thread tap5.

Finish

Chamfer all corners (10mm long (diagonal) bottom chamfers, 8mm long (diagonal) top chamfers1.For nice design, use sandpaper or other tools to create a nice finish of the two aluminium parts. I used step by step paper grit 200 up to 1500.2.


Step 3: 3D Printing (Optional)For design purpose you can print this special part if you have a printer and transparent filament like T-glase.

I used a wanhao duplicator 4x printer and simplify 3D software. If you want it lower or higher you can simply scale it along Z.

Link to model:

Printer settings:

Layer height: 0.37mm (single outline corkscrew method (vase mode)Shells: 1Infill: 0Top and bottom layers: 0Extrusion multiplier: 1.15Extrustion width: 0.5mmSpeed: 600mm/min (10mm/s)Temp extruder: 235CTemp bed: 80C


Step 4: AssemblyThe TEG module is placed between the heat sink and top aluminium plate1.

Use thermal paste for better heat transfer on both side of the TEG1.Place motor in heat sink with both motor wires and steel wire loop beneath it2.Screw the heat sink using two M3 bolts and through the wire loop3.Connect the motor to TEG and solder it using shrink tubes (optional)4.Screw the M4 screws all way through bottom plate5.Place the module on top of base and use 3D printed part if you want (Gives a little more power as it shields the candle flame)6.


Step 5: Self-regulating CPU CoolerThe module could be used in a computer to replace a conventional CPU cooler. It uses only heat from the CPU to power the fan, which in turn transfer the hot air awayfrom the CPU. It might not have enough efficiency for a modern CPU but this is more or less a proof of concept. It does not require a sensor, electronics or motorcontroller as the fan speed is self-regulated by CPU temp.

Currently tested on an AMD Athlon 64 3800+, 2400MHz single core, 89 Watts. Normal computer use was stable but I also did a 5 min stress analysis both with andwithout the motor fan compared to stock cooler. Clearly the fan helps to cool the CPU. The stock cooler is a 80x70x70mm heatsink (402g) plus a large fan compared tomy small device (85g with motor & fan):

Idle [stock cooler]: 30CIdle [TEG-fan]: 37CIdle [TEG-noFan]: 60C100% load [stock cooler]: 49C100% load [TEG-fan]: 75C100% load [TEG-noFan]: Cancelled at 95C to not damage it

After the test the CPU went back to stable 37C and fan RPM went to normal. Also be aware that I did not apply any down force on the device, it just rested on top of CPUand if youre a computer builder you know that is not very efficient. The device is also way smaller than stock cooler and a larger TEG and heat sink would probably do abetter job. Would be great to see someone else experiment with this! Though, I will not be held account for any CPU damage. This particular CPU has a rated max tempof 69C so I would not recommend the build as it is.

Update 1 (Second picture):Also tested with added small heat sinks on the bottom plate for better cooling from left-over air. I did this to show that parameters can easily be optimized further. Just tobe sure, I removed the extra aluminium during the test and temp increased to 75C as before.

Idle [TEG-extra cooling]: 37C100% load [TEG-extra cooling]: 71C


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Comments

16 comments Add Comment

Raphango says: Mar 7, 2015. 6:04 AM REPLYGreat!! =DDD

mickeypop says: Mar 5, 2015. 12:37 PM REPLYI made a sort of variant about 30 years ago. It looked like a small wrought iron chair with the fan blowing thru the back and sat on a pot belly stove. The chairseat and base were separated by the Peltier Junction. The heat blew all over the room and no batteries needed. The real secret is a good differential intemperature between the sides of the Peltier that is were the stand(chair legs) made a difference.

Joohansson says: Mar 6, 2015. 6:02 AM REPLYNice! Where did it go, did you sell it or trash it?

mickeypop says: Mar 6, 2015. 10:04 AM REPLYThat was 30 years ago. I probably left it when i moved. ---

Think about the way a swivel chair is made, a top seat and a base. Now replace the swivel with the Peltier and make the back of the seat a heat sink,open with bars running down and mount the fan blowing thru it. ---

For scale the base legs were around 2.75 inches (remember the peltier is 3/16 thick) and the back of the seat was probably 3 inches based on thefan diameter for an overall 6 inch height. ---

I used wrought iron because i had access to a welder and had the scrap, however most any metal would work. I just thought it was going to sit onblack iron anyway why not make it look right too.

brendanh says: Mar 5, 2015. 12:36 PM REPLYIf this could be up-scaled and applied to a wood heater, then I think you could market this at off grid solar homes. A lot (including myself) run a wood (orother) heater for 6 months every year which is also the lowest solar input time of the year. This could offset the need to run a backup generator. My woodheater goes 24/7 which makes your application very attractive as another alternative power source.

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Joohansson says: Mar 6, 2015. 6:06 AM REPLYGoogle Ecofan. They are a bit expensive, if I were you I would build one myself. Like this one but with a 40x40mm high power TEG:http://www.instructables.com/id/Thermoelectric-Fan-Driven-by-a-Candle/

your_dragon113 says: Mar 5, 2015. 4:01 PM REPLYyou can get these "Up-Scaled" fans through Most hardware stores which you place on your (wood burning)Stove and the fan powers up and helps movethe air.

U_eriksen says: Mar 5, 2015. 12:32 PM REPLYVery nice. I was just thinking if it would be possible to make a base plate with four small suction cups, so that the whole thing could be attached to a warm,flat/smooth surface, like maybe a window in the sun? That would make a nice, little portable fan.

If using suction cups, the 'height' of the cups would probably need to be adjustable, for fine-tuning (the suction cups would need to be almost fullycompressed when the alu plate is touching the glass/whatever) Maybe mounting the suction cups on small M3 screws...

Joohansson says: Mar 6, 2015. 6:01 AM REPLYThanks, You probably can, if you need a fan on the window =)

snoopindaweb says: Mar 5, 2015. 10:15 PM REPLY~(:-})={>---- ] Imagine that. Voted - Faved, Thank You.

Bongmaster says: Mar 2, 2015. 8:05 AM REPLYI recognise that tune in the vid, where was it from? :0

Joohansson says: Mar 2, 2015. 9:41 AM REPLYA very old Amiga chiptune, don't remember which one.

Bongmaster says: Mar 2, 2015. 2:08 PM REPLYi used to have it in my Mod/XM collection years ago x3lost them all tho and havent been able to 'track' many down again

MasterZii says: Mar 2, 2015. 12:19 AM REPLYCouple questions.

Do I need to have the plate in a triangle shape?

Do the plates need to be aluminum, as I only have copper at the moment?

And approximately how long did this take you?

I wish there was a video of this!!!

Joohansson says: Mar 2, 2015. 12:51 AM REPLYTriangle not needed. Copper will work even better. I put a lot of effort to making the design, planning for the instructable, taking photos, keeping highprecision of everything and polishing etc. The construction took about 14h in total I think but half of that was to make the aluminium look nice. Thenanother 8h writing, preparing photos and creating video. As with my other instructables I make them on the fly along with inventing the stuff. That makesit difficult to record videos. Would be easier if I would make another copy with same design but that will unfortunately not happen.

RtyQ says: Mar 1, 2015. 1:59 PM REPLYnice, would be awesome to use as a Raspberri Pi (or similar) cooling system since it doesn't cost any extra power

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Portable Airflow Companion