I tried OVERPOWERING my Vacuum! (Homemade Turbine)

Websites which were shown during the video:

In this video I will try to overpower my old vacuum cleaner. The problem is that its internal battery pack gave up and the suction power of the motor also somehow decreased. So in this video I will try to 3D print my own turbine/impeller and combine that with a BLDC motor in order to renew my old vacuum cleaner so that I do not have to throw it in the garbage. Let's get started!

Thanks to element14 for sponsoring this video.

0:00 The Problem of my Old Vacuum Cleaner
1:22 Intro
1:57 Suction Power of my Old Vacuum
2:33 Choosing a Motor/ESC
4:48 First Turbine Prototype
6:15 Second Turbine Prototype
7:24 BIG PROBLEMS!
9:31 Successful Test!
9:52 Final Assembly & Testing

[thecatofnineswords]

Vacuums need static pressure more than speed of airflow, and I think that's where the designed impellor let you down.
Excellent first attempt, and I look forward to seeing updates

[deadbird]

Next step: design a complete vacuum cleaner 😅

[olivierconet]

That's real engineering 😁 : designing, testing, failing and doing it again !
And always learning something.
Thanks for this video.

[mikefochtman]

Fun bit of experimenting. But I'd point out that most centrifugal blowers/pumps have a flow vs 'head' trade off. If you design a rotor for maximum flow rates, it probably will not develop much differential pressure. And vice versa. The differential pressure can be important when you think about how you need to draw the air through a dusty filter bag.

[Hackvlog]

"Get a new one! I need a better vacuum cleaner!"
-"No. We have a better vacuum cleaner at home"

[Emet-wdmz]

Am building DIY Vacuum cleaners for like 3 years now as part of my hobby and here are some tips that could help:

1. As someone in comments already pointed out, vacuums need static presure cuz when u "block" that properel with a *filter* it behave like if u block the intake. It will just spin without actually sucing anything. Maybe thats also why u had so little powerdraw. Cuz if u block the intake its like in a vacuum, there is no air resistance so the motor can achive desired RPM without drawing so much current.

2. Most comercal vacuum cleaners use some form of flexible material as a housing for motor with propeler. Its for reducing some unwanted noise from vybration of the propeler. When I was printing that housing I used TPU. I was able to make it completly silent with it so I could only hear the airflow.

3. 3D printers cant make a perfect propeler. Its not posible. Due to uneven infill or some extrusions... You cant make a perfect circle. It will vybrate and that can couse some problems for the bearing inside the motor. I personally killed multiple motors for this so I just switched back to DC motors. Cuz they are cheap and relatively easy to control. The best "circles" I had was when I had these setings in my slicer:

seams setuped at random, 3-4 perimeters, avoind crosing perimeters - true, hexagonal reduced infill, z-hop (I used PETG) and I usualy print on higher temperatures. This reduce visual quality but highly increasing the strengh and lifespan of the propeler. (once my propeler exploded and it was not nice, so strengh is more important than look)

4. In your design you needed to make the housing bigger becouse your propeler was scratching the housing. Keep an eye on this cuz the bigger is housing the less airflow u can achive.

With these I was able to make a vacuum cleaner that was stronger than the original one and also more silent.

Fun fact, I build 2 last year and one is workin to this day. The other one died cuz it accidentaly inhaled a cake with a screw when I didnt had filter on it... So it exploded...

EDIT 1: Just to make things clear, am not eating a "screw cake" I was eating a cake next to some screws cuz I was repairing a PC
EDIT 2: I forgot to say that I printed TPU housing with 0.8mm nozzle. Idk why but 0.4mm print was absorbing less noise. 0.8mm is silent for unknown reason
EDIT 3: Propeler was printed in PETG and the feature "avoid crosing perimeters" are just need cuz PETG is stringing as hell so with that setting there are almost no strings
EDIT 4: That silent cleaner was handy for myself cuz I was doing a lot of vacuuming near a 1yo baby that is scared from a loud noise.

[Personnenenparle]

The thing about your impeller is that you ended up reducing the diameter.
If you want to design one with real math, i can give you a few steps that are usually involved.
1. Find the max speed you can turn.
2. Find the cross section of the inlet.
3. Find the cylindrical surface area of your outlet.
4. With speed at the inlet you get volume flow.
5. With pressure at the inlet you get mass flow.
6. With mass flow, area of inlet and outlet and tangential speed of impeller at the inlet and outlet you get the angle of attack of your impeller at both ends.
7. The number of fins will impact static pressure if i remember right.

The maths for all of this isnt really hard, you just need to understand relative speed, conservation of mass and rotational/tangential speed relation.

[DavidMulligan]

Great Scott thank you for another great video! What we learn from failures and suboptimal outcomes are often more important than what we learn from our successes. I really enjoyed watching what you learned from each iteration. I also loved the premise of the project which was essentially "I don't have to do this, I just want to."

[big_o]

imagine being an electronic maker and throwing something away just because it doesn't work
the idea itself is absurd

[iamdarkyoshi]

As others have mentioned, you'll need to work on static pressure. A lot of impellers will put the outside wall of the enclosure onto the impeller itself, that way they don't have to try to get the blades close to the walls for better pressure. I'm curious what you could get away with just replacing the stock motor with a subtable BLDC motor with better speed than the brushed motor.

[LordHonkInc]

Repairing and/or reusing things with 3D printed parts is probably my favorite thing about 3D printing. I've got so many broken things in my house that I've kept going just by printing a few cents' worth of plastic, y'know, like "you thought I was done with you just because your grip broke? bitch I'm gonna make a whole new housing as long as your motor's still spinning" xD

[flounce]

Thanks for all your videos Scott! This is like the best channel on youtube. I am working on something similar and had an impeller get friction welded to the housing haha!

[christophlawrence]

Increase the surface area of the impeller. The airflow of an impeller is defined by the speed (as you pointed out) and its surface area. By increasing the number of fins or by increasing its size overall, you can increase the airflow quite considerably. In my last blower project, I needed a 150% increase in airflow. This was just about manageable without changing the motor by increasing the impeller size by 30%. At that point, the torque of the motor reached its limit. Bear in mind though that higher torque generates more heat. You can temper PLA and ABS (and almost all plastics) in a home oven to greatly increase its tolerance to heat, although it will result in shrinkage. The Formfutura Volcano PLA filament is a good option here, too, as it allows you to temper the parts with minimal shrinkage.

[bentfishbowl]

I love the idea of fighting e-waste, but you replaced the battery and its board, the impeller, the motor and the speed controller. The only thing that's left of the vacuum is the shell. And you made 4 plastic prints along the way.

[jeremyboyce]

Haha! Love the Makita mod. I modded the small vacuum I have in my office at work to take a DeWalt battery last year. Everyone laughs but it works great, the battery charges super quick, and I can swap the batteries quickly. All it took was a cordless impact one of our techs dropped from a tall scissor lift. Now I need to supersize the motor and impeller to take it up another notch.

[CrsHOvrRiD]

As an experienced mechanic/engineer allow me to make a couple suggestions of some things to improve your vacuum cleaner build.

First of all, you have to pay attention to the static pressure (less pressure equals less vacuum power and vice verse)

Static pressure is a measure of the force exerted by a fluid, such as air, against a surface or obstruction. In the context of a vacuum cleaner, static pressure plays a crucial role in determining the machine's ability to pick up dirt and debris effectively.

moving on

When looking to replace the electric motor, impeller, and impeller casing of a vacuum cleaner, there are several factors to consider. Here are some important aspects to keep in mind:
1. Power requirements (It is advisable that voltage and power is in range of the original motor if not changing the impeller/casing.)
2. Motor type and design (Brushless motors are generally more efficient, durable, and have a longer lifespan compared to brushed motors)
3. Impeller specifications (Pay attention to the diameter, thickness, and intake hole of the impeller. Changes in impeller size can affect the static pressure and overall performance of the machine.)
4. Impeller casing compatibility (The impeller casing is designed to house and direct the airflow generated by the impeller. The impeller and casing should fit together properly to ensure efficient airflow and prevent any air leakage. Also make sure that the impeller and the casing are compatible with each other.)
5. Quality and durability (Consider the quality and durability of the replacement components.)
6. Installation considerations (Check if any additional modifications or adjustments are required to fit the new motor, impeller, and impeller casing properly.)

Moving on

Material used to build the impeller and the casing plays a crucial role in generating static pressure as well as better performance etc.
They can be made from various types of plastics, such as ABS (Acrylonitrile Butadiene Styrene) or polypropylene.

Here are some Pros/Cons for plastic and metal impellers and casings:

Advantages of plastic:
- Cost-effective: Plastic components are generally less expensive to produce compared to metal parts.
- Lightweight: Plastic impellers and casings help keep the overall weight of the vacuum cleaner low, making it easier to maneuver.
- Corrosion resistance: Plastic is naturally resistant to corrosion, which can be beneficial in environments where moisture or cleaning solutions are present.
- Design flexibility: Plastic parts can be molded into complex shapes, allowing for optimized airflow and performance.
Disadvantages of plastic:
- Lower strength: Plastic impellers and casings may not be as strong as their metal counterparts, making them more prone to breakage or deformation under high stress or impact.
- Heat resistance: Some plastics may have limitations in terms of their ability to withstand high temperatures. This can be a concern if your vacuum cleaner operates at high temperatures or encounters hot debris.

Advantages of metal:
- Strength and durability: Metal impellers and casings are generally stronger and more resistant to deformation or breakage under high stress or impact.
- Heat resistance: Metal parts can withstand higher temperatures, making them suitable for vacuum cleaners that operate at elevated temperatures or encounter hot debris.
- Enhanced performance: Metal impellers can provide improved performance due to their ability to maintain their shape and generate higher static pressure.
Disadvantages of metal:
- Weight: Metal components are generally heavier than plastic, which can add to the overall weight of the vacuum cleaner.
- Cost: Metal impellers and casings tend to be more expensive to produce compared to plastic parts.
- Corrosion risk: Depending on the specific metal used, there may be a risk of corrosion if the vacuum cleaner is exposed to moisture or corrosive cleaning solutions.

Now, to help you with the design of an impeller and the
- There are several impeller types used in vacuum cleaners, and the efficiency can vary depending on the specific design and application. However, one commonly used impeller type known for its efficiency is the centrifugal or radial impeller.
- Centrifugal impellers consist of curved blades that rotate within a housing. As the impeller spins, it creates a centrifugal force that pushes the air outward, generating suction and creating airflow. These impellers are efficient at generating high static pressure and can effectively move air and debris through the vacuum cleaner's system.
- Another type of impeller used in some high-efficiency vacuum cleaners is the multi-stage or dual-stage impeller. These impellers consist of multiple stages or sets of blades that progressively increase the pressure as air passes through each stage. This design allows for enhanced suction and airflow performance.
- Keep in mind of the shape of the impeller itself and impeller casing, you have to make the design of both in such a way that when operating you can have maximum of the airflow from that turbine. The inside shape plays key role in how will Air flow thru the turbine.
- In your case (with printed impeller and casing) to improve a bit you can consider polishing the surface of both, it will help the air pass thru the casing better (less resistance due to rough surfaces of the printed parts)

It's important to note that the efficiency of a vacuum cleaner relies on various factors beyond just the impeller type, including the motor power, filtration system, airflow design, and overall construction. Manufacturers often develop proprietary designs and technologies to optimize the performance and efficiency of their vacuum cleaners.


Anyway, I am sorry for the long text but it is still not enough to fit it all in the comment. Just to justify my self, I have plenty experience in maintaining turbo compressors, turbines, compressors, high and low pressure compressors or pumps, or any equipment which is directly or indirectly connected to pneumatic and hydraulic systems.

Keep up great channel and content

[martyb]

Great video! Very interesting. For a self professed "not a mechanical engineer" the impeller turned out pretty damned nice. Well done.

[vanceacata]

Excelent video! I would suggest using the old impeller of the vacuum cleaner but mounted on a higher kv bldc. If you could double the rpm, it would be amazing. That should increase both airflow and static pressure. The factory impeller should be stronger and better ballanced than the 3d printed one.

[agnidas]

Real no bs engineering and DIY builds. Thank you ...

[Creamypie]

Trial and error is where great things start. This is already a job well done because you managed to figure everything out and make something out of the things you have lying around.