Spring 2016 Additional Fan Bracket Design

Posted by: Luis Valdivia (Project Manager)
Written by: Juan Mendez (Manufacturing Engineer)

Table of Contents:
Introduction
Design
Conclusion

Introduction:
Since weight became an issue with our vehicle, we had to think of an alternative solution to fix the yaw problem. Our alternative solution was to add an additional brushless fan to counter the yaw problem. In order to add on another fan we needed to find a way to mount it on to the current frame. We thought of drilling new holes on to the frame to add on to the bracket, but instead of making new holes, we decided to use the ones that were already on the frame. In order to put the fan between two of the ducted fans, I had to use the holes that were between two of the current metal brackets. I modeled the bracket to be 1.67 by .31 inches as shown in Figure 1 so that they can fit perfectly between two ducted fans.

Figure 1 Demonstrating dimensions of 5th fanbracket

Design:

I wanted to make sure that the bracket would enclose the bracket provided by the brushless fan so I made the bracket extend approximately 1.25 inches as shown in Figure 1.
After measuring the bracket that came with with brushless fan, we saw that it was 3.4 by 3.4 mm thick. This is equivalent to .13 inches. In order to make sure that the brushless fan bracket could fit into mine, I made the inner cut of .14 by .14 inches so it can slip in smoothly as shown in Figure 2A. In order to make sure that the 3D printer could print the part without having it warp, I had to make the outer dimensions be .33 by .34 inches thick as shown in Figure 2B. This allowed the part to be printed without any trouble.

Figure 2A and Figure 2B Demonstrating dimensions of bracket design

Conclusion:

The result were the parts fabricated shown below in Figure 3 A & B. The brackets were able to mount on smoothly into the brushless fans with no problem. They were then easily mounted on between the ducted fans on the vehicle as seen in Figure 4. Additional brackets were fabricated incase we needed to add a 6th fan to fix the yaw problem.

Figure 3A and Figure 3B alternate angles of 3D printed brackets

Figure 4 5th fan attached to 3D printed bracket