Wind Cannon 2: High-Powered PWM Fan System for Wind Simulator

The Wind Cannon 2 is an engineered 3D printable fan system configured to hold two (2) pulse width modulation (PWM) fans (120mm) in an inline configuration.  PWM fan output can be linked to PC simulation/game telemetry via an Arduino + SimHub to create what is commonly referred to as a “wind sim." This publication is intended to provide a 3D printable PWM fan housing and blueprints to create a high-powered fan kit suitable for intense wind simulation (e.g., in connection with racing sims, flight sims, etc.) or as a ridiculous desk fan that will keep you very cool with a high-velocity airstream.  Development of this design was based on the original Wind Cannon. 

IMPROVEMENTS OVER PREVIOUS DESIGN: 

• Increased air velocity by ~ 50% (measured at over 40 MPH);
• Decreased system weight and envelope;
• Smaller pieces which can fit on a standard Ender 3 or equivalent;
• Drastically simplified assembly process and reduced time to assemble;
• Standardized and less variety of hardware; and
• LED strip accommodation within the housing (optional).
• Custom electrical and wiring blueprints for high-powered Arduino/SimHub based wind sim setup (by KNIXT Design LLC: https://www.etsy.com/shop/KNIXTDesign) 

ORIGINAL WIND CANNON [FREE]:

https://www.printables.com/model/983736-wind-cannon-pwm-fan-housing-for-wind-simulator 

PROTOTYPE TEST OF WC2:

DISCLAIMER - THIS IS AN EXPERIMENTAL, HIGH-PRESSURE AND HIGH-VELOCITY DEVICE.  BUILD AND USE AT YOUR OWN RISK.  HEED ALL SAFETY PRECAUTIONS BELOW OR INJURY MAY OCCUR.

PRINTER REQUIREMENT: 

FDM printer able to accommodate pieces roughly 213mmx213mmx240mm in size is required. See sheets 3-8 of the drawing.  Ender 3 S1 Plus was used to print the prototype. 

FEATURES:

• Efficient, thin-walled housing sized to hold two 120mm PWM fans inline. Compatible with various PWM fans that can fit in housing (see sheet 2, section A-A of drawing for fan clearances).
• Each piece is no-support designed. Prototype was successfully printed without supports.
• 21 printed pieces total, using about 1.4 KG of filament.
• Each piece is sized to fit on an Ender 3 or equivalent.
• Walls were designed with 0.4mm nozzles in mind (wall thicknesses are multiples of 0.4)
• VESA (100x100 and 75x75) or desk mountable.

SYSTEM SPECS (if using the validated PWM fans in the drawing - linked below):

• Total weight (when assembled):……………………… ~ 2.0 KG [4.4 LBM]
• Max. measured nozzle outlet velocity:…………….. ~ 36.56 KNOTS [42.07 MPH] @ 300 CFM
• Ramp-up time (from 0%-100%):……………………… ~ 4 SECONDS
• Max. operating noise:………………………………………. ~ 86 dBA @ 2 FT.
• Max. electrical power draw:……………………………... ~ 76 WATTS 

DEVELOPMENT: 

This design is still being developed to increase max airspeed and dampen noise (e.g., via different nozzle geometries, housing features, etc.).  Future part releases will be available to those who purchase files published here.  Thank you for your support!

RECOMMENDED SLICER/PRINT SETTINGS: 

See drawing sheets 3-8.

ASSEMBLY:

See sheet 1 of the drawing.  In general:

1. Attach fans (9) to chassis (1) - and the intake safety grille (2) to the rear fan - using corresponding hardware (10), (11), and (12) and chassis standoffs (6).  Ensure your fans are facing the correct orientation to direct air towards the nozzle.  
2. Next, press-fit the front and back housing shells (3) and (4) around the fan/chassis assembly and secure the shell flanges using the corresponding hardware (10), (12), and (13) and housing standoffs (7).  
3. Next, attach the VESA-compatible bracket (8) to the middle housing flange using the corresponding hardware (10), (12), and (13).  
4. Finally, attach the nozzle (5) to the end housing flange and VESA bracket legs using the corresponding hardware (10), (12), and (13). 

VALIDATED FAN: 

Bluegears Bgears b-BlasterPWM 120x38 2Ball PWM High Speed Fan: httpss://amzn.to/4d2lRiR

VARIABLE CONTROLLERS USED IN VIDEO:

https://amzn.to/3WRNu8W 

CUSTOM WIND SIM ELECTRONICS AND WIRING:

See attached drawing of KNXTWND22A00, provided by KNIXT Design LLC (https://www.etsy.com/shop/KNIXTDesign).   

Validated electronics referenced in drawing: 

(1) Arduino Uno REV3: https://amzn.to/410wxdR 

(2) 12V 10A 120W Universal Regulated Switching Power Supply: https://amzn.to/41esonT 

(3) HiLetgo 2pcs DC 12V 2 Channel Relay Module: https://amzn.to/4b7N2cD  

SAFETY PRECAUTIONS (PLEASE READ ALL POINTS BELOW PRIOR TO USE):

• DO NOT AIM DEVICE DIRECTLY AT FACE WITHOUT EYE PROTECTION.
• DO NOT PLACE ANY OBJECT(S) DIRECTLY IN, NEAR, OR AROUND FAN INLET.
• POTENTIAL SHRAPNEL HAZARD IF OBJECT(S) CONTACT OR ENTER FAN INLET.
• POTENTIAL PROJECTILE HAZARD FROM DIVERTER CONE IF MISPRINTED OR DAMAGED DURING ASSEMBLY. CAREFULLY INSPECT PRINTED PART(S) AND HANDLE WITH CARE.
• DO NOT TOUCH OR ATTEMPT TO TOUCH FAN BLADE(S) WHEN IN OPERATION.
• KEEP OUT OF REACH OF CHILDREN AND ANIMALS.
• EACH 120MM FAN REACHES ANGULAR SPEEDS UPWARDS OF 6,500+ RPM AND WILL LACERATE.
• IT IS RECOMMENDED TO MOUNT THE DEVICE AT AN ELEVATED POSITION, AIMED AT USER'S CHEST OR SHOULDER (E.G., USING A TALL VESA POLE MOUNT).
• USE AT YOUR OWN RISK

PN: PR3DWND22A00

VERSION: 0

PN: KNXTWND22A00

VERSION:0