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TOPIC: Wannabeaflyers Eppg Dream

Wannabeaflyers Eppg Dream 1 year 4 months ago #304

Hi guys mini update , still waiting for my motor temperature sensors to arrive before I can re-assemble my E-one unit, in the mean time I did a mock up fit of the E-one unir to my Paramotor frame and 1st thing I had to do to get correct prop position and keep COG high on my back was to make a mounting interface plate and turn the E-one upside down ..see attached pictures ..

NOTE ignore the rough hacked out wood plate it was done to get a sense of the fixing points and to allow me to centralise the motor/ Prop in the frame . this will be drawn up on CAD and cnc machined at home ....

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Last Edit: by Wannabeaflyer.

Wannabeaflyers Eppg Dream 1 year 4 months ago #323

he's back lol:- ok guys just thought I'd chuck in another progress report ( snails pace but progress ) my NTC thermistor sensors arrived in the week and have mounted tem ( will put 2 in as redundancy measure cos I don't wanna open this puppy again) and used high templacing cord to anchor them in position before I apply some sort of bonding agent... now heres the tting im in two minds as to what I should use ....

if I use hard high temp epoxy, will it be too rigid and damage the fine winding wires , if I use silicon which has a nice cushion effect will it mess with my readings as to get te best the probe needs to be up against the winding and not measuring air as it were..

you guys got any thoughts / experience wit this sort of thing .. been looking on the net but must be asking the wrong question as it were.. loads of bumpf but not the info I think I need ..

Also used the cnc at work to make an adapter plate to allow me to mount my E-one unit to my existing paramotor frame ..kinda glad I did not cut metal yet as the MDF full scale model highlighted an apparent offset ref the Prop to cage clearances so will need to offset some holes , No biggie but a nice option to use before I spend money on material..

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Wannabeaflyers Eppg Dream 1 year 4 months ago #324

Looking good calvin :-)
What is the motortiming sensor wires glued with. It looks like silicone.
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Wannabeaflyers Eppg Dream 1 year 4 months ago #327

Hi Bo, The Hall sensor PCB seems to be bonded metalwork using a hard maybe 2 part epoxy mix in some places and silicon as strain relief or cushion where the PCB is near Coil wires, May have to just ask Bruno AT Alien power systems just in case . Cheers
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Wannabeaflyers Eppg Dream 1 year 4 months ago #369

yes I know boring but hey its more progress , still not reassembled my motor :-( too many things going on LOL anyways I have posted some picture of what I call my electronics module which is one piece add on which contains ESC , MCB,, Master switch , Ubec Servo throttle interface ...

Freesh Off the CNC today at lunch tine so really pleased with this :-)

Also posted my provisional Connection diagram and please its open for comments . so feel free to comment away LOL
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Wannabeaflyers Eppg Dream 1 year 4 months ago #377

Special thank you for the inclusion of a circuit diagram. So clear and soooooo useful for us newbies to compare our own plans to.
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Wannabeaflyers Eppg Dream 1 year 4 months ago #394

Ok guys not to bore you but just fitted my 3d Printed modified Servo tester housing .Ohhh am I loving this 3d Printer or what LOL. Tried to take the Pick with my GoPro but too close as they are not made for close ups ( will post clearer picture soon ,

This Housing is the last element of the What I call power module ..Which includes ESC,UBEC,FUSE,MASTER SWITCH,& servo tester all mounted on removable plate .. idea being all wiring contained in one smallish space ..

enjoy and feel free to comment if ya'll like always room for improvement ..still not happy with routing of the wires, but I have a cunning plan :-)
Attachments:

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Wannabeaflyers Eppg Dream 1 year 3 months ago #427

Hi Guys . small steps as they say , Motor now re-assembled and fitted to my E-one Kit , Minor mod required ref Spacers But Bo already advised me that would be the case , No big deal, and so im happy to say all the elements other than the battery pack and new E-Prop are nearly done ... Also managed to convert my Scalextrix controller to act as new throttle so will post picture of that in the other section ..

OK still have some small bits to be made before First real power up test , but the mocked up assembly seems to be on the money and the dry weight of the whole E-one unit and Frame excluding the Battery Pack is so far 17KG...... ( This may need to be looked at further down the road)

see Attached Pictures ,, and as always guys feel free to comment if something does not seem right ofr could be done differently . Cheers

Note the Plywood E-one mount will be changed for 5mm Aluminium once that material is Bought and machined .. the current setup is to allow me to do a quick mock up to check fits and layout check. :-) also the Motor / ESC connection Block will be machined tomorrow the one seen in the photo was a quick and dirty lash up to check the possibility of using a dedicated part for the motor/esc connection as im not currently using Soldered Terminals ..

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Wannabeaflyers Eppg Dream 1 year 3 months ago #428

What batteries are you going to use?
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Wannabeaflyers Eppg Dream 1 year 3 months ago #432

Hi Paul
based on this motor im going to need 66.6 V to get the optimum performance .. this motor is 85KV so to get the Correct Prop Revs im goon need to add to my current batteries ( I have a mix at the moment 2 off 22.2 V @10 AmpsHrs and a couple of 22.2V @5amp Hrs ) the best configuration I'm going to get out of this selection will be 44.4V @ 15Amp hrs I think .... so this will be for spin up testing ..

I will need to spend some more money to get up to an 18S2P pack to get me 66.6V @ circa 20Amps...that's the plan anyways Cheers
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Wannabeaflyers Eppg Dream 1 year 3 months ago #464

Hi Guys , final wiring and test battery connected today so was hoping to give you some news to say she's spinning up and i'll soone be doing some Ground running tests. That would have been the plan .. one small hurdle ...er Motor not spinning Boo Hooo .. wiring seemed to check out OK no blue smoke (Phew ) and all lights and voltages are where the should be ... im using a servo tester direct to the ESC as a test before I connect my Modified Scalextrix Controller ..

ok power good , Ubec , Supply good , Servo tester proven to work on another test setup ,11.1 2.2AmH Lipo for test used OK , Throttle set to max .. Master Circuit breaker on .. lights on , No Beeps But Clicking sound coming from ESC I Guess ...Massive Hearing problem so its hard for me to localise sound ) anyways it appears im doing the throttle calibration wrong ..so shout out to Bo and the crew can give me any tips on how you calibrated your throttles ... I have never powered this ESC up so Hoping I have not Frigged it .. I sthe principle the same on most ESC ?? The method works on my smaller test motor/ esc setup every time so I think the servo tester and Scalextric controller are OK .. any assist will be greatly appreciated guys ,, I have e-mailed Bruno at Alien Power systems but thought I'd ask here as well :-)

Oh Oh forgot to add C12090 Motor spins up fine on another Brushless motor controller at work so ticked that off the possible fault list

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Last Edit: by Wannabeaflyer.

Wannabeaflyers Eppg Dream 1 year 3 months ago #465

It's an Alien ESC, right? Have you checked the ESC's programming with the included USB connector and application and have you tried to power up without doing calibration (throttle at zero and wait for the ESC beep). I have not calibrated my ESC with the throttle at all. Only done the programming with the program. The program automatically checks for firmware update as well.

BTW: Remember to use only a small amount of motor brake (10-15%) so you don't burn the ESC ;-)
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