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TOPIC: WingIt Electric Paramotor

WingIt Electric Paramotor 6 months 3 weeks ago #111

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The first thing to get out of the way is the name. WingIt is the name of the business that I started to manufacture RC gliders. It kind of got attached to this project during the construction of the motor and it stuck.
The project started with the design and construction of the motor. I don't have to detail that process for you as it is covered in wonderful detail in a thread on RC Groups.
You can find it here
www.rcgroups.com/forums/showthread.php?2...r-Test-Results-added
The RCG thread has lots of calculations, pictures, performance data and even a couple of videos.
I would encourage you to have a look at it.
I need to take a couple more pictures tomorrow for the start of this thread which will be long with lots of interesting home made stuff.

Graham

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Last Edit: by Graham.

WingIt Electric Paramotor 6 months 2 weeks ago #112

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These pics will give you a good idea of how the project has turned out
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WingIt Electric Paramotor 6 months 2 weeks ago #113

Hi Graham.
Welcome to our community. It's really great that you've shared your project. I have to say, I am very impressed that you have built your own engine. Was it only a one-time barley, or do you plan to build more than this one.

Regards Bo

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CEO - G-Air
www.g-air.eu/

WingIt Electric Paramotor 6 months 2 weeks ago #114

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Hi Bo
If you have read the RCG thread, you may have gathered that we were lucky to get it right the first time. The performance of the motor has exceeded my initial expectations. However, during the building process, I became aware of ways in which the design could be improved. So if I were to do it again, (build more motors) I would want to make some design changes. They are just mechanical changes to make things fit together better and lower the cost of machining. However it is quite expensive to make the motor so I could only do it (make more) if I was going to sell them. I would need to sell them at about $1000 each to make it worthwhile, so if there is a market for a motor at that price than I would certainly consider making them available

Graham

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WingIt Electric Paramotor 6 months 2 weeks ago #115

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Moving on to the prop. This was also made by me and has gone through three iterations. The initial design was done using Martin Heperle's JavaProp software to get the basic parameters right. The configuration was then imported into Rhino CAD and a 3D model was constructed and used to cut the prop on my CNC. The first prop had some manufacturing problems. The second one was made from some very light meranti wood and broke when it sucked up a plastic bag during testing. (the bad was not empty). The third prop was cut from a nice hard wood called ash and is the one you see in the pictures of the complete system. The current prop is 1.2m diameter and 603mm pitch. I may make another prop if testing indicates that we need to change any parameters.

Graham

PS - weather still pretty crappy - not suitable for test flight
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Last Edit: by Graham.

WingIt Electric Paramotor 6 months 2 weeks ago #118

Hi Graham , saw you youtube vid's ages ago so I have to say its great that you have some more technical data here on this forum, actually just printed off the whole thread form the link you posted and have to say even at 1st glance there is some great info in there.

I had the idea of trying to Mod a Fischer Paykel motor to suit but that's clever stuff LOL ( thought id use there stator and rewind it & make new rotor as the magnet used are very weak ) so I have some Motor design tech guys at work looking at it for me and they will run some Simulation models and see if its a rubbish idea or has some merit ....always the dreamer and looking for the robust coast effective option :-)

Just wanted to Welcome you to the forum, its early days but step by step Bo is getting there .. the more members the better ..

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WingIt Electric Paramotor 5 months 4 weeks ago #189

Brilliant work! Pretty much exactly what I'd like to do. Where did you get the steel for the stator laminations? Is there anywhere that sells it in reasonably small quantities, or did you have to find a local manufacturer and cut a deal with them? And what's the basic process for making the bell? Cast in one piece out of aluminum?

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WingIt Electric Paramotor 5 months 4 weeks ago #190

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dekutree64 wrote: Brilliant work! Pretty much exactly what I'd like to do. Where did you get the steel for the stator laminations? Is there anywhere that sells it in reasonably small quantities, or did you have to find a local manufacturer and cut a deal with them? And what's the basic process for making the bell? Cast in one piece out of aluminum?


The motor was completely designed in CAD before we began building it. The stator laminations were laser cut by a transformer manufacturer who happened to have some stock of 0.35mm steel in the correct grade. I don't know where you would get it, but the best source would be a transformer manufacturer local to you.
The bell was CNC cut from a solid piece of aircraft grade aluminium. It was a very wasteful process and is one of the processes i would change if I were to make more of these motors.

I have added a few pictures taken during the build process

Graham
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Last Edit: by Graham.

WingIt Electric Paramotor 5 months 4 weeks ago #191

Here's an interesting idea... how about 3D printing the bell, and using that to make a mould to cast it out of aluminum?

Too bad about the steel. I don't know of any transformer manufacturers around here, but I'll do some searching. I wonder why nobody has capitalized on the hungry market for this stuff yet? All we need is one bloke with a roll in his garage to cut off reasonable sized pieces and mail them out. I'd do it myself if I had a place to put it.

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WingIt Electric Paramotor 5 months 4 weeks ago #192

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dekutree64 wrote: Here's an interesting idea... how about 3D printing the bell, and using that to make a mould to cast it out of aluminum?

Too bad about the steel. I don't know of any transformer manufacturers around here, but I'll do some searching. I wonder why nobody has capitalized on the hungry market for this stuff yet? All we need is one bloke with a roll in his garage to cut off reasonable sized pieces and mail them out. I'd do it myself if I had a place to put it.


I am very familiar with making moulds for composite products but have no tools or experience with casting aluminium. I do not consider it worth the time and expense to set up for it.
The stator laminations cost me about $220 for materials and cutting. The steel needs to be very flat. My laminations were extremely flat as delivered. Also, they have to be laser cut (or punched for larger volumes). The average home based laser cutter will not have the power to do this properly.
I am not an expert on the grades of steel, but apparently the steel used for motors is different to that used for transformers - probably because the range of frequencies used are different.
My stator guy is a transformer manufacturer and happened to have some of the correct grade for motors.

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WingIt Electric Paramotor 5 months 4 weeks ago #197

Hi Graham,

very nice work. I wish we had the tools and experience to do the same here in Australia.

I read the rc thread and wondered about your thrust results. From my experience, 50 kg is desirable for no wind takeoffs. have you tried a larger prop, which seems like it could work according the the past threads. The eprop 125 is a very powerful prop and gives more thrust that the Helix 130, but is much harder on the motor for torque.

wondering also if hall sensors be useful?

I like the overall look too.. have you figured out a price for the entire frame? best, Peter

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Last Edit: by ozeflightclub.

WingIt Electric Paramotor 5 months 4 weeks ago #198

Hi again,

I was talking with another flier who has also tinkered with motor design and thinks with big motors, every winding probably needs to be individually controlled.

Stacking bits of the motor in series/parallel, then stacking electronics also in parallel, just makes everything harder and less efficient.

He also thinks that because the motor is where the movement happens, and where the electricity is used - the FETs should be right in there with it all, where they get max efficiency and cooling all at once.

Interested in anyone's thoughts on this..

best, Peter

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