November 06
BMFA club affiliation No 0340
FLY SAFE – Fly Again
Next gathering at St Andrews Rugby Club November 6th - Monday
And the next December 4th No meeting Jan 07
I do hope you have all paid your subs to Mike by now, if not please do so we are still the cheapest in the area, with well cut grass.
FLY Safe, fly again and enjoy – make the most of the weather while it lasts!
The clocks are about to do their hour trick so the autumn/winter is upon us. Don’t be too disheartened we still do get good flying days even if they are short.
For this issue I must give a huge thanks to Wayne Giles for the electric words of wisdom below. It is the forerunner to the next issue where I will be giving some thought to Noise.
ELECTRIC FLIGHT CONVERSIONS
By Wayne Giles October 2006
Until about two years ago, I had been a lifelong builder of glow powered models and had always considered electric power as a very poor alternative, such models being desperately under powered or flying house bricks. As most of my models are sports aerobatic, (Acrowot or similar) I never got round to trying to convert to electric flight. The fact that I was a retired electronic engineer, always made me feel somewhat guilty about it, so I bought an IFO to fly round my garden which was fun but struggled for performance with a 7 cell NiCad setup feeding a standard 280 brushed motor.
Replacing the 280 motor with a 280BB improved the situation and changing the supplied Sanyo 600AE cells for Sanyo 500AR ones made the IFO a reasonable performer and demonstrated two principles of electric flight performance; firstly use an adequate motor to start with and secondly make sure you use the batteries which are capable of delivering the current you need to produce the required performance.
This success encouraged me onto other more ‘normal’ electric models and to look at converting IC models to electric power. During this period, brushless motors appeared on the scene followed very shortly by Lithium polymer batteries, the combination of which has transformed electric flight from an underpowered poor relation to a very realistic alternative to IC powered models. We all know about the advantages of no noise, no oily ‘goo’ and guaranteed starting (and in-flight restarting) that electric power has over IC power, but many modellers need convincing that the power/weight ratio of electric models can challenge that of IC models. The answer to that is: “Yes – now it can”
Although I am a convert, it does not mean to say that I believe electric models are better in all respects; IC models still have that indefinable something, be it the smell of a diesel, or just the mechanical noise and slight unpredictability of a glow or diesel engine. As an engineer, I can still see the attraction of a purely mechanical power plant and how the total reliability of an electric motor set up can be less attractive. Never mind – we now have the danger of lithium batteries catching fire and motors starting unexpectedly to make up for the loss of unreliable starting and carburetion and fuel feed problems!
I believe that many modellers are put off electric models because they feel that they “Just don’t know where to start”. It is a basic fact that you do need to have some understanding of electricity basics to be able to specify motors and batteries. There is an alternative of asking a knowledgeable dealer, about what to buy, but you need to be sure that he is knowledgeable and reasonably honest – after all you are asking him what he should sell to you!
If you want to work it out yourself, you can do so with only a little basic knowledge and some trial and error. The basic knowledge needed of electricity is very simple; so don’t be put off by electrical terms.
Voltage, measured in volts. Think of it as electrical pressure, like the pressure in water measured in feet of head.
Current, measured in amps. Using the water analogy it is the equivalent of water flow, in litres/minute (or gallons/minute if you are as old as me)
If you have a battery, (tank of water) feeding a motor (waterwheel) then the power of the motor depends on the voltage (water head) and the current (rate of water flow). The power is equal to the volts x amps = watts (water head in feet x water flow in gallons/minute). One horsepower is 33,000 ft.lbs per minute, which could be a flow of 330 gallons per minute from a head of 10 ft. as 1 gallon of water weighs 10lb. The direct electrical equivalent is 746 watts, which could be 100amps at 7.46V.
If you have followed that it should all now be clear - if not, don’t despair, you can still work out what power system you need for an aircraft, using fairly simple rules. Remember that the voltage is a function of the battery and the current depends on the voltage applied and the motor load it is feeding, which in turn depends on the load (ie propeller) on the motor.
A very good basic rule of thumb in deciding how much power you need is to take the total weight of the model (in pounds) and multiply it by 50watts for a trainer type model or by 100watts for an aerobatic model. You can now start to look for a suitable motor/battery combination to deliver the required power. A very simple shortcut is to look up the performance details of motors on the Internet. Forward-looking manufacturers publish such data, which is a great help and cuts out a lot of blind experimentation. Good published data will suggest propellers, batteries and motors to produce specified powers.
MOTORS
The options are brushed or brushless, (the latter split into inrunners and outrunners) geared or direct drive. The only advantage of brushed motors is cost; they are less efficient, heavier for a given power and fairly short lived, as they tend to be hard pushed in model applications. I would therefore advise the use of brushless motors and to avoid the complication and cost of a gearbox, the extra torque of an outrunner motor is a good choice. Geared brushless motors are generally only used in specialist competition models.
BATTERIES
A few years ago, NiCad’s were the only option, but NiMh packs increased the available power/weight ratio by over 50%. Now lithium polymer packs have doubled the NiMh figures. Coupling this with the capability of brushless outrunners to deliver efficiencies of over 80% and you can now see why electric flight has been transformed.
I have carried out comparison battery testing of the best NiMh cells and the latest lithium polymer 20C rated packs, which demonstrate and confirm the above figures. Combining these results with the specification of the latest outrunner motors show that the combination shows a power/weight ratio of 1.7Hp/Kg, which competes easily with IC power. Electrical systems have the advantage that they can swing large propellers slowly, which is much more efficient than a high revving small propeller.
An IC engine may be able to produce a higher power/weight ratio but it is not possible to use the power without a gearbox.
ELECTRIC CONVERSION EXAMPLE
To demonstrate how to work out the motor/prop/battery combination for a typical aircraft I will go through the calculations for a conversion I am carrying out at present. This is to convert a Glens Models 58” span Extra 330 from its intended power plant of a 46 2-Stroke to an electric outrunner motor.
We can go through a logical sequence: -
(1) Looking at the model specifications, we can see that the quoted weight with a 46 IC 2 Stroke is 5.375lb; equal to 2.440Kg. We must initially assume that we shall finish up with an aircraft of the same weight. This means that we need to aim at an input power of 5.375 x 100W = 537Watts
(2) The average weight of a 46 motor with silencer is 500g and we should also allow for a half full 8oz tank of fuel at 100g. This means that we have saved about 600g by removing these, leaving an airframe weight of 1.84Kg
(3) We now need to find a motor/ESC/Battery combination that will ideally meet the power and weight requirements. Looking on the Model Motors website, we can see that the AXI 4120-14 outrunner can cope with about 350watts to 700watts, depending on battery and propeller fitted. The various combinations of batteries and props. show that 14 x 1700mAh NiCad cells and a 13 x 8 prop. produce figures of 14.6V, 37.9A and 551 watts input. We can use this as a starting point and look for an equivalent lithium battery.
(4) I would suggest that only the latest 20C lithium packs be used (more on that later) and we are looking for a pack that will deliver 38A at a voltage of about 14.6V. If we now look on the Flightpower website and look at the specifications for the 3300mAh and 3700mAh packs, then you can see that a 4-cell 3700mAh pack will maintain 13.8V at 37A which is 10C for the 3700mAh cells. This is a bit less than our target, but is ok to start with; we can always increase the power by loading the motor with a slightly larger propeller, so that it takes a bit more current.
(5) If we now add the weight of the motor+ESC+Battery to the airframe weight, we have 1.84Kg+0.32Kg+0.038Kg+0.38Kg. This gives a new total weight of 2.578Kg, or 5.68lb. Ideally we need 568Watts and the setup will probably give around 480 – 520Watts, but it is a good starting point.
(6) When the system is up and running measure the power with a ‘Wattmeter’, ‘Medusa’ or similar device. (Cost £30 - £45). If the power is too low, use a slightly larger prop. – A small change can make a big difference to current and power.
(7) Checking likely duration; we are discharging the battery at about 37A equivalent to 10C for a 3700mAh battery so that the pack should last approximately 0.1hrs, or 6 minutes at full throttle. Assuming we fly at an average throttle opening of 2/3 throttle we can expect a flight time of about 9 minutes. At my age I find my concentration is failing well before this time! (I find that very hard to believe, editor)
The above system can be used for working out the power setup for any aircraft. The steps are the same; estimate the overall weight, work out the required power, find a suitable motor/ESC/battery/prop combination, recheck the weight and power requirements with this actual power pack, go round the loop again if you are way out and then go and fly it. You should be able to make minor adjustments with prop changes and larger adjustments by adding or subtracting a cell on the battery pack.
BATTERY CHOICE
The suggested cells on the Model Motors website are SubC NiCad’s and only 1700mAh. Even using the latest and best 3700mAh NiMh cells, the pack would weigh about 900g instead of 380g for a lithium pack. Lithium saves well over a pound in weight – more than 20% of the aircraft weight! A quick calculation shows that if we went the NiCad way we would need to add two more cells and finish up with a model 25% heavier and needing over 700Watts.
The above is the advantage of the latest lithium cells, the downside is cost and, as we all know by now, the potential danger if mishandled.
Costs are coming down and will continue to do so because of demand, but we will have to continue to be careful with lithium batteries and not abuse them. We have been spoiled over the years, as both NiCad’s and NiMh cells will withstand horrendous abuse without complaint. If you wish to go half way, you might consider lithium ion cells which are available in metal cases and are unlikely to ignite. These are about midway between NiMh and lithium polymer in terms of power/weight ratio, and will probably be available cheaply in the near future. They are being developed for use in portable power tools so large quantity production is likely with resultant low prices.
Assuming you are using lithium polymer, you will no doubt be aware of the special charger necessary and the dangers of charging in cars etc.
There is another characteristic of lithium batteries which is not so widely known and which is not advertised by suppliers and that is their life dependence on discharge rate. If you cane them by taking too much current, their working life is dramatically shortened in terms of charge/discharge cycles before they lose capacity. It is for this reason that I would suggest the use of 20C rated cells and only operate them at 10C rates.
Keep your eye on Bob Smith’s “Technology” column in Quiet and Electric Flight magazine; he is intending to test this aspect of lithium batteries and quantify the problem, so that the best battery brands will be clear. At present some suppliers make 15C and 20C claims for lithium packs that cannot cope with these discharge rates. Operating such packs at high discharge rates results in a working life of literally only a few tens of cycles.
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