Demystifying

Electric Flight

Our Best effort to Get you

More confused

(c) Bill Hauth, Dave Borkowski 2-26-09

Agenda
Part 1
Motors
Construction
Structure (inrunner, outrunner, brushed, brushless)
Key Specs.
- Stator thickness & diameter (what 2208-16 means)
- Number of turns & Kv
- RPM approximation from Kv
- Max Power
- Max Current

Controllers
Key Specs.
- Max Continuous Current
- Operating Voltage Range
- Max BEC Output

Batteries (LiPos)
Series Parallel configuration (what 3s 1p means)
C rating
Balancing
Connectors (Deans, Power Pole etc.)
Soldering
Wire gage
Charging (CVCC)
Chargers
Storing

(c) Bill Hauth, Dave Borkowski 2-26-09

Agenda
Part 2

Power
- Basic Definition
- Performance and power requirements

Propeller
- Pitch Speed & Thrust requirements

Efficiency
- How the losses factor in

System Examples
- Selecting a system for a 42 oz 3D plane (Dave B’s
latest)
- Converting a 40 U-CAN-DO to electric (Billy’s project)

Software Tools
- Dave B’s “rule of thumb” quick and dirty spreadsheet
- Scorpion Calc
- MotorCalc
- DriveCalc
- ThrustHP

(c) Bill Hauth, Dave Borkowski 2-26-09

Electric Power System

1. Motors
2. Esc (Motor Control)
3. Batteries
4. BEC
5. E-Props

(c) Bill Hauth, Dave Borkowski 2-26-09

 Motor Selection
Why’s it so Confusing ??

(c) Bill Hauth, Dave Borkowski 2-26-09

 Motor Selection
Why’s it so Confusing ??

All these Numbers

Park 400
22-08-12
Power 60
In Runner Out Runner
3-6 cells
KV 520 1500 Watts (c) Bill Hauth, Dave Borkowski 2-26-09
 Motor Selection
Why it’s so Confusing ??

1. It’s new to most modelers

2. There’s No Standard Motor Designation

3. Motor Selection is Made with Glow

Model
Information Ex. 40 size 60 size ect.

4. 100’s to choose from

(c) Bill Hauth, Dave Borkowski 2-26-09

High Rpm “KV”

Gear Box Needed

For most Applications
Astro-Flight’s
Early Brushed Motor

(c) Bill Hauth, Dave Borkowski 2-26-09

Lower RPM
More Torque
Big Diameter Prop
Direct Drive
Most Popular
Easy to
Manufacture

(c) Bill Hauth, Dave Borkowski 2-26-09

(c) Bill Hauth, Dave Borkowski 2-26-09
Parts Breakdown of an Out Runner Motor

(c) Bill Hauth, Dave Borkowski 2-26-09

 Just Like Our Glow Engines
Electric Motors Come in All Sizes
Small Glow Small Electric

(c) Bill Hauth, Dave Borkowski 2-26-09

 These are Comparable in
Power
Large Glow 4.1 hp Large Electric 4.8 hp

(c) Bill Hauth, Dave Borkowski 2-26-09

4010 is the motors internal
size.
40mm is the Stators Diameter
10mm is the Stators Length

12 is the turn count. The

number of wraps of magnet
wire on one leg of the stator

(c) Bill Hauth, Dave Borkowski 2-26-09

 350 in this case is the Motors KV ratting (RPM PER VOLT)
Higher the turn count = less rpm-more torque- big prop –low KV-more thrust
Lower the turn count = higher rpm- less torque- small prop- high KV-more
airspeed
Motor Wattage Stays the Same (c) Bill Hauth, Dave Borkowski 2-26-09
 4020-10 630kv 1500 Watts
4020-12 542kv 1500 Watts
4020-14 484kv 1500 Watts
4020-16 415kv 1500 Watts
Converting from Star to Delta hookup, the RPM/Volt value is multiplied by
1,73.
From Delta to Star hookup, multiply the RMP/Volt value by 0,578.

(c) Bill Hauth, Dave Borkowski 2-26-09

E-Flight Lists There Motor Size’s to there Glow
Equal
Power 60 – Power 46

(c) Bill Hauth, Dave Borkowski 2-26-09

Others to this can motor- Speed 400

(c) Bill Hauth, Dave Borkowski 2-26-09

To Achieve Powered Flight we need to supply Thrust to
over come Drag and to create Lift to over come Weigh

Model Size is Designated By it’s Engine Size “.60 size”

When We Talk Electrics It’s in Watts “800 Watt size”

~ 50 - 75 W per lb for trainer to sport

performance
~ 80 - 125 W per lb for aerobatic performance
~ 150 - 175 W per lb for high performance 3D
 Great Planes Venus II 60-90 2 stroke
Wingspan: 66“ Wing Area: 866 sq in Weight: 8.5-
9.5lb

9.5 lbs. X 125 = 1188 Watts

Look for at least a 1200 Watt Motor
(c) Bill Hauth, Dave Borkowski 2-26-09
These are Motors for the Venus
• OS 91 FX Scorpion 4020-12

2.8 BHP at 15,000 RPM

14x6 10,900
14x8 9,500 Max Continuous Power1500 Watts
14x10 8,400

(c) Bill Hauth, Dave Borkowski 2-26-09

Why This Motor ? Test 1
Specifications

Stator Diameter ............................ 40.0 mm (1.575 in)

Stator Thickness ........................... 20.0 mm (0.787 in)
No. of Stator Arms ................................................ 12
No. of Magnet Poles ............................................... 14
Motor Wind ........................................... 12 Turn Delta
Motor Wire ...................... 22-Strand 0.25mm (30 AWG)
Motor Kv ............................................. 542 RPM / Volt
No-Load Current (Io) @ 21 v ...................... 1.92 Amps
Motor Resistance (Rm) ............................. 0.020 Ohms
Max Continuous Current ............................... 85 Amps
Max Continuous Power ............................... 1500 Watts
Weight ....................................... 304 Grams (10.72oz)
Outside Diameter .......................... 48.7 mm (1.917 in)
Shaft Diameter ............................... 6.0 mm (0.236 in)
Body Length .................................. 41.2 mm (1.622 in)
Overall Shaft Length ....................... 96.0 mm (3.779 in)

1.Input Data from the O.S. Engine

2.Read Horse Power 1.882 Hp
3.1 Hp = 746 Watts
4.Multiply 746 x 1.882 =1404 Watts
5.Look for a Motor that’s close to the
wattage 1500 Watts
(c) Bill
6.Read Static Hauth, Dave
Thrust Borkowski
10.4 lbs. 2-26-09
Test 2 Software

(c) Bill Hauth, Dave Borkowski 2-26-09

ESC (Electronic Speed Control)

BEC 10A Receiver Battery Eliminator

(c) Bill Hauth, Dave Borkowski 2-26-09
ESC (Electronic Speed Control)

Key Specs

• Brushed (2 wire) vs Brushless (3 wire) …. Forget

brushed!

• Voltage: 4s usually dividing line Low vs High

• Current: 1.2x - 1.5x good safety margin ex: 50A max so

1.2 x 50 = 60A controller. If the controller gets too hot to
touch get a bigger one!

(c) Bill Hauth, Dave Borkowski 2-26-09

 BEC Battery Eliminator Circuit

• The battery eliminator circuit (BEC)

eliminates the need for a separate
receiver battery. Instead the receiver
(and servos) are powered from the
same battery that powers the motor. It
regulates to voltage to 5v or 6v

• If we get beyond 4s often you won’t

find a BEC on the ESC. Why you ask?
It’s because of the heat generated to
drop the voltage from 18v (5s) to 5v

• So we employ a stand alone BEC

• Can be powered from the motor

battery or another LiPo pack (2s 1000) Hi Voltage 42v in
Low Voltage 12.6

(c) Bill Hauth, Dave Borkowski 2-26-09

 LiPo Batteries
C rating Why is this confusing
Balancing No lipos gone wild
Connectors Deans, Power Pole etc.
Soldering Learn how
Wire gage Do it right no skimping
Charging Use the right one, CVCC
Chargers Lots to choose from
Storing Care and feeding

(c) Bill Hauth, Dave Borkowski 2-26-09

Batteries
LiPo configuration (s) series (p) parallel
Nominal cell voltage is 3.7v, fully charged is 4.2v, 3.0v
discharged

4s
4p

Series 3.7 + 3.7 = 7.4v Parallel (2) 7.4v packs

5000 mAh Capacity 5000 mAh Capacity
2s1p 2s2p

Note: Always use identical cells, or packs when configuring this way.
Do not mix and match, consider age or number of cycles too.
(c) Bill Hauth, Dave Borkowski 2-26-09
(c) Bill Hauth, Dave Borkowski 2-26-09
Battery “C” Rating
ƒ ‘C’ always equals the capacity of a cell or pack, generally in mAh
ƒ A “milli” amp is one thousandth of one Amp, or [1A / 1000] = 0.001
Amp
ƒ mAh means milliamp hour or the current draw (capacity) for 60
minutes
ƒ A “2200” pack simply means you can expect a 2200 ma load to be
powered for (about) one hour.

The C multiplier:

A number in front of the C indicates it’s discharge capacity, it is simply a

multiplier

Example: 20C 2200 pack. What is its max rating?

20 x 2200 = 44000 and 44000mah = 44000 / 1000 = 44amps.

So the 2200 pack @ 20c has a max discharge rating of 44amps.

Electric fliers best friend

Fun fact:
C rating tells us the internal resistance of the battery.
The higher the resistance (lower C) the more the battery will heat up under
load. The best have high C ratings (30 – 40) and generally are the most expensive

(c) Bill Hauth, Dave Borkowski 2-26-09

LiPo Basics (the rest of the story)

• Balancing
• Connectors (Deans, Power Pole etc.)
• Soldering
• Wire gage
• Charging (CVCC)
• Chargers
• Care (evaluating, storing)

(c) Bill Hauth, Dave Borkowski 2-26-09

Chargers
Operating voltage range: 11.0~18.0Volt
Charge current range: 0.5A~2.0A
Lithium bettery cell count: 2 to 4S
Price $24
Input Voltage: 11~17v
Circuit power: Max Charge: 50W / Max Discharge: 5W
Charge Current Range: .1~5.0A
Discharge current range: .1~1.0A
Ni-MH/NiCd cells: 1~15
Li-ion/Poly cells: 1~6
Pb battery voltage: 2~20v
Price $38
(c) Bill Hauth, Dave Borkowski 2-26-09
Battery
Analyzer

(c) Bill Hauth, Dave Borkowski 2-26-09

Lipos Gone Wild

(c) Bill Hauth, Dave Borkowski 2-26-09

Electric No Brainer from E-Flight

(c) Bill Hauth, Dave Borkowski 2-26-09

Specifications
Wing span: 1170mm/ 46 in
Length :1140mm/ 44.9in
Weight : Approx 965g 34oz
Wing Area: 500 sq.in
Wing Loading: Approx
9.77oz/sq.ft
Motor: Torque 2818/900
Servos: 4 Micro servos like HS-
(c) Bill Hauth, Dave Borkowski 2-26-09
65
 Key Idea’s
Motors
9 Power in Watts equivalent to Horsepower – determines performance
9 Naming convention relates to Stator Diameter and Thickness ex. 2030-12
9 Kv determines motor speed, related to number of turns
9 Outrunners are optimum choice today (excluding ducted fan systems)

ESC
9 Choose based on number of cells – battery voltage is key
9 Use a current (max) safety factor of at least 20%
9 Battery eliminator circuit (BEC for receiver) normally included 1s – 4s
9 Use separate BEC for systems that are 5s +

(c) Bill Hauth, Dave Borkowski 2-26-09

 Key Idea’s

LiPo Batteries

9 3.7v nominal, 4.2v charged 3.0v discharged (in practice don’t get below 3.3v)
9 ‘S’ number of series cells ‘P’ number of parallel cells
9 Always use identical packs in series or parallel
9 ‘C’ is the discharge multiplier……hot battery = not enough ‘C’
9 Balancing chargers are the rule
9 Store at 50% charge
9 Battery analyzer is worth the $$

(c) Bill Hauth, Dave Borkowski 2-26-09