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« on: October 09, 2011, 12:13:12 PM »
roopeshkrishna
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Good Morning  all respected Friends and Colleagues..last day, i was spending my evening with some seniors, including my Director Sir, for a test trial of our boat models, for a model boat race. it was part of our model boat club formation. so, we choose three identical crafts, all made by me, in same pattern, and weight of each craft was balanced with led weights. we choose the fresh water canal, part of the prawn farm, and placed two bouys within the length of 40 meters. the instructed plan was an "8" pattern, in to 6 laps. then from some dramatic incident i came to know about the importance of brushed motor, in ship and boat modeling..so i recognized the importance of brushed motor, for its less current consumption and comparitively coolest operation..yes, so the importance of the ESC for the Brushed motors..

all we know simple methods to make an ESC for brushed motors..but make this one, with BEC of 5 Volts, 3 Amps, its usable capacity is 30 Amps, ( but can pump up to 60 Amps in need), without heating it up, works from 5 volts to 18 volts DC..

can feed it with from simple toy motor, Cr 120, RS 370, 380, and yes massive CR 800 or more..and proved for hours of operation..as it works within the feasible range of current it heats up a little..i used here, all modern generation MOSFETs to reduce the total size and weight of the ESC. and driven by a simple IC, and not with a servo, to alter the speed.




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« Reply #1 on: October 09, 2011, 12:16:44 PM »
roopeshkrishna
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one of the reliable source of a good motor gear combination is from the center locking actuator of a car.the motor will be heavily brushed, drops a little current, even at full throttle, runs fast with torque. we can buy these actuator as itself, but i collect it all from junkyards and scraps. with a 50 Rs/- we can get more than 6 or 7 motors as assy. so we can open the casing, and can take out the motors. its too reliable one..

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« Reply #2 on: October 09, 2011, 12:18:47 PM »
roopeshkrishna
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here you can see i added a gear support attachment, by removing the original spline shaft, is replaced with a thick bicycle spoke..

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« Reply #3 on: October 09, 2011, 12:19:37 PM »
roopeshkrishna
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can collect any numbers we need..is sure a battery saver with great performance..guaranteed..

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« Reply #4 on: October 09, 2011, 12:22:42 PM »
roopeshkrishna
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whenever we consider about an ESC that we made ourselves, we feel inferior..NO..with new generation devices, we can make tiny but effective electronic devices to our needs..with this configuration, we can run a three volt high Ampere motor, with a supply of 6 volts, and spans up to 12 Volts 20,000 RPM motors with 15 to 20 amps and more...

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« Reply #5 on: October 09, 2011, 12:23:20 PM »
roopeshkrishna
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can feed any motors in any ampere rating...

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« Reply #6 on: October 09, 2011, 12:32:28 PM »
roopeshkrishna
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now time to make the ESC...we were making ESCs for brushed motors with a servo to drive its potentiometers. but it will be cumbersome and heavy..so, by using a single IC, to drive the ESC power device we can eliminate the servo. and total weight of this proved stuff is 18 grams. and sizes spans to a standard servo.
specs: can operate from 6 volts to 18 Volts DC.
          BEC voltage 5 Volts 3 Amps.
          rated capacity 30 Amps at 18 Volts.
          Can burst up to 60 amps, but heats up.
          Weight : 18 grams.
One of the cause of heating up the ESC is over loading. so i chooses a new generation power device, is capable to handle 70 amps at 18 volts. so, within a 20 amps drop the heat is too low, that is negligible. we can use any high power MOSFETs, and IGBTs for our need. i used industrial MOSFETs, and thanking to my friend, who sells industrial power devices.

now time to make one..we can purchase, the heat zink, according to our needs, or can scrap from any old scraped PCBs, like mother board, or a board of a TV.

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« Reply #7 on: October 09, 2011, 12:34:00 PM »
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for even more heavy use, and unwilling to cool it with water, can choose this type of heat zink, and can add a tiny CPU fan over it..cool..

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« Reply #8 on: October 09, 2011, 12:37:02 PM »
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now..collect all needed devices..two power devices, one to drive motor, and one for BEC, of 5 volts 3 amps..and the IC is for converting the pulse from receiver to device..

solder it in a way, that the print facing up, to get a high amp rated circuit. and can add brass rods in power lines.solder it all in a way, to reduce size and weight..

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« Reply #9 on: October 09, 2011, 12:40:01 PM »
roopeshkrishna
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buy, or collect, one RC connectors with wire, or we can take one from a scraped servo.
is must to feed the receiver, in to throttle line.the supply to the receiver will come from ESC.

solder all devices in a compact manner and sealing it with insulation tapes. and hide it within the heat zinks.
solder all needed power and filter capacitors as compact as possible.

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« Reply #10 on: October 09, 2011, 12:41:21 PM »
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pack it all in black insulation tape, or can shield with heat shrinking tube.

it also makes it water tight.

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« Reply #11 on: October 09, 2011, 12:42:14 PM »
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showing the size comparison...

and time to check...

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« Reply #12 on: October 09, 2011, 12:44:02 PM »
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its proven..we tested this new device about 4 hours, in grueling modes..it also can be used in aircrafts with brushed motors...
yes see the test video..
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« Reply #13 on: October 09, 2011, 12:49:58 PM »
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all respected Friends,please do not throw away your faithful brushed ones..make this one ESC and run yoyr crafts...its all worth..inexpensive..i took about 40 minutes to make this one..and spend nothing than that to buy an Omelet with a coffee...

after thourough checking, make a label of yourselves, and print it out..fix it...proud..?  yes...sheer satisfying..and save loads of money...if a short circuit happens, only damage will be the loss of power device..is cost less than 18/Rs for one..
and one of the good thing of this used device is its cut off threshold..with an addition of a simple zener diode, we can set its cut off threshold from, 5 volts to 10.5 volts, so can save battery from over draining...if anyone need this one..make one and enjoy your crafts...

i will post a 60 Amps ESC, with reverse, when i get time. and yes a simple water cooled one with 120 amp capacity... Thumbs Up

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« Reply #14 on: October 09, 2011, 01:55:13 PM »
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well done..kudos..
it would be very helpful if you post a detailed circuit diagram along with the specifications of the MOSFETs and other electronics used...
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« Reply #15 on: October 09, 2011, 03:23:08 PM »
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it is sure Tatu..i will post all detailed circuit diagram, and a data sheet of all needed components used. will also post an ESC and circuit, with reverse, is an essential function in boat modeling. give me some time to make all scanning and photographs about this.
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« Reply #16 on: October 09, 2011, 03:32:57 PM »
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Well done Roopesh Krishna,
  Can you pls give a complete circuit diagram and component details of the ESC
  and about your foam boat project, did you make your own sterntubes or buy it,pls
  give me reply

  Noble
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« Reply #17 on: October 09, 2011, 03:36:02 PM »
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Noble..its sure, i will post all detailed circuits here. and in an even more easier way. i also will post a detailed posting to make motor coupling of boat, along with drive tubes. will also add more powerful ESCs with water cooling.
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« Reply #18 on: October 09, 2011, 03:51:09 PM »
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 Thank you for the reply and I'm excepting more innovations from you
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« Reply #19 on: October 09, 2011, 04:09:21 PM »
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Welldone Roopesh!

Which MOSFET are you using? 30A at 18V seem to be pretty good for a device available at Rs18! Would like to see the datasheet of the device.

-Ismail
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« Reply #20 on: October 09, 2011, 04:23:19 PM »
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sure Izmie..i got these device from my friend, who deals electronics components as whole sale. he informed me when these new generation devices reached him actually intended for inverters. previously i was using big heavy MOSFETs and IGBTs for ESCs..
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« Reply #21 on: October 09, 2011, 04:25:19 PM »
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in reality, i was not thinking about these stuffs, because of ,yes some laziness...but its sure to understand the importance of our own circuits ourselves..we can also make ESCs for BLDC..
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« Reply #22 on: October 09, 2011, 04:56:18 PM »
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Izme, here one IRF Z 44 costs about 15/Rs...and 48 is 20/ Rs...cool..? so, 48 is about 40 amps feasible..but need a good heat zink..still works perfectly..size?  nowadays dosen't  matter...
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« Reply #23 on: October 09, 2011, 05:28:42 PM »
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Yes, these devices seem to be perfect for the job. Thanks for the information.

I made ESCs a while back but its difficult to get the required parts in India. I hope the devices are available commonly in Indian electronics stores.

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« Reply #24 on: October 09, 2011, 07:01:56 PM »
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Izmile..we do not need any cutting edge stuffs and materials to make needed things for us. all needed MOSFETs and IGBTs are easily available in market. i am living in between two smaller towns as Vatakara and Thalassery. even these towns hold all needed voltage regulators and power devices with them. if you are un able to get MOSFET or IGBT, can go to any BJT s that can hold up to 20 amps or 30 amps Collector current, but i preffer bridge it with two or three..life long..and with an additional high amp diode in motor line prevents any damage to motor, or power device due to back EMF, or short circuit happens by armature failure..some BJTs are proven for years for their faithful working..but to reduce weights we must look for new generation power devices and high density copper wires, to reduce size and weight. it works nicely...and happy to hear that you were making needed stuffs for you..positive..thank you. Thumbs Up
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