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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 »
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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 »
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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 »
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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 »
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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 »
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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 »
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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.

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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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« Reply #25 on: October 09, 2011, 07:04:12 PM »
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Good job

PS: Good to see some fresh air on the forum.
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« Reply #26 on: October 09, 2011, 07:05:56 PM »
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one of the most interesting thing that i found from my experience in boat and ship modeling is, wasting of motor power un intentionally.means, in aircrafts, we must need 75 % of total power at least. but in boat modeling after 60% of motor power, the phenomena Cavitation takes place, wastes our valuable motor power, thus battery. so adding a current limiter circuit, we can adjust the ESC to maximum feasible limit, so can avoid battery wasting and increase motor life..i will add all proven circuits here, that i hope it may help you all in modelling..
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« Reply #27 on: October 09, 2011, 07:07:59 PM »
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Good evening and thank you Anwar Sab..i will post all good stuffs that proven in modeling life of , 41 years..so i hope it will help us all as you all inspired and helped me..
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« Reply #28 on: October 10, 2011, 12:49:56 AM »
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Circuit Diagram with a list of the required components please.
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« Reply #29 on: October 10, 2011, 02:13:35 AM »
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http://members.tripod.com/Peter_Horvat/REGLER.gif
make this brushed motor ESC in your lunch break...


http://members.tripod.com/Peter_Horvat/myprojects.htm
and earlier page of this forum
http://www.rcindia.org/radios-and-receivers/simplest-tx-rx-diy-anyone-interested/msg51753/#msg51753
and the link given was
http://www.stefanv.com/electronics/escboth.html

If you want low current, just reduce the number of MOSFET and increase if want higher current rating.


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« Reply #30 on: October 11, 2011, 11:55:46 AM »
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Why the pic link modified I don't know.
However, here is the schematics. The MOSFETs may be replaced with IRFZ44.
http://norbique.rchomepage.com/esc/imgs/sch2.jpg
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and

http://www.stefanv.com/quiet/escboth/figure1.gif
make this brushed motor ESC in your lunch break...
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« Reply #31 on: October 11, 2011, 02:48:46 PM »
roopeshkrishna
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Kalyan..its great..a million thanks..but we do not need any given complicated circuits to reach a high levels..its all proved..for hours of gruesome use..not by me..but with my students..no mercy is shown until battery goes down..and all we know, in water the motor will take even more current to drive the same motor with a marine screw. one of the real head ache that i face with present, aeromodelling BLDC, is instant over heating and un necessary current draining. in water all we know, after a particular speed of the intended marine screw, the Cavitation occurs, so we waste the power. i found many simple ways to cool down the ESC and BLDCs, but its even more easy and practical to use a Brushed motor, especially an intentionally reworked.its nice..
Friends..sorry for the delay for the circuits and part list...and i am willing to share even more easy way to make the same, that you only need some simple power device, and a simple soldering iron, and some high density wires. with that concept, you can avoid using any transistors, ICs, like BA series, to convert the pulse to motor pulse, and the size will be reduced even further..yes the weight..

any how, i will add all detailed circuits and part list, that i hope it may help you all a lots. so, i have to draw all circuits in CAD, and started, as i do not keep any printed matter to make my stuffs. give me a little time..please..and within that time i am sharing some more of my ESC projects, that all proven.. and will share the ESC with reverse, is essential in ship and boat modelling. and also a simple BLDC ESC.

here are some more simple made ESCs, are well proven, and reliable. with a cost of an ice cream.

first one is a simple ESC, is rated at 20 amps, for comparatively less power applications.still i added the BEC ( Battery Eliminator Circuit) as 5 volts 2 amps, to drive some HD servos.can lifted up to 6 volts if needed.Burst current can go up to 25 Amps, but the power device can hold 30 amps continuously.

BR-ESC-20-OX-1.jpg
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« Reply #32 on: October 11, 2011, 02:51:55 PM »
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from the photograph, can see the size of the ESC, and weighs mere 12 grams.

we can add a good sticker after completion of the work and testing, gives us a good look and satisfaction.

BR-ESC-20-OX-2.jpg
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« Reply #33 on: October 11, 2011, 02:59:17 PM »
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here is the even more heavier ESC, is intended for big boats and ships. is rated 40, (but 60 Amps real), Amps, its really meant for multiple motor driving, with a mixing facility, that avoids the use of a conventional rudder. and can also used as normal with big or tiny motors as well. a fan is applied to cool the ESC when we use two high power motors in same line, by mixing. can operate from 6 Volts to 14 Volts, and will not heats up even with heavy loads. the fan is also connected to load comparison, so, it will not drain any un wanted current in idling. as load increases the speed of the fan also increases. and can add a simple switch, up to 7.4 Volts to 11.1 volts, LiPoly, so will shuts off the output, when the battery input reaches the lowest threshold, that saves the battery from over discharging. can adjust the threshold as we needs.its some heavy, weighs 37 grams, including all driving circuits. but still costs of two Masala Doshas... Drool

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« Reply #34 on: October 11, 2011, 03:03:18 PM »
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BEC is divided in to two individual section, as can use two receivers in same frequency or coding, to get in depended motor control, instead of mixing.it allows to use any basic radio set, without a mixing functions.
BEC is 5 volts 5 amps, as it is meant to handle HD servos.

add a good sticker after completion..

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« Reply #35 on: October 11, 2011, 03:09:58 PM »
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so we can see how simple is to make some useful stuffs for modeling ourselves...we do not need to go to any complicated circuits today, as all complication is completed inside your receiver..itself..and i will add some even more easy way to make a good powerful ESC, that you need only two MOSFETs one for BEC and one for motor..and in to 30 Amps without heating up.. so..?  lots of crafts around us...with wrommmmm......wrommmm.....while enjoying some ice creams for balance money...Thumbs Up
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« Reply #36 on: October 11, 2011, 11:48:58 PM »
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Circuits Please
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« Reply #37 on: October 13, 2011, 11:23:42 AM »
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Rao, a little time, because i do not have any printed matters regarding my projects. andat present, i ordered for a BA series IC, as it is even more easy to wire, as it need only 5 leads to connect, to some very few external components. here, the circuit posted by Kalyan, is too complicated that it even uses an opto coupler..so, the size of the device and complexity also will be great. if i am un able to get the related IC, i will give you an even more easier option to make an ESC for brushed motors, and with that you will find how easy to make an ESC your own..for that you need only a 30/Rs and some wires.. Thumbs Up
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« Reply #38 on: October 13, 2011, 10:50:43 PM »
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I don't know why complication arise while
1. circuit diagram,
2. PCB,
3. Component layout 
4. dimension
5. Test result is available in both case as link given. And they are not mine but proven circuit without wasting much power and weight as well.

Both are pwm speed controller and with BEC.

and even in second case free wheeling action with PMOS too.


http://norbique.rchomepage.com/esc/imgs/pa.jpg
make this brushed motor ESC in your lunch break...


and

http://norbique.rchomepage.com/galleries/esc/bigimages/img_4835.jpg
make this brushed motor ESC in your lunch break...


Looks clumsy to you...  I dont know.

At least Something is grater than Nothing (Here Black Box).

As you specified Rs.30/-, So request to list up component with cost at least which require no DTP or drawing tools, only typing in quick reply is sufficient.

It may be made simple with linear regulator (MOS) and low pass filter only, but with grate power wastage which require large heatsink.

Another simple circuit given.
http://myweb.tiscali.co.uk/norcimradiocontrol/Radio11_files/image035.jpg
make this brushed motor ESC in your lunch break...

Source :
http://myweb.tiscali.co.uk/norcimradiocontrol/Radio11.htm
« Last Edit: October 13, 2011, 11:26:32 PM by KALYANPRODHAN » Logged

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« Reply #39 on: October 14, 2011, 06:06:49 PM »
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Kalyan..thanks for the details and photograph..its all great..and easy to do..a million thanks.. Thumbs Up
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« Reply #40 on: October 14, 2011, 10:45:36 PM »
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Great work roopesh sir...Waiting for the circuit diagram and component list...
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« Reply #41 on: October 15, 2011, 07:53:03 PM »
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thank you Jatayu..but my efforts are to help you all just you all helps me by sharing all your ideas..but here our Kalyan, is already posted all needed circuits and detailed photographs is nice, and hope you all may got a clear idea about this device. so i hope my further efforts are un necessary. but my ideas are even more simple, that you need not even a soldering iron.. Thumbs Up
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« Reply #42 on: October 16, 2011, 01:24:15 AM »
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krishna, We are still waiting for your component list.
Another thing to know, all MOS body and voltage regulator body shorted through Heat Sink!
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« Reply #43 on: October 16, 2011, 01:51:22 AM »
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For any problem, Usually we somehow arrive at a complex solution sir, but the main point of solving is by the simplest method. Looking forward for your simple ideas on making this esc!!

And yes another thing, i had noticed it earlier too , All the TO-220 Packages are shorted through Heatsink?
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« Reply #44 on: October 19, 2011, 10:54:56 PM »
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Rao, a little time, because i do not have any printed matters regarding my projects. andat present, i ordered for a BA series IC, as it is even more easy to wire, as it need only 5 leads to connect, to some very few external components. here, the circuit posted by Kalyan, is too complicated that it even uses an opto coupler..so, the size of the device and complexity also will be great. if i am un able to get the related IC, i will give you an even more easier option to make an ESC for brushed motors, and with that you will find how easy to make an ESC your own..for that you need only a 30/Rs and some wires.. Thumbs Up

Circuit of the ESC you had shown in your pics of your posts on 9-oct-2011 please.
why do you need printed materials of your projects to post the circuit diagram. You can easily draw the ckt using the paint application of your windows O.S. Even simpler is drawing the ckt by hand on a piece of paper, get it scanned and attach the scan to your post. You don't need any CAD skills to do that.
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« Reply #45 on: October 20, 2011, 08:52:31 AM »
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I will be happy even with your component list please.
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« Reply #46 on: October 20, 2011, 01:22:20 PM »
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I am excited to know I can now
thank you Jatayu..but my efforts are to help you all just you all helps me by sharing all your ideas..but here our Kalyan, is already posted all needed circuits and detailed photographs is nice, and hope you all may got a clear idea about this device. so i hope my further efforts are un necessary. but my ideas are even more simple, that you need not even a soldering iron.. Thumbs Up

I am excited to know making ESC’s without solder Iron ... Thats Cool literally also …. Lots of savings surely….awaiting your component details with Circuit diagram.

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« Reply #47 on: October 20, 2011, 01:45:12 PM »
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Keep hoping and waiting.........
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« Reply #48 on: October 23, 2011, 08:20:32 AM »
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Yes, let us wait for at least one month for one hour circuit. (Lunch break must not exceed 1 hour). Or another lunch break.
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« Reply #49 on: October 23, 2011, 12:25:01 PM »
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i have only half an hour lunch break
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« Reply #50 on: October 23, 2011, 10:22:31 PM »
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how long can the forum members be taken for a ride and how many times.
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« Reply #51 on: March 13, 2012, 10:53:54 AM »
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Great work Krishna. Any updates on this as I am interested in building your esc. Would really appreciate if you could provide with a detailed component list, circuit diagram, component layout and so on as soon as possible.
Thanks
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« Reply #52 on: May 14, 2012, 11:50:21 PM »
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great ESC...
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« Reply #53 on: May 15, 2012, 12:11:01 AM »
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i already started a new thread about the full ESC making.. still updating.. need a little time.. to complete.. Thumbs Up
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« Reply #54 on: May 15, 2012, 02:22:29 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..


What is the shaft size of the motor used here? I guess it is 3mm or so...and the prop size?? I guess its 7 inch...
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« Reply #55 on: November 28, 2012, 07:34:58 AM »
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hi, can u provide the link of ur nw thread
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