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Midland Helicopters . HeliProz . ZoomsHobbies

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e-Electric Conversions > Converting Caliber ZG To Electric...Need Help Please.
 
 
Wayne Mann
Senior Heliman
Location: United States of America

Hi Guys,

I am also posting this in the Aerial Photography section as well.

I am in the middle of converting my Kyosho Aerial Video machines from G26 power to electric power. I have had my belly full of vibrating, tail rotor kicking, inconsistent from day to day and just plain noisy engines.

The Caliber ZG mechanics drive train is very similar to the Maxi Joker’s drive train. The engine drives a secondary pulley via belt with a standard pinion gear/main gear for the second stage. So I am thinking the efficiency losses will be nearly the same between the two machines.

With virtually no experience with electric helicopters and less than none if you count interest, I need a little help. I have been reading for the past three days, day and night trying to rap my head around as much useful information as possible. I have formulated a basic plan of attack with regards to my basic needs and the type of equipment I want to use.

My all up weight is going to be in the 22 to 24 pound range…this is a guess, will probably be a lighter.

At that weight I will be using 810mm Rotor Tech blades which is just under a 72” disk.

I need 1550 to 1600 head speed for my set up for rotor head stability and faster forward speed stuff.

I think an Actro 24-5-32 engine from what I have read is what I need. I will spend the money on the Pleti 370-40-A2 if it is a much better choice for the power requirements that I have.

The Kontronics Jazz 55-10-32 ESC…may not handle the 12S2P A123 cells, not sure?

A123 cells in either a 10S2P, 11S2P or 12S2P

One of the threads I was reading was talking about the efficiency loss in the drive system and through the electronics. For normal Aerial Photography and Video work according to this thread a .85 loss was to be expected. If you Maxi Joker guys run the numbers how much head speed loss are you experiencing? If the numbers say you should have 1400 for a head speed, what is your real head speed.

These are my numbers:

Motor KV 435 x voltage 11S2P A123 at 39.6 volt = engine speed of 17226 divided by gear ratio of 9.23:1 = 1866 head speed x a .85 efficiency loss = 1586 rpm for head speed, which is right where I want it.

I have the option of going to 9.44:1 or 9.03:1 for gear ratios or I can make a pulley if necessary. I may have to have a pulley made any way if the machine shop can not adapt my clutch bell pulley so that it can be fastened to an 8mm motor shaft. I can obviously also change the cell count in the batteries to a 10S or to 12S for speed changes or efficiency requirements.

I would love to have a 9 to 10 minute run time out of this set up if possible. Does that seem reasonable?

Now does anyone have any great inspirational thoughts or words of wisdom that they would like to throw my way…please? Pretty please. I am mostly concerned about the ESC handling the 12S2P A123 cells if I need to run the 12S2P packs. The efficiency loss number seems also to be a big guess, at best, until you get something running so that you can determine the actual losses. I’m hoping that some of you with the Maxi Jokers can tell me what your actual losses were.

Thanks for the help in advance


Wayne Mann
05-11-2008 08:01 PM
 
 
ludocopter
Heliman
Location: Normandy - France

hello,

You're a good project.

Actually, I convert and I use a lot of electric. For your project I take a actro 32-3 or 4.
My intensity with 10S lipo is 18A idle statio. The electric power (input not meca) is ~ 650W for 4,8kg and 1550 t/m (motor actro 32-3 and castle creation HV110).
After a calcul, if the weight in load is 7kg, then the power add ~350-400W, total : 950W electric max.
If you're 10S A123 then U=10*2,8 (in load) =>28V, I=950/28=34A !!!
The time of flight will be ~ 3-3,5min !!! for 1P and *1,8 in 2P
for 14S A123 => 39V, I=950/39=24,3A
The time of flight will be ~ 5,5min for 1P and *1,8 in 2P

If you can, take a lipo TP lite 5S4P8000ah * 2. It's my config on other heli (millenium, actro 32-3, HV110, ratio 9,23, TP lite 8000mAh, weight : 5,2 kg) the time of flight is 18min (practise F3C).
excuse for english

ludo

milli_E700, Henseleit MP-XL-E, swift 620SE, T500
05-14-2008 11:18 PM
HOMEPAGE  
 
 
R.J.
Senior Heliman
Location: SF bay area, CA USA

Hi Wayne,

I did an electric conversion of a Robbe Lama (Futura SE mechanics) which also has a two stage drive.
http://www.scalerchelis.com/phpBB2/...php?f=42&t=8519

Using the headspeed calculator here, I found the actual headspeed (1330 rpm) to be the same as the calculated headspeed (1329 rpm).
http://www.scalerchelis.com/phpBB2/...php?f=42&t=6071

Hope this may help.

Regards,
Rick
05-18-2008 08:31 AM
 
 
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e-Electric Conversions > Converting Caliber ZG To Electric...Need Help Please.
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