Making an esc better?

[GriffinRU]

Thank you Brian and Rene for input,

I think, I found better way to monitor LiPo cutoff without additional trimpots or switches, only programming with Castle Creation software.
There will be some odd wiring, but that shouldn't be a problem with more then 4S LiPo. Actually, that's probably will be the only correct way to use LiPo cutoff.

And, Yes I am back from vacation.

[GriffinRU]

Mod3 prototype board for MambaMax.

Mods for Quark:

Copper heatsink, assembled (temporary with alum. side panels), bottom side with taped holes for fixing inside stock housing, top view inside stock housing, same view with brains.

Details later...

[suicideneil]

Dude, I am in awe at your work...
If that doesnt keep the 125b cool, nothing will (except maybe a bucket of ice, but I dont think that would be practical). As for the new MM mod3, well, looks complicated, so knowing you it will be good- looks beefier than the prototype MMM we've just seen pictures of at anyrate.

[Serum]

Great work Artur!

If you need a place you can get cheap PCB's made, let me know. Same style yours are (with desired thickness of copper, painted and text printed, through metalizations) for bargain prices.

Looks like this board can house serious fetts!

[zeropointbug]

That looks great Griffin! I would love for you to make me one of those clamps for my other Quark that should be here shortly (thanks to AAngel). Looks like it should bleed enough heat away from the top FET's... although, not as well as my clamp.

You see my clamp has to be used with a custom heatsink of some sort, and well, you have seen my Mega Quark, haven't you?

[Serum]

it's not said that a shitload of heatsink helps cooling anything. It's the thermal connection that matters. And copper is superior to aluminum.

[zeropointbug]

Not with the heat density we are dealing with. The thermal interface on the side of this one is not as wide as the one I made, which would matter more... and there seemed to be only a few degree difference between the FET clamp and the fins of the heatsink. It keeps the esc under 90F under the most stressful, over geared conditions.

[snellemin]

I'm speechless with all the custom stuff that I see he makes.

[suicideneil]

He does make exceedingly good escs. As for heatsinks, a big one with poor connection would be the same as a small one with excellent connection I would have thought, so a big one with excellent connection too would be even better- makes sense to me anyway.

[joeling]

Ha ! I just sent Artur a pm. I want to be an early paying adopter this time. The humidity & temperature here is an ideal place to torture test these.

Regards,
Joe Ling

PS : still running a sacker with 5S & recently busted my 8XL. Just managed to install a 9XL from Mike with 13/46. BK12020. I want something better

[BrianG]

While a larger heatsink is nice to have, there does come a point where you don't get much increase in cooling performance. A heatsink can cool only to ambient temps and as the delta between the HS and the air gets closer, cooling rate slows down. Besides, these ESCs being anywhere from 85% to 95% efficient means that not a whole heck of a lot of power is being wasted as heat TBH. Just doing the internal mod and adding a little extra heatsinking to the Quark goes a LONG way to improve its thermal performance without sacrificing size or weight.

[zeropointbug]

I think the efficiencies are between 94-97% IMO.

Yeah, I agree, the internal mod does work pretty good at getting rid of thermals... but I still don't know how/where the thermal diode is placed. Which makes me worry, if it is pushed enough, the top FET's could overheat/burn up. But it is fine for great power that we need from it... I was just saying that mine would be able to handle a much larger and heavier vehicle than a MT, really, I would be limited to the tracers in the Quarks PCB long before the FET's were to get too hot.

[GriffinRU]

Thank you,

Heatsinking is a complex problem, but if you familiar in the field then you can create very efficient system.
To help out with Cu vs Al I did a quick web search and found this:
Nice pdf. collection and general info
Hint why copper is the key here, very nice and compact write-up

to zeropointbug:
I think it is very difficult to find a member on this forum who haven't seen your Quark:).

And, yes I can make you plates, no problem, especially I am working with Mike's help on this one as well.

[suicideneil]

Hyperthetical question time again:

I had a thought last night in bed (pack it in). Ignoring how good sensorless escs are these days at reducing cogging, would it be possible to use a HvMaxx brain with a more powerful powerboard. The theory being that you could run a sensored motor which is much more powerful than the Hv6.5/4.5, yet do so at higher voltage and/or amp levels. Just a random idea I had, but it would be nice if it were possible (will have to see the price on Novaks new Hv system and how powerful that is when its released in the newyear). The only downfall is that there are precious few high-powered sensored motors easily available for Rc use.

[BrianG]

Should be possible... with some additional modding other than "simply" adding a different power board.