Electric propulsion system for PPG and Ultralights

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hy, i'm back with some updates check this link: https://endless-sphere.com/forum...

it is hard to update on 2 forums, so you can check the updates there,

here is a hint:

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Nice work!  Oh is that Elon Musk, or Richard Branson calling you!

 

FF = PI > S.E.T

 

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Wow, incredibly impressive!

 

Thanks for posting the updates.

 

Be safe!

 

JC

 

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That is completely awesome!!  Certainly a lot of progress from you first posts.

 

do you have a concern on the isolations:

 

With the high currents involved, any sliver or speck of anything falling there can make an easy short,....or maybe even the washer moving around a little bit.

Why not increase the isolation, since no obvious purpose to make it small (there is still huge copper all around--plenty to spare)...you could have a 100 mil gap with no downside, but plenty of increase in safety against accidental shorts.

 

Wondering-- How do you solder?  Maybe use a hotplate/oven to get the coper slabs near the melting point, then hit those spots with a soldering gun?  Maybe reflow solder paste?

 

I wonder if there is some sort of crimp terminal (like a hollow 2-part rivet that could be installed in the copper, then crimped to the lead (you see some oddball rivets used in heater glow wires, where soldering is not possible)

 

When in the dark remember-the future looks brighter than ever.   I look forward to being able to predict the future!

Last Edited: Fri. Jan 7, 2022 - 10:53 PM
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+1

Also consider making the insulating strip between the copper strips slightly wider and longer than the copper to add some insurance around the edges.

Letting the smoke out since 1978

 

 

 

 

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Yep, about washer clearances, they are temporarily, i have ordered copper washers for beter conductivity and they have a smaller outer diameter, and the clearance is 1mm around, and that space will be filled with textile/fiberglass cable insulator, the busbars on the perimeter will also be isolated with thin sheets of transformer insulation (is some kind of plastic with fibers and is flexible).

The small clearaces is due to the fact of inductance reduction, there is a study here https://www.youtube.com/watch?v=zGsHuoK9Egs , so im trying to make the inductance as small as posible everywhere, i even have eddy current shielding inside the pcb-s (4layers). V1.2 and 1.3 controllers had huge inductance issues, i had a year of study and learning, now im fixing everything it was not wright. 

About soldering i have a 100w and a 400w huge soldering irons (i cand adjust temp on both) , they gave excellent results in the past on v1.2 controller where the copper bus was even greater surface and had to solder fets to it. 

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Hy, i'm back with huge update, remade the gate drivers, command module, went with 4 layer boards. Check it out here: https://endless-sphere.com/forums/viewtopic.php?f=30&t=113852&start=75

Here is a hint

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