Challenging motor stutter issue

Hello all! I had previously posted this on RCgroups but through the course of my troubleshooting I am beginning to think this is not a motor control issue as I had initially thought. I have gone full circle at this point and think it may be flight controller related, so I am asking here for ideas.

My rcgroups thread has all the troubleshooting steps and a video: http://www.rcgroups.com/forums/showthread.php?t=2446122#post32033709

Summary: One of my motors cuts out intermittently under high throttle. It never happens on the bench though, only in flight. It is always the same motor, even if I change orientation of the vehicle in software. I have swapped out every combination of power distribution, ESCs, motors and props, with essentially no change. I also swapped the flight controller (a pixhawk clone), but it was same lot and software configuration, and issue was the same.

The flight controller is running apm:copter 3.3rc5, although the issue was the same on the latest 3.2 branch as well. Unit is mounted on soft 3dr foam, upside down.

Anyone heard of a software bug related to the upside-down mounting?

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Replies

  • Swapped FCS to "normal" orientation with a known good board. No change.

  • Dataflash log from recent flight. You can see when I ramp throttle, pitch and roll both diverge quickly. The RCOU on ch2 (the arm that is acting strangly) looks a little noisy but it is hard to tell since it is logged at a lower rate. Can anyone comment on whether that looks normal?

    15-06-30_14-02-40.bin

    https://storage.ning.com/topology/rest/1.0/file/get/3702038479?profile=original
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