That's a bold statement ... Worlds Best. But it's even larger than that. Not just Worlds Best, but best for most all applications less than 30 Amps (limit of the tests). That means:
- duration ships that only pull 2 to 8 amps per rotor
- most all 6S and smaller ships (exception of nano-ships)
- any-size FPV racer
- any other ship in between
Why almost any size? Shouldn't a small FPV racer use a smaller and lighter ESC for response? Yes, if it does better on a net-lift response test. In other words, when you penalize the ESC for it's weight, is it still better and faster? What i continue to see is ESC manufacturers downsizing critical components of the ESC at a net loss. They weight savings is lost because of greater thrust loss and response. In other words, this heavier ESC will out accelerate, in the real world, a smaller and lighter ESC.
Why post this? To move technology forward, we need to report to industry what works and what doesn't. For some reason (i don't know why), this ESC works better than all others tested:
- for generating maximum thrust from the motor***
- for net-lift efficiency or the grams of weight it can lift (after it lifts the rotor) per watt
- for response (how fast it can generate targeted lift)
These tests were conducted on multiple days on multiple rotors of highly variant size, always being immediately compared back to another DYS 40A multicopter test to ensure that the baseline wasn't changing.
The ESC that dominated is a DYS 40A OPTO Multicopter using SimonK. The photo is included because there are two others that carry a similar or same name.
- Not the white cover DYS BLHeli 40A
- Not the one that is says "Programmable" versus "Multicopter" in the blue/purple band across the front
Have i tested all ESCs? No, but if you are convinced you know of one that would work better, let me know. I've tested most all of the following and one or more of their variants:
To do a test like this, a highly repeatable and finite test stand is needed. It took a while to develop one but what works is one that:
- measures (at a minimum) volts, amps, thrust, motor temp (shoots IR up the aft end of the motor)
- eliminates harmonics between the rotor and load sensor (this proved difficult but achievable)
- is calibrated and proves repeatable within 1.5%
- controlled by a system that can precisely repeat a rotor test (uses a Audurino Mega)
- directly feeds the data into Excel for analysis (uses DATAQ)
- uses a test script that produces repeatable results
- uses a test procedure that minimizes repeatability error (used average of multiple tests)
How much better is this ESC? On average:
- 4.4% higher net lift (after it lifts itself)
- 2.3% more net-lift efficient (usually the larger the better)
- from more than twice the response or the same response as other ESCs (usually the larger the better)
So how to make it better?
Step 1: Strip it naked. See photo below.
... remove the cover
... remove the heat plate (better to locate the ESC under prop wash to run cooler, see below)
Step 2: Right-Size the bullet connectors or wires (see above where heavy wires are replaced by 2mm bullets)
... remove the large bullet connectors or wires
... replace them with ones that are the most net-lift efficient (where heat loss = weight loss)
Step 3: Seal the ESC. Seal it with Electrical Sealant to protect from moisture and conductive dust
... tape or plug connectors and wires
... repeatedly spray each side from different angles
... a mistake i made was not sealing the bullet connectors and solder
- don't tape them off like i did
- insert a male connector into the end of bullets so sealant doesn't get inside them
Step 4: Locate ESCs under Prop Wash. See photos below. The turbulence generated by the prop does not adversely affect lift when the ESC is placed on edge to the prop wash.
... Use something non-conductive like hot glue to bond the ESCs to the motor mast or spar
... Face the FETS (the little square warehouses or Fire Emitting Transistors) to open air
... Protect the ESCs from below from ground contact (not needed here because of clearance)
back-side with hot glue
front-side with FETs completely exposed to open prop wash
Step 5: Tie up wiring. Use dental floss to secure wiring away from the prop.
***Note: The T-motor Air 40 in high-timing mode (an option) generated higher thrust, but at the sacrifice of efficiency and motor temp. Also, the T-Motor Air 40 was 2nd best and close in performance. If you are using an Air40, it probably isn't worth switching.
I just read through all 21 pages of this discussion.
First, I have a question that no one has asked. I get that the Aluminum heat sink quickly rises to the temperature of the FETs and may not be able to dissipate the heat to AIR very well with the heatshrink surrounding it and such.
My question is- if ONE FET gets hot (compared to the others on the same ESC) and that heat is dissipated across the entire heatsink AND the other FETs, could that save that one FET from damage?
Next, I saw pages and pages of arguments about new, faster ESC designs using newer FETs and other components. I saw a lot of arguments back and forth but no actual data. I saw Forrest offer to test any of these new ESCs and more. Can we get one of the racers who loves the new ESCs to work with Forrest and end the arguments with real data?
Personally, I'd be interested to know if:
1) The new, lighter ESCs can handle heat better and do not require a huge heatsink.
2) The newer ESCs can handle crashes better.
My application is a camera ship for film production that will:
1) Fly for 30 minutes on one battery
2) Be stable for slow pans and reveals
3) Be fast and agile enough to follow boats, cars, and other fast moving objects