Brushed Motor Controllers for Boats,ships and Cars..with reverse function..

Started by roopeshkrishna, April 19, 2012, 10:22:47 PM

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roopeshkrishna

      Connect the servo, to the throttle stick channel of your Radio set.. make sure the movement is in correct direction, as we increase the throttle.. if it is reversed, we can simply reverse the channel by servo reverse switch.. make sure the travelling length of the drive rod is perfect.. if it is too high, you can replace the drive rod to inner position on servo.. or by radio EPA adjustments..  and if it is too low, can add a long servo arm, or can do with AT of the radio..
      Now the ESC is completed with radio set.. means at present we can control the speed variation with our radio set remotely.. in this stage, we can add this to any craft that need not a reverse.. then we can look to add the reverse function.. :thumbsup:
Phoenix.........

roopeshkrishna

          Up to here we made the electromechanical ESC for brushed motors in an esay way.. now it is working.. now we can add it to our crafts one need not reverse.. so, from here we can make a simple set up for reverse.. a simple set up..? yes again, we are not going to add any complications.. so, here at beginning i cleary mentioned you all about two types of switches.. yes the first one is the simple micro switch, and second one is the mighty toggle switch.. at first we are going to add the simplest mode of reverse with micro switch.. the wsitch is controlled by the same servo, one drives the potentiometer, by the command from the TX..so, at first we can go for it.. this mode is simple.. but with a great drawback.. means, the reverse is controlled by the battery pack itself.. so, we cant adjust the speed in reverse.. to reduce speed in reverse, we can tap the half battery voltage, by splitting the battery, or by adding some heavy duty resistors.. go for a look..
Phoenix.........

roopeshkrishna

             this one is simple reverse stage.. on this stage, we can add the existing battery for this purpose.. but the dis advantage will be, is the sudden on of the motor in reverse.. but can tap the battery as half, to reduce the motor thuds.. or can add a simple 10 watt 10 Ohms resistor in series with motor..
             If we examine, about the potentio meter, we will find that there must be a free gap between the full length of the potentio meter and the stop point.. means motor starts to run only when the potentio meter reaches a particular level towards high throttle.. so, we got a gap with the arm of the potentio meter.. so, this gap can be simply utilized for adding the reverse switch.. this arrangements saves one additional servo, intended for reversing, in the next step..  so, here we are adding the simple reverse switch.. this will be most usefull in boats, ships, and land based models, as it is an essential in RCying.. the speed of the reverse can be controlled by adding some diodes in line, or by adding some high watt resistors.. can go for a check..
Phoenix.........

roopeshkrishna

to add the simple reverse switching, we need two micro switches.. make sure the switches are in good quality..we can use a micro switch with two poles, ( with 6 leads, 3 each side,), but here i am using two switches glued to gather because of non availabilty of combination switch.. can see two switches are glued togather.. make sure the control leaves are in same position..
Phoenix.........

roopeshkrishna

we can see the perfect glueing.. and can see the two poles and 6 leads..
now sand the arms a little, and glue a washer over it.. this makes two identical switch as one.. then one press actuates both, simultaneously..
Phoenix.........

roopeshkrishna

the switch is ready.. now we have to fix it in such a way, that operated by the same servo, one drives the potentiometer.. you can fix it according to your set up, and here you can see how simple it is.. we know there must be a dead point, on the potentio meter, as it comes down.. in this region, motor stops instantly.. then we have a little space again, on same potentio meter, that gap can be utilized for reversing..
Phoenix.........

roopeshkrishna

can see a piece of foam board, over the arm, to drive the switch nicely.. and make sure the switch is depressed fully when the control arm reaches the proportioned end..

time to connect.. take two wires, coming from ESC as out to motor.. we were using Yellow, and Black wires for this.. so, solder the two wires on the NC contacts of the switch..
Phoenix.........

roopeshkrishna

now we have two C terminals as Contact.. solder two idendical wires to the C poles as shown.. these wires will lead to motors.. as in FWD direction.. when switch is not pressed, the Contact, passes through the NC ( Normally Closed, or Normally Contact), pole, drives the motor in one direction..
Phoenix.........

roopeshkrishna

now can see the two wires leading to the heavy duty motor.. in this time the motor will work in one direction..
and solder one red and one black wire, in opposite to the phase of the first wire set.. note the polarity is reversed here...
Phoenix.........

roopeshkrishna

now connect thw two new Red and Black wires, to a second battery, for an example, you can see two identical batteries here, in 6 volts, and conected in series for FWD motor control.. and the new set wire are connected to one of the battery, as 6 volts for reverse.. so, when the switch activated by the servo, the motor will start to run in reverse..
this circuit configuration is simple and robust.. this kind of set ups are very appropriate for big boats and big ships, as a permanent ESC control.. can also be used in big scale land based vehicles..
because of the simplicity, the circuit have a little flaw.. is, it is not possible to control reverse in a proportional manner.. so, we can add a proportional control in FWD and REV.. for this we need an additional servo, and a DPDT toggle switch..
Phoenix.........

roopeshkrishna

Phoenix.........

roopeshkrishna

up to here we worked on ordinary transistors.. now we have a little more nice option by making same electromechanical ESC, by a MOSFET.. the MOSFET is poered by a PWM ( Pulse Width Modulation ) circuit, acts as a chopper circuit, is far better than an ordinary circuit.. this MOSFET can handle up to 6 to 10 times current, while half in size of the used transistor.. so, here at first we must need a good stable PWM generator to attain a PWM signal to drive the MOSFET.. this circuit is wired around the famous IC NE 555.. from here we need some knowledge in Electronics, especially wiring a PCB, and component laying.. :thumbsup:
Phoenix.........

rc ram