Mein wahnsinniger Synergy-Eindecker

[Clugh]

I purchased a small brushed ESC for proportional control of the pump but I also brought a Turnigy rc controlled 30 volt 10 amp switch. I found this on M.A.C.K scale boat. products then realized they are all over the place. It was 17.00 on the WWW.

[Clugh]

Hi,
Here the parts needed for a 3rd or 4th channel proportionate pump control. A brushed esc and a 370 motor based pump. I'll see how much she flows shortly. The BOMEX graduated cylinder is 1000ml . It cost me around 10 dollars on ebay.. It's good to have one anyway for oil and gas mix on the 2 strokes....In a rough calculation if the ambient water is around 70 degrees it should be able to lower temps by about 10 degrees but it needs to be able to truly flow a liter a minute or more.. Telemetry on pump flow would be really nice to have.

[Clugh]

I also have a system to cryogenically cool with Co2 two 123mmx56mm cooling plates the water will be routed through. That should give you alot faster transfer of heat with the cooling water. A Peltier coolers right on top with diamond paste would give you solid state cooling operation. These plates will be mounted flush in the 3DP battery tray way down in between the rails. That's all really left to do and this girl can get wet...

BTW SMC has >12000 Mah drag cells now so Ill have to get a set. I play to get Brian Buass to do the 1818 and 1919 ABC's. I already have a matching pair of Octura X455's ground down to 52mm sent to me by Andy Brown. I've never run the props. They are super sharp and beautifully prepared.

[Clugh]

Hi,
Here the parts needed for a 3rd or 4th channel proportionate pump control. A brushed esc and a 370 motor based pump. I'll see how much she flows shortly. The BOMEX graduated cylinder is 1000ml . It cost me around 10 dollars on ebay.. It's good to have one anyway for oil and gas mix on the 2 strokes....In a rough calculation if the ambient water is around 70 degrees it should be able to lower temps by about 10 degrees but it needs to be able to truly flow a liter a minute or more.. Telemetry on pump flow would be really nice to have.

Ok I tested it. The 12 volt pump on 3 s lipo can pump uphill 1.35 liters a minute. The exit port on the boat will look like a super soakers stream off the side of the boat when it sits statically in the water pumping. This doesn't include the rudders water pickup when the boat is running. If I add a check valve inline with each source before they feed a main inlet that feeds all the components you could set the operation on the 3rd channel that operates the pump's speed control so the pump is running full blast when the boat is sitting still and off when the boat is WOT just using the water pickup as its source. With the Insane hardware sets u also have the option of a dual water pickups in rudder. That's now three separate sources of cool water coming into the boat before the radiator and circulating through the components to cool them. The pump will reverse as well so you could use it as a bilge pump in a scale application. The small pump from OSE is little powerhouse if it can indeed pump 1.8 liters a min uphill off the receiver battery at 6 volts. That would be impressive based of what I have just looked at here in the simple flow test.

[Clugh]

Okay the proportional pump control is working with the 10PX. To keep it clean ill just install a dual water pickup blade in the rudder and the pump picks up water from it. I'm close to 3d printing the battery trays but I want the cooling plates flush mounted at the front of the tray near the motor. Id like to use the equipment as the ballast so Im trying to distribute the weigh evenly so all I have to do to get the cg correct is slide the batteries forward or aft in the battery tray. I tested ithe system with a 3000 mah 3s lipo battery . The brushed esc has a BEC but I'm not going to use it. I doubt it has the current I want for 25kg servos. Ill probably run the pump inverter of a 12 volt regulator or a 20 amp BEC.

[Clugh]

35 volt 4700 microfarad ETTI Marine cap bank. Much more capacitance and more parallel caps than the 8s castle bank.. If you buy 2 then you can hook them up in series for HV setups later and they will support up 16s lipo (70 volts). If you build your own cap bank its better to space them out more so they can breathe.

You glue the caps upside down on the cooling plates like this with a high thermally conductive gel adhesive. Its poise is much higher than epoxy for potting coils. Tt has more thermally conductive filler in it.

[Clugh]

Methods of Cooling Capacitors


The most common cooling methods include self-cooling, forced ventilation and liquid cooling. The simplest method for cooling capacitors is to provide enough air space around the capacitor so it will stay sufficiently cool for most applications.

“Most applications,” but not all. In many designs and installations self-cooling through natural air circulation simply cannot cool capacitors adequately. In higher power cases, the larger heat load may require additional cooling by means of an external heat dissipator or heat sink (not unknown, but not common with capacitors since they take up a lot of space); a fan, which can forcefully direct cooling air over the capacitor; or liquid cooling. Water-cooled capacitors are usually employed in applications such as induction heating, melting or annealing, as well as in high-frequency welding systems.

Here, losses in the form of heat are desirable. Induction heating, a controlled and contactless method of heating, takes place when an electrically conductive material is placed within a variable magnetic field. Induction heating finds applications in many industries for forging, welding, sealing, etc.

Induction heating is ideal for automated production lines and controlled environments – for example, the automotive industry uses induction for heat-treating a variety of chassis and drivetrain parts.

As induction heating experts will note, installing the proper cooling system will extend the life of an induction power supply, reducing maintenance costs and downtime. A typical induction heater system includes a power supply, impedance matching circuit, tank circuit and applicator. Choosing proper capacitance for the resonant circuit is important in designing a resonant induction heating system: the capacitance affects the resonant frequency, output power, ESR, Q-factor, heating efficiency and power factor.

The resonance tank in an induction heating system is normally a parallel set of capacitor and inductor which resonates at a certain frequency. A bank of capacitors provides the needed capacitance in order to reach a resonance frequency matching the capability of the power supply. The inductor is the source of electromagnetic energy.

In these applications, the system’s capacitors can reach temperatures that require liquid cooling. These water–cooled capacitors are specially designed for use in inductive heating and melting plants for power factor improvement and also for tuning of the circuits for varying inductive loads. The liquids that are commonly used in such systems are water, a mixture of water and chemical solutions, and de-ionized water.

As Anthony Kenny states in his article on the subject, “Most traditional cooling systems are designed to cool a capacitor by passing the cooling medium over the external casing of the component.” However, such methods of cooling (which only bring the cooling medium into contact with the external case of the capacitor) are not as efficient thermally as the designs of water-cooled capacitors where water is passed through the interior of the capacitor so that heat is extracted as close as possible to its where it is generated. In most modern water-cooled capacitors, the cooling medium passes through the interior of the component.

The cooling conditions in place will help determine the performance and operating lifespans of these water-cooled capacitors. An Environmentally Correct Cooling System


Now that we’ve spent some time reviewing methods aimed at ensuring that the temperature of a capacitor is maintained within acceptable limits, let’s move on to an emerging capacitor-based technology that is showing promise as a “green” cooling agent.

Designs for what is known as electrocaloric (EC) cooling use materials that change temperature under an electric field, leading to a temperature difference between the hot side and the cold side. Multilayer ceramic chip capacitors (MLCCs) are promising EC cooling elements because they operate at low voltages, possess large breakdown fields, contain inner electrodes that facilitate heat transfer and exhibit sufficiently active EC material.

As Xavier Moya et al. note in their research, “the observation of electrocaloric effects in commercial multilayer capacitors has inspired the possibility of environmentally friendly cooling.” This type of cooling system boasts increased efficiency, with few or no moving parts and without the need for refrigerants that harm the environment or pose a fire hazard.

What is more, EC multilayer ceramic capacitors can be fabricated in a manufacturing-compatible process. Recently, a group of scientists from Xerox Parc described in the journal Science an EC cooling material employing lead, scandium and tantalum (PST) in multilayer ceramic capacitors that change temperature under an electric field.

These researchers obtained a system temperature span of 5.2 degrees C and a maximum heat flux of 135 milliwatts per square centimeter. They used a large-volume fabrication technique often employed in the electronics industry to produce a device from MLCCs that, the scientists say, shows how lab-scale devices that change temperature under an electric field could be scaled up.

When they applied an electric field of 10.8 MV/m, the capacitors underwent an adiabatic temperature rise (and fall) of 2.5 degrees C per cycle at room temperature. With the cold sink steadily cooling over the course of about 100 cycles, its temperature dropped by up 5.2 degrees C compared with the hot sink.

According to the researchers, the measured heat flux was reported to be more than four times higher than other EC cooling demonstrations, and the temperature lift was among the highest for EC systems that use ceramic multilayer capacitors, according to the researchers.

The device invented by the research team isn’t fully solid state. The electrocaloric effect involves alternately applying and removing an electric field to the material to increase and decrease the material’s temperature, respectively. The PARC device has two layers of multi-layer capacitors lined up between copper rails and separated by insulators. The upper layer contains five capacitors, while the lower one has four and is capped by an aluminum heat sink at each end.

The device physically moves the capacitors back and forth between hot and cold regions to effect cooling. An actuator moves the top layer so that its capacitors are always aligned with those below, while an extra capacitor at either end comes into and out of thermal contact with the heat sink below it. Repeating this process results in cooling.

Multilayer capacitors of PST have been demonstrated to be well-suited for cooling applications. With further development, one day these electrocaloric cooling devices may even replace today’s refrigerators and air conditioners.

[Clugh]

Aluminum Electrolytic Capacitors for DC-Link On-Board Charger

I bet the boys knew nothing about cooling with the capacitors themselves! Read about the MLCC and "eviromentally correct" cooling methods . Please take the time to read through it. I'm sure you will enjoy it if you enjoy electronics.

Thanks for your time and patience,
Hubert

[Clugh]

Interesting

Liquid Coolers - TE Technology

Something like this is ideal.. I'd rather have the extra weight it would bring versus The smoke trying to pull a lot of current! I can make it smaller and cool it cryogenically. Then you can really handle considerably more current across the power system. The motor can generate enough torque to snap the beryllium blades. I plan to age them after they are sharpened and balanced.