Final Year Project Intermediate Report

Bachelor in Aircraft Engineering Technology (BAET)

ELECTRIC POWERED PARAMOTOR

Student name
SYAFIQ BIN BAHRI

Supervisor name
MR MOHD KHAIRUL ADHA BIN MOHD JAMIL
Co-Supervisor name
MR MOHD EZWANI BIN KADIR

UNIVERSITI KUALA LUMPUR

MALAYSIAN INSTITUTE OF AVIATION
TECHNOLOGY

January 2012
 ELECTRIC POWERED PARAMOTOR

SYAFIQ BIN BAHRI

Dissertation Submitted in Fulfillment of the Requirements for the Bachelor of

Aircraft Engineering Technology (Hons) Mechanical
University Kuala Lumpur (UniKL MIAT)

JANUARY 2012

I
 DECLARATION PAGE

I declare that this dissertation is my original work and all references have been cited
adequately as required by the university.

Date: 18 MAY 2012 Signature :

Full Name : SYAFIQ BIN BAHRI
ID No : 53259109009

II
 APPROVAL PAGE

We have examined this report and verified that it meets the program and Universitys
requirement for the Bachelors of Aircraft Engineering Technology (Hons) Mechanical.

Date: 18 MAY 2012 Signature :

Supervisors Name : MR MOHD KHAIRUL
ADHA BIN MOHD JAMIL
Official Stamp :

Date: 18 MAY 2012 Signature :

Co-Supervisors Name : MR MOHD EZWANI BIN
KADIR
Official Stamp :

III
 TABLE OF CONTENT

CHAPTER CONTENT PAGE

TITLE PAGE I
DECLARATION PAGE II
APPROVAL SHEET III
ACKNOWLEDGEMENT IV
TABLE OF CONTENTS V
LIST OF TABLES VIII
LIST OF FIGURE IX
LIST OF GRAPHS X
ABSTRACT XI
List of Abbreviations /Notations / Glossary of terms XII

I INTRODUCTION
1.1 Overview 1
1.2 Brief description about paramotor 2

II LITERATURE REVIEW
2.1 Knowledge of the research review 7
2.1.1 Concept 10
2.2. Reason why we choose Brushless DC motor instead of 9
using brushes Motor 14

2.3 Brushless DC Characteristics 15

2.4 Basic structures Brushless DC 15
2.5 Problem statement 17
2.6 Objective of the project 20
2.8 Project synopsis 21

IV
III METHODOLOGY
3.1 Methodology of the Project 22
3.2 Flow chart 22
3.3 Equipment list 27

IV RESULT AND DISCUSSION 51

4.1 Data Collection 52

V CONCLUSION AND RECOMMENDATION 63

5.1 Engine 64
5.2 Batteries 64
5.3 Recommendation 66
APPENDIX
REFERENCES 78

V
 LIST OF TABLES

NO TITLE PAGE

Table 4.0 Motor Temperature 52

Table 4.1 Maximum RPM 54

VI
 LIST OF FIGURE

NO TITLE PAGE

Figure 1.1 Foot launch 3

Figure 1.2 Trike 4
Figure 2.1 Manufacturer Data 8
Figure 2.2 Snap 10
Figure 2.3 Simioni 11
Figure 2.4 Nirvana 11
Figure 2.5 Epac 12
Figure 2.6 nirvana 13
Figure 2.7 Elecpara 13
Figure 2.9 Disassembled view of a brushless dc motor 16
Figure 2.10 Brushless dc motor = Permanent magnet ac motor + 16
Electronic commutator
Figure 2.11 Shows the heat transfer from piston engine 18
Figure 2.12 Shows that few accident happened during take off and 19
landing.
Figure 3.1 Bench Test 27
Figure 3.2 Steel Roller 29
Figure 3.3 Type of roller 30
Figure 3.4 First Bench Test Design 31
Figure 3.5 Second Bench Test Design 32
Figure 3.6 Final Bench Test Design 33
Figure 3.7 Pulley System 34
Figure 3.8 Propeller Mounting 35
Figure 3.9 Complete Electrical Circuit 36
Figure 3.10 Electrical Brushless DC Motor 37
Figure 3.11 Batteries Circuit 42
Figure 3.12 Electrical Speed Control 45
Figure 3.13 Trike Complete Design 46
Figure 3.14 RPM Instrument 47
Figure 3.15 Temperature Sensor 48
Figure 3.16 Multi meter to measure voltage 49
Figure 3.17 Amp meter to measure 49
Figure 3.18 Weighing scale 50
Figure 3.19 Digital Spring Scale 51
Figure 4.1 Graph (motor temperature) 53
Figure 4.2 Graph (motor RPM) 55
Figure 4.3 Graph (Thrust) 56

VII
Figure 4.4 Graph (battery voltage) 58
Figure 4.5 Graph (Wire Temperature) 61
Figure 4.6 Graph (ESC Temprature) 62
Figure 4.7 Graph (Battery Temperature) 63

VIII
 ABSTRACT

Paramotor is the simplest of all powered aircraft consists of a small motor

driving a propeller, worn like a backpack under a paraglider wing and providing thrust to
take off, climb and maintain level flight. Electrical powered engine for paramotor is still
new to the world and normally paramotor used piston engine as their engine to get trust.
Now, we will do the research on possibility of using electric motor to powered
light aircraft, paramotor in replacement of piston engine. This is in line with the global
trend towards green technology.

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1.0 INTRODUCTION

We believe that more than 100 years after the invention of the internal
combustion engine, incumbent automobile manufacturers are at a crossroads and face
significant industry-wide challenges. The reliance on the gasoline-powered internal
combustion engine as the principal automobile power-train technology has raised
environmental concern, created dependence among industrialized and developing
nations on oil largely imported from foreign nations and exposed consumers to
volatile fuel prices. In addition, we believe the legacy investments made by
incumbent automobile manufacturers in manufacturing and technology related to the
internal combustion engine have to date inhibited rapid innovation in alternative fuel
power-train technologies. We believe these challenges offer an historic opportunity
for companies with innovative electric power-train technologies and that are
unencumbered with legacy investments in the internal combustion engine to lead the
next technological era of the automotive industry.

For this project, we will do some research in order to replace the mechanical
engine for the Para motor/trike to electrical engine. In our research we do some
experiment on the performance, durability, safety, cost operation and lot more.

In order to realize the environmental campaign we would introduce the

electrical performance light aircraft which associate with local automobile
(motorcycle) manufacturer. We are very proud if the combination of two local body
can introduce the new system which is beyond other expectation.

1
1.1 About Paramotor/ Trike

Paramotoring is the newest and latest development in ultralight foot-launched

air sports. The entire aircraft will actually fit in the trunk of your car! This is an
exhilarating yet simple way to aviate, also being the easiest powered aircraft you can
learn to fly. With minimal training by aviation standards, you can enjoy the incredible
experience of flying anytime the weather is calm.

The small, lightweight engine drives a propeller and the entire unit is strapped
to your back with a harness that allows you to fly beneath a standard paragliding
wing. Combining a paraglider with a backpack engine allows you to fly from level
ground, without the need for hills, mountains, wind, thermals or a tow rope. Foot-
launching and landing also allows you to operate on virtually any type of terrain, such
as wet sand, tall grassy fields, bumpy and rocky slopes, or anywhere else that using a
wheeled aircraft would be impossible.

Paragliding itself has developed into a popular aviation sport in the last 12
years. It has its roots in hang gliding, but without the rigid structure, being easier to
learn, lighter in weight, and most importantly can be carried in a backpack. Canopy
design over the last couple of years has seen an amazing amount of progress,
combining higher performance with increased safety.

Paragliders are typically flown from a hill or mountain, with the pilot seeking
lift to stay aloft for a 'soaring' flight. Without the rising air produced by thermals or
wind deflecting off the ridge, the glider and pilot simply descend slowly until
reaching the ground. Towing with a winch will also allow pilots to gain altitude
briefly, but the lift must still be found to maintain altitude for an extended period.
With the paramotor disconnected, you can use your wing with a standard harness to
fly from hills, ridges or mountains, joining the thousands of people who already enjoy
this unique sport throughout the world.

With a paramotor, the flight can be extended for as long as your fuel lasts! A
paramotor is a fair weather machine, and flying in strong or gusty winds or other bad
weather conditions is not recommended. On a mild weather day, you can step into
flight, gain altitude and cover incredible distances with your paramotor. Climb away

2
from the ground to a couple thousand feet, switch the motor off, and enjoy the glide.
Your paramotor can be restarted in flight when needed to continue flying.

Paramotoring, or powered paragliding (PPG) is absolutely the most accessible

form of aviation available to the public.These motors are the most powerful, yet low
maintenance aircraft engines you will find. They are rugged, reliable and easy to use.
There is no easier way to fly than paragliding, and with the addition of the paramotor,
well, the sky is not the limit - it's the destination.

Paramotor can be devided by two:

- Foot launch

Fig.1.1 shows paramotor foot launch during take off

3
- Trike

Fig.1.2 shows paramotor trike during take off

In many countries, including the United States, powered paragliding is minimally

regulated and requires no license. The ability to fly both low and slow safely, the
open' feel, the minimal equipment and maintenance costs, and the portability are
claimed to be this type of flying's greatest merits.

4
1.2 Paramotor for beginner

For paramotor you can solo in as little as a day with ability, exceptional
conditions and intense training. But you a far from ready to venture out on your own.
You will need to learn to ground handle the wing and some basics, then when the
weather is good you will get your first tow/flight.

Paramotor engine can stop during flight during to engine failure or fuel tank
empty but it's a glider, and glide it will! The loss of power only limits your ability to
maintain altitude. The glider flies about 6 feet forward for every foot lost (a 6 to 1
glide ratio). So you'll be dropping just over 3 mph as you glide forward at about 20
mph. With even moderate skill it can be landed in quite a small space too. A motor
failure is rarely more than an inconvenience.

It is probably the safest form of private aviation ever devised, It is safer than
flying in small planes or riding motorcycles but not as safe as driving. One reason for
the good safety record is that most problems will prevent the pilot from successfully
taking off.

Like other adventure sports, it's as safe or dangerous as you make it. Powered
Paragliding has a very good safety record amongst pilots that have been properly
trained by a professional. It is of course crucial that you receive instruction from a
certified professional and use safe equipment.

Paragliding is an outdoor sport and the weather is unpredictable. A thorough

understanding of the air, and the dynamics of flight makes a trained pilot much safer
than an untrained pilot. The primary safety factors are personal judgment and attitude.
You must be willing to learn gradually and to think with your head not with your ego.
If you do not, then you can get injured or killed; if you do, then you can paraglide
well into your life.

Motor-on flight time can easily exceed 2.0 hours based upon mild throttle
usage. Periods of extended full-throttle will burn fuel at a faster rate or with an up
down throttle. If your motor is equipped with a starter or you are strong enough to
pull the starter cord you can shut your motor on and off as you please, gliding for
hours on thermals.

5
 This is the most popular question that people always ask about this sports.
Therefore, start from now on the paramotor with combustion engine are no longer
relevant because of a lot negative feedback from pilot.

6
 Chapter 2 : Literature Review

2.1 Knowledge of the Research Purpose

The research is based on the component, process, documentation, procedure

and the system which is related to the project. The scope of this project are include
Brushless DC motor, Lead acid Battery and paramotor. Paramotor is a form of
ultralight aviation sport.

Some said this kind of activity is one of an extreme sport and some of them
are consider as a hobby. In Malaysia, not all the people notice about this activity and
only few people that can afford to owned the paramotor. As we a aware, normal
paramotor is using piston engine which will produce a lot of harms to the consumer
and also the environment.

Therefore, we are coming with the new ideas that can counter all the problems
by replacing the normal combustion engine to an electrical brushless motor. Moreover
in this project we will used brushless motor DC which powered by lead acid battery.

7
 COMBUSTION ENGINE ELECTRIC MOTOR

TYPE SNAP 100 Simonini Nirvana EPAC Ctric motor

Mini 2 Plus
(G24)

SPEC

Engine 2 Stroke 1 2 Stroke 1 2 Stroke 1 Direct Drive Brushless motor

Cylinder Cylinder Cylinder DC
Yuneec Power
Drive 110

Displacement 96 cc 206cc 210cc Equivalent 100cc Equivalent 90cc

Compression 11:1
ration

Max. Power 12 kW @ 12.43 @ 12.50 kW 3.6KW@ 70km/h

9000 1/min 6000 rpm (6,000 rpm)

Max. 14 Nm @ 9.3Nm@1000rpm
Torque 8800 1/min

Reduction Gearbox Belting

1:2.25

Fuel Premium Premium Premium Lithium Polymer Lead Acid

Unleaded Unleaded Unleaded (LiPo)

Tank 8 Litre (2 10 Litres / 10 1 x 30Ah Pack 5x20AH / 2-3hours

gallons)/ 3.5hours litres/3hours (54cells/Pk)
3hours
25 ~ 30mins

8
Weight 19kg 30kg 23 kg 30KG Estimated 30kg

Electronic NO YES YES

ignition

Trust 45kgf 74kgf 58/54 kgf 50kgf In progress

Voltage 66.6V 60V

Output 10KW

Fig. 2.1 Above table show you the technical data between Paramotor manufacture

9
There are few famous company that produce the paramotor equipment and the engine
itself. In here we will bring forward to show the comparison between them.

SNAP 100

Figure 2.2

Combustion engine powered paramotor 90cc, this paramotor have very light weight
between all 5 designs above just only 19kg. This SNAP 100 bring 8 liter of fuel and
can fly almost 3hours. If compare to our electrical powered paramotor, we have same
engine capacity where is 90cc, our estimated about weight is around 30kg, so we got
extra 10kg of weight (May be reduce by reducing some of the battery).

10
Simonini Mini 2 Plus (G24)

Figure 2.3

This is paramotor that powered with 206cc combustion engine, most all of the
combustion type engine used 2 Stroke 1 Cylinder engine. Engine capacity 206 cc,
weight around 30kg and bring 10liter of fuel where can fly arount 3.5 hours. If
compare with our paramotor, this G24 can produces high power because of engine
capacity.

Nirvana

Figure 2.4

Almost the same with G24, this paramotor have very light weight its just around
23kg if compare to the performance of this engine. Its used 210cc of engine capacity,
bring 10liter of fuel and can fly 3hours.

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Electric powered Paramotor

Epac

Figure 2.5 Epac Paramotor

This is one of the company from china that just product the electric powered
paramotor. The engine capacity if compare to combustion type is around 100cc, no
need fuel, no need to do servicing, very clean engine and silent. This Epac used LiPo
battery or in other word known as Lithium Polymer. The weight of this Epac is 30kg.
The problem with this Epac is the battery just only can supply around 25-30 minutes.
They did not mention about how to charge the battery.

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Nirvana

Figure 2.6

Nirvana is the best company in this aviation sports and there always come out with
the new latest design and also update technology which look at the performance of
their paramotor. Even there are coming with this new technology they still cannot
reduce the weight of the engine. The more performance that they looking for the more
weight augmentation will come out.

Our Project (Elec Para)

In our project, we will use brushless DC motor as an engine and if we compare to the
combustion engine capacity, our engine capacity is equivalent to 90cc. we will used
Lead acid battery to powered the motor. Our estimated about weight for this Elec para
is around 30kg and if we compare with other Electric paramotor for example the epac,
that epac only can fly around 25-30 minutes, but for our project, we estimated that
this Elec Para can fly around 2-3hours.

Figure 2.7 shows the brushless motor with propeller

13
2.2 Reason why we choose Brushless DC motor instead of using brushes Motor

Although it is said that brushless dc motors and conventional dc motors are

similar in their static characteristics, they actually have remarkable differences in
some aspects. When compare both motors in terms of present-day technology, a
discussion of their differences rather than their similarities can be more helpful in
understanding their proper applications. Table 1 compares the advantages and
disadvantages of these two types of motors. When discuss the functions of electrical
motors, we should not forget the significance of windings and commutation.
Commutation refers to the process which converts the input direct current to
alternating current and properly distributes it to each winding in the armature. In a
conventional dc motor, commutation is undertaken by brushes and commutator in
contrast, in a brushless dc motor it is done by using semiconductor devices such as
transistors.

Table 1.0 Comparison of conventional and brushless dc motors

14
2.3 Brushless DC Characteristics

Voltage on the motor determines speed and current in the motor determines
torque. These relationships are linear and nearly identical to a standard Brush DC
drive. The application of the product then is essentially like the more familiar brush
machine. Speed accuracy is very high, in fact with the most widely used Brushless
drive, the accuracy is synchronous (0% speed error) due to a digital encoder and drive
controller position regulation. Torque to inertia ratios are very high providing high
accel/decel rates and excellent dynamic response. Controller bandwidth ( 30 to 40
Hz) is 5 to 8 times higher than the Brush DC drive. Motor thermal characteristics is
the major advantage of Brushless DC in that a thermal speed range of 100 to 1 at full
rated torque is available on the standard motor and totally enclosed motors are
available in very small frame sizes. Motor efficiencies range from 90 to 96 % and
controller efficiency is 97% giving overall efficiencies better than brush DC systems.

2.4 Basic structures Brushless DC

The construction of modern brushless motors is very similar to the ac motor,

known as the permanent magnet synchronous motor. Fig.2.9 illustrates the structure
of a typical three-phase brushless dc motor. The stator windings are similar to those in
a polyphase ac motor, and the rotor is composed of one or more permanent magnets.
Brushless dc motors are different from ac synchronous motors in that the former
incorporates some means to detect the rotor position (or magnetic poles) to produce
signals to control the electronic switches as shown in Fig.2.10. The most common
position/pole sensor is the Hall element, but some motors use optical sensors.

15
Fig.2.9 Disassembled view of a brushless dc motor

Although the most orthodox and efficient motors are three-phase, two-phase
brushless dc motors are also very commonly used for the simple construction and
drive circuits. Fig.3 shows the cross section of a two-phase motor having auxiliary
salient poles.

Fig.2.10 Brushless dc motor = Permanent magnet ac motor + Electronic commutator

16
From this survey, we can conclude that combustion engine paramotor is power then
electrical motor from the performance, but if we looked to electrical motor it is the
perfect power unit producing zero vibration or noise during operation and with only a
single moving part it is virtually maintenance free.

2.5 PROBLEM STATEMENT IDENTIFIED AND PREVIOUS RESEARCH

DONE BY OTHERS

FROM PISTON ENGINE

- Too much vibration from the existing engine.

As we know every combustion engine that used its either in the aircraft, car
and motorbike must have a clearance for the engine vibration. An internal combustion
engine produces power in the form of controlled explosions. These explosions
produce powerful pulses of energy that cause the engine to vibrate in response.
Engine designers do their best to make these forces cancel out to minimize vibrations.
But, no matter how well the designer does his job, he cannot eliminate all inherent
vibrations in an engine. Therefore we need to remember that it is perfectly normal for
an IC (Internal combustion) engine to produce a characteristic vibration spectrum
signature. Vibration analysis of IC engines then must focus on "variations" from the
"normal" vibration signature.

If car the vibration from the engine can be divided and transfer to many
component for example suspension, bushes and tire but for paramotor the vibration
will transfer to the pilot body especially pilot leg.

17
- Excessive heat produce.

In every combustion engine must always related with the heat that produce by
the engine it self. It is happen when the fuel and air mixture are burn in the
combustion chamber and the temperature will rise up.

fig. 2.11 shows the heat transfer from piston engine

More over the optimum heat are needed for combustion engine in order to make sure
the fuel and air mixture will burn perfectly. Therefore this kind of situation makes
pilot for paramotor will suffer with the heat that produce from the engine because the
engine is only located at the back of pilot shoulder.

- Heavy in weight.

Combustion engine are heavy compared to electrical motor because it is

involve with too many equipment in the engine and it also involve with the fluid. In
one complete set of piston engine it will equip with piston, heavy duty crank case,
crank shaft, bearing, carburetor, fuel tank and etc. This will makes the engine heavy
compare to electrical motor.

- High frequency of sound from the combustion engine.

Since the engine is only located at the back of pilot shoulder, the solid sound
from the engine and exhaust will disturb the concentration of paramotor pilot. Every
movement and explosions inside the combustion engine will produce the loud sound.

18
Therefore in this situation all pilot must need a very good set of head phone to
communicate and it will cost them a lot of money.

- Produce smoke from engine.

Nowadays, global are keep talking about the green campaign, save the world
with the green engine. Most of all manufacturer its either automobile, marine and
aviation are brainstorming to produce the engine which can save the world without
any pollution produce. Automobile engineering are already come out with solar car at
the first stage and now on they start with hybrid car instead.

In this project, we are replacing the existing power plant which is piston
engine to an electrical motor. From here we can see that electrical motor will never
produce any smoke from the operation.

- Not safe during takeoff and landing.

According to the heavy weight engine that paramotor pilot have to carry
during flying. Pilot need to run during take off with heavy weight engine which can
expose them to an accident. This is also happened during landing. Paramotor pilot
must land with the same heavy engine which the maximum load will take by the pilot
foot. This kind of situation makes this kind of sport very dangerous.

fig.2.12 shows that few accident happened during take off and landing.

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2.6 OBJECTIVE OF THE PROJECT

Scope of the replacement the engine:

1) No noise produces

As we know that this electrical dc motor is only use battery for their power
source. In here we can see that no combustion occur and no exhaust needed which can
produce a very loud sound. With this kind of motor will make pilot feel very
comfortable to fly, no obstruction in communication during flight and they do not
have to get a very expensive communication system in order to illuminate the sound
from the engine.

2) Save the environments

Since there are no fuel, air and combustion will occur in electrical motor, so
automatically they are no hazardous smoke will produce. Therefore this will support
the campaign of save the world with no air pollution. Moreover this new system not
only save the environment but save the pilot itself during ground handling, take off,
cruise and landing.

3) Lighter in weight ratio

This electrical paramotor is only use one electrical DC motor with battery it
will reduce the weight of the paramotor itself. To compare with the combustion
engine, which require too many internal equipment and this kind of engine are also
involve with fluid as the power source.

4) Good for beginner

Beginners are always expect everything must be very simple and easy to
handle, so they can concentrate and perform every order from their instructor. There
are a lot of advantages by using this electrical motor for paramotor, for example less
sound. This can help beginner pilot can concentrate and get the information from

20
instructor clearly during take off cruse and landing. It is because communication is
very important in aviation.

Since the weight of the engine is less, the beginner pilot can easy to perform
the take off and landing because there are no excessive weight that will burden them.
Therefore this new system of paramotor are one of the thing that we can do in order to
develop this sport among aviator and also public.

2.8 PROJECT SYNOPSIS / SUMMARY

Specific Methods (Designing/Manufacturing) and Testing (If Used) Our

research in this project is to achieve the new technology which able to replace the
normal engine (piston), thus will able to do testing and collect the data for the new
engine system performance. Moreover, we really hope that Modenas would be able to
take part and share the technology to complete this project.

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 3.0 METHODOLOGY

3.1 FLOWCHART

START

Built the bench test Electrical

mounting Motor

Order the propeller
mounting

Bench test and the
Monitor & data collection
Review the
Result
Create few
questions for
survey to Pilot


Install to actual
paramotor

Engine ground
test (final)

Analyze the
engine
behavior

Pilot Test

Data
collection

END

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From this flow chart with define the problem in sports aviation which is general start
from paragliding, paramotor and ultralight aircraft. From here the obvious problem is
more coming from the paramotor. From here we are doing a complete research about
paramotor and in the same time as a research we are doing a demonstration flight with
real paramotor. From here we are able to collect the data which can classified as a pro
and also a contra of flying with this kind of aircraft.

Furthermore to support our research in this aircraft, we made a questionnaire

and distribute to professional and also student pilot. As a result more to disadvantages
of paramotor we keep continue to find the solution of the problem that occur. As in
chapter two, literature review have shown and support our research and also the result
from the survey that says conventional paramotor can produce a lot of harm to the
pilot, environment and also civilians.

Therefore, we are coming with new ideas to counter this problem by making
an comparison between combustion engine and electrical motor. Since the engine is
the main equipment which can makes paramotor fly, so we only focus on replacing
the combustion engine with the new system. The comparison between two engine
shows the outstanding result and they are a lot of differential between them.

Thus paramotor with electrical power will give more advantages to compare to
normal combustion engine. We do the further research on electrical motor until we
find a brand new motor bike that using electrical motor as a combustion engine
replacement. Fortunately, the motorbike is coming from the local company which is
Edaran Modenas sdn bhd. We make an affort to contact them to do a collaboration in
order to make this project succeed.

The next step of getting the engine system are moved by sending a formal
latter from university which endorse by Unikl MIAT Deputy Dean and MoU between
Unikl MIAT and Modenas. Now we are waiting for the result of the application.

When the engine is arrive we will do a bench test to get the data of engine
performance and the suitable propeller that can be use. In here also we can design the
correct engine mounting to connect to the paramotor frame. After that we will do the
test flight and get the few basic data which is climbing rate, air speed, weight and

23
endurance. From the pilot test we are able to do the actual comparison to the
conventional paramotor.

3.2 ENGINE RUN FLOW CHART

1 Mount the electric motor : The electric motor must be attach to the engine mounting
properly. In this area, the attachment must be able to sustain load from vibration of
the engine and propeller, also it can be able to take load from forward thrust.

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2 Final check :

- Bench attechment : before perform the engine running, double check

with all attachment of screw and bolt at the
bench test. Vibration that occur from the engine
running can loosen the attachment.
- Wiring Connection : wiring connection in the circuit is one of the
most critical parts. If the battery wiring is not
connect properly, one of the component in the
system will explode and damage. Make sure the
engine orientation will connect properly,
otherwise the motor will not turn or it will turn
other direction which opposite from the desire
direction of rotation.
- Propeller Mounting : propeller attachment must be monitor before
running, during running and also after running.
The material that being use to become a
propeller mounting and the propeller screw
mounting must be suitable. Propeller is turning
in a very high speed velocity, it can cause the
excessive centrifugal force and also forward
thrust.
- Gauge Attachment : To get an accurate reading, the gauge the
location of every gauge must be correct. The
wrong place of attachment will lead to
inaccurate reading because of obstruction,
improper place and etc. For example
TACHOMETER, the proper place of
attachment is perpendicular to propeller blade,
therefore it can detect the propeller rotation.
However, even the location is right for
tachometer, is still need something which can
act as a reflector and it must be attach to the
propeller facing to tachometer sensor.

25
 THERMOMETER; must be located near by
the equipment and it must be away from any
interference/ obstruction of other equipment.
The most critical device that need to be monitor
is the motor, wire, electrical speed control
(ESC) and each battery.
VOLTMETER; must be located at the positive
terminal at the battery. Therefore, the solid
battery voltage can be measured without any
losses from resistance in the circuit.
AMPMETER; also need to be located just after
the battery positive terminal. Inhere the goal to
monitored the battery behavior can be achieve.

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3.3 Equipment list

Bench test

Figure 3.1: Bench Test

To achieve an accurate reading for any data from the engine/ electrical motor,
the design of bench test is very important and it must be free from any
disturbance or excessive friction. Moreover the bench must be tough enough to
carry the load, weight, vibration, heat and high operation of engine. The bench is
like a real engine mounting because it can take all the forces that being produce
from the engine/ electrical motor its either idle, minimum cruise speed or the
maximum operation during take off or emergency.

A typical bench test, is usually very heavy and it is welded every metal piece to
ensure it is rigid and strong. It is also usually equip with a metal wheel and the
bench it self is very heavy and it is not portable. Therefore, here the bench design
must be user friendly and must be portable so that the operator may able to
bring elsewhere. The best design is, bench can be dissemble and assemble, and

27
the rigidity or stability is still remain. To simplify the process of installation,
every piece of bench parts have been mark permanently. The design must be
simple and easy to handle or to do the maintenance.

The bench must be versatile so that it can be use for another type of engine or
can be use to get as much data as possible. This may save a lot of cost and time to
complete the new task of data collection.

Bench test weight

Bench test are usually made with a heavy type of metal and as the resultant, the
bench test become very heavy and it is very hard to move to the different place.
For the normal bench test all the joining are attached with welding and the
structure become very rigid.

In this project, the bench test has been modify into a very simple shape and it is
portable. Every piece of the bench are able to dissemble and it is easy to carry to
any places. All the attachment has been done with bolt and nut. The bench
become very stable and rigid after all parts has been assemble and it is ready to
take load from any type of engine.

28
Steel roller

Figure 3.2: Steel Roller

The engine mounting for this bench test is attached with the steel roller which
shows in figure 3.2, therefore it will allow the engine mounting to moved
forward and backward. In order to measure the thrust that produce by the
propeller, the engine and the mounting must be able to moved when the
propeller is running. When it moved the whole thing will press the measurement
scale then the data can be recorded. In here the mounting roller and the track
must have a very less friction in order to get an accurate reading of the thrust
that produce by the propeller.

Steel roller and the steel pipe has been selected in order to use as a mounting
roller and a track instead of using a plastic or rubber roller. The lesser friction
that will produce from the roller the better and the thrust reading will be more
accurate.

29
Another type of roller:

Figure 3.3: Type Of Roller

Some of the roller are made by the plastic and the shape is exactly like a normal
wheel which it is require a u shape track to move. Some roller are made by the
rubber so both type are not suitable because too much friction between roller
and the track.

30
Early design for the bench test before finalize.

Bench test 1:

Figure 3.4: First Bench Test Design

This picture in figure 3.4 shows the early design of the bench test. This kind of
bench test is very simple and portable. This kind of bench test also easy to
handle but it is not versatile because it is limited for only tractor type engine.

However even it is portable, this kind of bench test is not independent because
the bench need something to hold it for example bolted wall or another solid
bench. From this kind of bench also, the operator require to have a special tools
to measure some specific data for example thrust.

31
Bench test 2:

Figure 3.5: Second Bench Test Design

The second bench test is also very stable according to a platform, also it is easy to
moved and easy to store. This kind of bench test is also good because it is
universal which can be use for another type of engine. Moreover this bench does
not require a special tools to do a measurement.

However the problem from this bench is, it is easy to tilt up when running a very
high speed engine. The tendency of the bench fall of is very high so it can be very
dangerous to the machine and also the operator. Therefore the safety wise from
this design is not that permissible.

32
Final design:

Figure 3.6: Final Bench Test Design

33
Pulley system

Figure 3.7: Pulley System

This electrical bldc motor is equipped with a pulley system which connect the
propeller mounting pulley and the bldc motor shaft pulley, shows in figure 3.7.
Both of this pulley is connected with a belting system which is more efficient to
compare with a chain. By using a belting system it can reduce a noise and
required no lubricant on it.

The reason why this propeller attachment is using the pulley system is because
of the rotating ratio. With this kind of system the rotating ratio can be various its
either 1:1 or 1:2 or etc. the operator can select which 1 is suitable for the safe
operation.

34
With a various ratio of the pulley system, the result also can be various which the
optimum operating rotation will be achieve. In here the aircraft can fly with the
safe operation and with the best performance.

Propeller mounting

Figure 3.8: Propeller Mounting

In this project the propeller mounting will be attach with 6 Allen key screw. In
figure 3.8 shows the typical paramotor propeller mounting. There are few
different method of attachment between propeller and the propeller mounting
which is bolt and nut. By using an Allen key screw it will be less equipment and
also less weight. But the propeller screw hole and the mounting tread must be
perfectly align. Otherwise one or two screw must be fail to fit in.

35
Electrical circuit

Figure 3.9: Complete Electrical Circuit

Before doing the engine test, the most important things is the electrical circuit
for this system. This kind of operation, electrical circuit must be connected
properly and the operator could not take for granted. Since the bldc motor are
operate with a very high voltage and current, all connection must be completely
perfect because the possibility of explosion is high.

In this project, the original circuit from the manufacturer cannot be use because
of there are too many accessory which attached at the main circuit for example,
lamp, reverse throttle, instrument and etc. In here the original circuit has been
modify and has been simplify.

If the connection is not in a proper way, the chances of battery damage are very
high2. Therefore, before the engine is set up, the complete circuit of this system
has been drawn and it is approve by the manufacturer (modenas).

36
Electrical bldc motor

Figure 3.10: Electrical Brushless DC Motor

The advantages of brushless D.C. motors are apparent in terms of speed,

response, reliability and power density3.
The primary advantages of brushless D.C. motors are:

Low Maintenance
No Brush Sparking
High Operating Speeds
High Efficiency
Compact Size
Fast Response

But brushless D.C. motors are not without their drawbacks. They are more
expensive due to their complex control system, the use of rare earth magnets and
the need for rotor position sensors. (Higher costs are overcome by a longer life
and lower maintenance costs.) They are primarily used in fractional horsepower

37
applications; however, they have been used as drives in electric vehicles up to
100KW.

This kind of engine is perfect for electrical aircraft because it is powerful and can
rotate the propeller to achieve the optimum thrust for flying. This electrical
motor is using a 52v to 60v for the normal operation so the power supply, which
is battery must be good enough to supply the maximum current.

The reason being of using bldc motor is because of the lighter weight to compare
to a normal combustion engine. The whole electrical bldc motor without the
battery is only 9 kg which normal combustion engine without fuel tank is 23kg.
In here it is prove that electrical bldc motor have save another 14kg of weight. As
we are aware that aircraft must be very light for flying to save more energy that
produce and can be last very long for the endurance.

Even the electrical motor have a lot of advantage such as light weight, no
pollution, less vibration during operating, less noise, ease for maintenance, cheap
and simple in construction, there is a few things that bldc motor cannot
challenge the normal combustion engine. The normal combustion engine can
achieve the maximum power any time regardless the fuel level, but for the bldc
motor, the maximum power is very limited and can only be achieve during first
20 minute.

After 20 minute of using the full throttle, the operation will be maintain to 45
minute then the rpm will drop rapidly but the electrical bldc is still operate but
in a very minimum power. So it is proved that the battery power will drop
rapidly when it is at the minimum operating voltage.

38
Construction

Brushless D.C. motors are most commonly constructed with a radially
magnetized permanent magnet rotor, mounted on a steel cylinder, and phase
windings wound on a slotted, laminated, non-salient stator. There are usually
multiple phase windings; however, a single winding can be wound so that its
distributed over the stator core. 6 This is the reverse of brushed D.C. motors
(rotating armature and stationary field) and allows brushless D.C. motors to
have less internal resistance and much better heat dissipation in the stator
coils 7 resulting in higher operating efficiencies since heat can more efficiently
dissipate via the stationary motor housing.8

Brushless D.C. motors do not use carbon brushes or a mechanical commutator;
rather, commutation is done via a complex electronic controller used in
conjunction with a rotor position sensor (e.g., photo transistor-LED,
electromagnetic or Hall Effect generators). 9 This is the primary reason why
brushless D.C. motors are low maintenance and non-sparking. In addition,
without brushes or a mechanical commutator, they have less shaft friction or
inertia, less audible noise and much better torque to weight ratios (power
density).10 Hence, they are much smaller in size than a comparable brushed D.C.
motor.

Operation

Brushless D.C. motors operate in conjunction with an electronic controller and a
rotor position feedback sensor. Based upon the actual rotor position, the
controller sequentially energizes or switches on the stators phase windings so
that torque is continuously generated as the permanent magnet (PM) rotor
rotates. 11 This switching action is called electronic commutation. To sense the
rotors angular position, position sensors are used. When the PM rotor passes
one set of phase windings, a signal from the position sensor is sent to the
controller which then sends a signal to switch on the next set of phase
windings so that the magnetic fields of the rotor and the stators phase windings

39
remain synchronized. The torque/speed characteristic of the motor is
determined by the magnitude of the signal and the switching rate of the
controller. 12

For example, in a 2-phase motor, when the phase 1 winding is energized, the PM
rotor will rotate to align itself with magnetic field produced by the phase 1
winding. When the phase 1 winding is turned off, the phase 2 winding is turned
on and the rotor will continue to rotate to align itself with the magnetic field of
the phase 2 winding. This on and off switching of the phase windings will
maintain torque of the PM rotor. 13

The number of windings and the type of switching sequence determines the
phase winding utilization and the torque response of the motor. Fewer windings
and fewer switching pulses give the motor less winding utilization, more inertia
to overcome and a poorer torque response. The most common configuration of a
brushless D.C. motor is three phase six pulse. 14 In this configuration, the stator
has three phase windings connected in a delta or star configuration with no
neutral. The windings are excited by 6 pulses sequentially with each winding
being switched by pulses of opposite polarity. This delivers a linear torque speed
characteristic, similar to a brushed D.C. motor. 15

Applications

Brushless D.C. motors are widely used in the fractional horsepower range for
disk or tape drives 16 for computer peripherals as well as in CD/DVD players,
cooling fans, laser printers and photocopiers. 17 In addition, they are often used
as spindle drives 18 in machine tools because they can be driven at very high
speeds with fast acceleration, deceleration and reversing responses. The larger
horsepower sizes have found application in electric vehicles. Since they do not
have brushes, hence, are not susceptible to arcing, brushless D.C motors are safe
for environments with flammable gases, such as in the petrochemical industry. 19

40
Torque

Since the resource and time is very limited, the torque produce cannot be
measured. However, here as the result from discussion and few reference, there
are two type of torque that appear which is mechanical torque and the electrical
torque.

Electrical motor torque is proportional to the product of magnetic flux and the
armature current. Mechanical or load torque is proportional to the product of
force and distance. Motor current varies in relation to the amount of load torque
applied. When a motor is running in steady state, the armature current is
constant, and the electrical torque is equal and opposite of the mechanical
torque. When a motor is decelerating, the motor torque is less than the load
torque. Conversely, when a motor is accelerating, the motor torque is higher
than the load torque. 20

41
Battery

Figure 3.11: Batteries Circuit

The battery that coming with the bldc motor is Nano gel battery. It come with
five stack of batteries and the connection must be in series. One stack of Nano gel
batteries is equal to 12V and the requirement for this bldc motor operation is
52v to 60v. So there must be 5 batteries that connected in series.

Nano gel is an advanced range of sealed-activated batteries, totally sealed units
supplied pre-charged and requiring no acid-filling to commission. Utilizing a real
gel electrolyte rather than liquid, the Nano Gel is able to cover the active plate
material more effectively, providing a larger effective surface area and
preventing lead from sulphation. The nature of Nano Gel provides maximum
cling to the plates which is able to withstand severe vibration and prolong
battery life.

Valve regulated lead acid batteries once activated, are totally sealed. This
eliminates spills and leakages, making them particularly suitable for
motorcycles, ATVs and personal watercraft. Each battery is supplied with an
easy-fill acid pack for activation, no further maintenance or topping up is

42
required. Robust and vibration resistant, maintenance free batteries last up to
three times longer than conventional batteries.

How batterys work

Motorcycle batteries contain individual cells, each one produces just over two
volts. Six-volt batteries have three cells and twelve volt batteries have six cells.
Each cell has stacks of lead plates which are alternately charged positive and
negative. The individual plates are separated by an insulator usually made from
treated paper or fibreglass. The lead plates in each cell are connected to each
other, positive to positive and negative to negative. Each group is then connected
to those in the next cell in series (positive to negative).

The clear fluid inside batteries (conventional, high performance and
maintenance free) is called electrolyte, a mixture of water and sulphuric acid. In
Gel Nano batteries this electrolyte is a gel rather than a liquid. The chemical
reaction between the lead and acid produces electricity. Electricity is produced
when the electrolyte in a battery reacts with the lead plates in the cells. The
sulphuric acid changes the lead into lead sulphate, and, in doing so deposits free
electrons on the positive plates.

These electrons cling to the plates until a load is placed on the battery, e.g. when
the ignition is turned on. At that time the electrons move from the positive
plates to the negative plates producing electrical current.
Charge and discharge cycle

All batteries have a limited lifespan as the cycle of charge and discharge that a
battery performs is finite due to the continual material loss from the plates
during the electro-chemical reaction. Over time a battery will lose its capacity,
this timescale will be less for high-usage motorcycles and vehicles.

43
Overcharging

A battery will be irreversibly damaged if it is subjected to an excessive charge by
a charger or by a faulty motorcycle electrical system. Overcharging can generate
heat which evaporates electrolyte, also damaging the plates by increased
material loss.

44
Electrical speed control

Figure 3.12: Electrical Speed Control

The purpose of this electrical speed control is to control the whole electrical and
engine system. Electrical speed control is acting like a computer box and all the
equipment is connected together.
The capacity of this electrical speed control is:
Working voltage : 60V
Throttle voltage : 1.2-4.3V
Maximum current : 70A
Cutoff Voltage : +12V
Degree : 120degree

45
Trike and paramotor body

Figure 3.13: Trike Complete Design

46
Measurements test

1. Rpm measurement
Test it by using G.T power rc tachometer.

Figure 3.14: RPM Instrument

G.T power rc tachometer is used to measured a propeller RPM from a remote

control. It seem this tachometer used in a very light aircraft which is UAV, it still
can be used in this project because the maximum RPM that this tachometer can
take is until 9999 RPM. Therefore the maximum operating RPM for this motor is
3500 4000 RPM.

Before used this G.T power rc tachometer, make sure the user read the operation
manual and understand the requirement to operate this instrument.

47
 2. Temperature
All the device temperature are getting with a portable pointer
temperature sensor.

Figure 3.15: Temperature Sensor

This temperature sensor is one of the best temperature gauge that can be used to
get a temperature at the all equipment. This instrument is act like a laser pointer
to get a temperature reading. This instrument is very handy, accurate and can be
done in a short period of time.

Since the size of this temperature sensor is small, it is become very easy to a user
to use it to get a temperature reading at any specific place or area. Before doing a
measurement, the best practice is the user must always calibrate the instrument.
Be advice that, always read the manual before use this instrument to avoid the
damage at this instrument.

48
 3. Voltage
Battery voltage is measured by using multi meter (voltmeter)

Figure 3.16: Multi meter to measure voltage

4. Current
Current is measured by using amp meter

Figure 3.17: Amp meter to measure

49
 5. Thrust
To measure the thrust, the simple way to get a reading is by using a
weighing scale. In here the weighing scale can shows the reading in kg or
pound. There are two type of weighing scale which is analog and digital.
The reading of the digital is almost accurate because it is not vibrate like
an analog scale.
However the problem of the digital scale is, it will lock the maximum
reading. Therefore the reading that can be taken from this instrument is
only a maximum thrust. In this kind of experiment, the BLDC motor must
be run in a maximum speed till the battery is drain out and the reading of
the thrust must be taken in a certain period of time.
To get a specific thrust measure in a certain time, the reading must be
taken by using an analog weighing scale. With this kind of instrument the
reading will be measured all the time and the operator may able to see
the different thrust in a certain period time.

Figure 3.18: Weighing scale

50

6. Friction test
To get an accurate reading for the thrust measurement, the friction
between roller and the track cannot be abandoned. Therefore the
measurement of the friction must be taken by using a spring scale. In
figure 3.19 below shows the digital spring scale that being used to
measured the friction which act at the bench roller.

Figure 3.19: Digital Spring Scale

51
 CHAPTER 4: RESULT AND DISCUSSION

4.1 Data Collection

Motor Temperature

Table 4.1: Motor Temperature

TIME (Minute) Motor Temperature (C)

0 28.6 C
< 9 30.0 C
10 38.4 C
20 40.8 C
30 40.6 C
40 39.6 C
50 36.4 C
60 34.0 C
70 32.8 C
80 32.6 C
90 31.8 C
100 30.8 C
110 30.6 C

The bldc motor temperature in this operation is not that critical because the
whole surface of bldc motor are more expose into the wind flow. During the
operation the propeller blade will rotate and in the same time will cool down the
engine.

52


Motor Temperature
45
40
35
Temperature (C)

30
25
20
15
10
5
0
0 <9 10 20 30 40 50 60 70 80 90 100 110
Motor Temperature 28.6 30.0 38.4 40.8 40.6 39.6 36.4 34.0 32.8 32.6 31.8 30.8 30.6

Figure 4.1: Graph (motor temperature)

According to the graph in figure 4.1, the engine temperature a very constant and
it is dont need an extra device tho cool down te engine during maximum
operation. The graph above also indicate that temperature during maximum
operation which is engine at full throttle until the batteries is no more power.

53


Motor RPM

Table 4.2: Maximum RPM

TIME (Minute) RPM

0 0
< 9 2940
10 2280
20 2070
30 1980
40 1950
50 1440
60 920
70 850
80 600
90 280
100 70
110 0
120 0
130 0

From the table 4.2 above it shows that the rpm of propeller during a maximum
operation which is at the time of full throttle. It is also shows that the maximum
propeller rpm Is about 2940. The bldc motor can be consider as very powerful
because the rotation after reduction pulley still can achieve almost 3000 rpm.

54
 Motor RPM
3,500

3,000

2,500

2,000
RPM

1,500

1,000

500

0
0 <9 10 20 30 40 50 60 70 80 90 100 110
RPM 0 2940 2280 2070 1980 1950 1440 920 850 600 280 70 0

Figure 4.2: Graph (motor RPM)

As we can see in the graph in figure 4.2 above, the motor can pick up to almost
3000rpm within less than 9 second and it is drop constantly after 10 minutes.
From here we can conclude that the disadvantage of bldc motor is, it is cannot
maintain the maximum power for a long time. The behavior of the motor is
100% depending on the power of the batteries1.

55
Thrust

Thrust
16

14

12

10
Trust (kg)

0
0 <9 10 20 30 40 50 60 70 80 90 100 110 130
TRUST 0 15.2 8.5 8.5 8.2 5.5 4 3.2 3 1.2 0 0 0 0

Figure 4.3: Graph (Thrust)

The behavior of the graph in figure 4.3 above is almost the same with graph of
the rpm. This graph shows that the thrust that acting during the full throttle.
According to this graph the maximum operating that this motor can achieve is
15.2 kg maximum power of thrust. This will shows that the typical operation of
electrical motor which is the maximum power of thrust cannot be maintain for
along time.

It is mean that when the battery power is starting to drop there are no more
chance to the operator to achieve the same maximum power after that. This is
the this advantages of using the electrical motor.

To compare to the normal combustion engine, the behavior of the engine is

totally different. Since the electrical motor performance is acting totally
dependence on the battery power but the normal combustion engine is against it.
The normal combustion engine can give the full power at the maximum thrust
when the fuel level is full. It is also can give the same power during the fuel level
at the medium level and the best is the combustion engine still can compensate

56
the pilot desire to get a full power at the moment of the fuel level in lower
position.

However this graph shows the behavior for the bldc motor at the maximum full
throttle from the beginning of the operation until the moment it stop. The
conclusion from this graph shows that the aircraft still able to fly safely because
for the normal safe flying the pilot only need a full power only during takeoff
which for the first 10 minute according to the maximum a/c weight. The rest of
the flying is only a normal cruise speed which the speed almost minimum.

57
Battery Voltage

Battery Voltage
70

60

50
Voltage, V

40

30

20

10

0
0 <9 10 20 30 40 50 60 70 80 90 100 110 120
Battery Voltage 64.3 57.5 57.5 54.9 52.4 52.3 52.3 52.3 52.3 52.3 52.3 0.31 0.25 0

Figure 4.4: Graph (battery voltage)

The battery voltage graph in figure 4.4 is totally different to the rpm graph and
also the thrust graph. From this graph it is prove the data from the manufacture
which is the electrical bldc motor can only work effectively from 60v to 52.1v
only.

Moreover the result from the battery manufacturer is almost the same. The
result could not be the same due to a few factor which is room temperature,
proper charging system, proper equipment during testing and also proper
equipment to get the measurement.

If both graph rpm and battery voltage combined, it can shows at the maximum
voltage what is the maximum rpm and at what range and time will the battery
voltage drop rapidly. The two graph can able to present a data of what happen
after the voltage drop rapidly, what had happen to the bldc motor. It is prove
that the bldc motor still can rotate the propeller blade but in a very minimum
power.

This kind of behavior is also shows the behavior of bldc motor is against the
normal combustion engine. For the normal combustion engine when the fuel is

58
finish the engine will stop immediately but for the bldc motor the propeller blade
still can rotate even the battery voltage is drop.

59
Device Temperature

There are three other graph in figure 4.5, 4.6 and 4.7 below which shows the
harness temperature, electric speed control temperature and battery
temperature. This three equipment is measured at the room temperature.

As we are aware the device are cost more then a thousand, it must always be
protected from any causes which can be a result of damaging the equipment.
Therefore temperature is considered one of the factor that can bring hurm to all
the equipment.

There are three component that always expose to the high temperature which is
wire (harness), battery, motor and electrical speed control. In this experiment,
the data from the device will be collected every 10 minutes and must be
recorded.

60
Wire Temperature

Wire Temperature
45
40
35
Temperature (C)

30
25
20
15
10
5
0
0 <9 10 20 30 40 50 60 70 80 90 100 110 120
Wire Temperature 24.6 27.6 36.6 39.6 34.4 27.6 26.2 26 25 25.2 24.6 24.6 24.6 24.6

Figure 4.5: Graph (Wire Temperature)

This aircraft is using 60 volt with 20AH of operating power. For this system is
considered as a very high operation. The proper type of wire must be used to
avoid the excessive current and excessive voltage moreover the wire also must
be able to sustain this amount of loading.

In figure 4.5 above shows the temperature of the wire (harness) during 2 hours
maximum operation. From the wire specifications, the wire can be operate up to
100 degree Celsius. Since the maximum temperature in this system is only at 40
degree Celsius, the wire is just perfect to use in this system.

Wrong wire selection can cause the battery terminals will burn and it can
damage the battery. Moreover if the wire is too small, the wire it self will burn
and no current flow and the system will never working.

61
Electrical Speed Control Temperature

ESC Temperature
35

30
Temperature (C)

25

20

15

10

0
0 <9 10 20 30 40 50 60 70 80 90 100 110 120
ESC Temperature 26 26.5 27.2 27.6 28 29.6 29.4 29.8 33 28.6 28.2 28.8 28.1 27.9

Figure 4.6: Graph (ESC Temprature)

This device is like a brain and it is also the main system that transfer the
electrical signal from throttle to the brushless dc motor. An electrical speed
control also know the motor turning orientation therefore, this device must be
operating precisely at all time.

Usually when operating in a high speed (maximum speed) and the voltage
amount is also high the most dangerous situation is, the temperature is too high.
Therefore, every single things in the system, temperature must be monitored at
all times.

From this graph at figure 4.6 above, it shows that even the system is operate at a
maximum speed all the time for two hours the temperature is quite consistence.
The behavior of electrical speed control is normal and still able to sustain the
load that being used at all time.

62
Battery Temperature

Battery Temperature
35

30
Temperature (C)

25

20

15

10

0
0 <9 10 20 30 40 50 60 70 80 90 100 110 120
Battery Temperature 27.8 28.4 28.8 29.4 29 28.4 28.4 28.2 28.2 28.4 28.6

Figure 4.7: Graph (Battery Temperature)

There are 5 batteries which is connected in series. The capacity of each batter is
12V and the total five batteries is 60V.During the experiment, the temperature of
every battery is taken in every 10 minutes and recorded.

In figure 4.7 above shows that, the average of five batteries temperature which is
taken every 10 minutes. During the experiment, each batteries are located side
by side but each battery temperature is different. This is because of the electron
travel and the friction occur.

63
 DISCUSSION

CHAPTER 5: CONCLUSION

From this project it is prove that a different characteristic between two kind of
drive terrain which is electrical bldc motor and a normal combustion engine. In
here also it will present that both have the advantage and disadvantage. To
choose which engine is better performance and what engine is suitable, the
objective of the project will determine which one better.

5.1 Engine
The characteristic of electrical bldc motor is dependable with the power of the
batteries. In order to get a maximum high performance power this type of engine
need a very good power source which is batteries.

Even this electrical bldc motor is dependable to the battery power, this motor is
very powerful and good enough to replace the combustion engine for the light
aircraft such as trike and also the paramotor.

5.2 Batteries
The batteries that being use is Nano gel type. The battery construction is almost
similar to lead acid batteries and the weight is too heavy. There are five stack of
batteries that being used and it is connected in series to achieve the workable
voltage.

The total weight of all five batteries is 30kg which is the weight is more then 10L
fuel weight for paramotor. This batteries has a good power supply but due to the
weight it will require more usage and it will drain more battery power during
take off.

The best battery for this kind of aircraft is Lithium Polimer. The battery power is
still in the same range but the weight is way lighter then nano gel batteries.

64

For this kind of aircraft the most important things Is the whole aircraft must be
very light. This is due to limited power resource from the battery. The lighter the
aircraft the lesser power needed from the battery and the longer time that the
aircraft can fly.

65
5.3 RECOMMENDTION

Proper battery

One of the reasons why this electrical aircraft invented is to reduce the
weight. Since the power is obviously lesser then a normal combustion engine,
this aircraft must be build as lighter as it can. Therefore, every single equipment
in this aircraft must be very simple and lighter in weight ratio.
In here, the proper type of battery is the most important, because this
electric motor is using a very high voltage and also a very high current. If the
user is using a normal lead acid battery, the weight will be increase because of
the size and also it need more then one battery. The normal lead acid battery 12V
the weight is about 7kg, and to suite with this aircraft operating voltage which is
60V.

Brushless Dc motor

In this project, to achieve the goal which can fly the aircraft with 1 man,
the high RPM and high torque are needed. Therefore the electric motor that
needed must be good enough to sustain such a requirement and the operation
must be on par with a normal combustion engine. Its hard to get a very good
motor but at least the electrical motor can achieve more then a minimum
requirement of flying.
Moreover the electrical motor must be heavy duty which can be operate
in a maximum operation at all time. The most important things is, the motor can
achieve the mission objective which is less maintenance and did not produce any
pollution. The motor must be able to pick up to rotate the propeller into a very
high speed rotation regards to a propeller proficiency.
The motor that being used in this project is brushless dc motor, which is
the most suitable and potential to fly this aircraft. The motor that being used
must also light weight and no other accessory which can add more weight to the
aircraft.

66
Pulley System

Pulley system can be considered as an accessory which can be used to
upgrade the engine performance. In this system, pulley can increase the
propeller RPM up to 7000RPM. With this amount of RPM and the propeller
efficiency, it can boost more power to this aircraft. It can help a lot during
operation especially during take off and also rapid climbing.
As an accessory the pulley system must be very strong and the most
important things is must be very light. Therefore, this pulley system must be
made by using aluminum. In this project the pulley system had been made by
using aluminum material and it is in a various size.


Propeller

Propeller is considered as the main component in this aircraft. In order to
fly and to achieve the best performance, the propeller must be very efficient and
sync with the RPM that produced by the electric motor. There are few propeller
characteristics that need to be consider before it can be used.
Before deciding which propeller is suitable to used for flying:
1) Propeller diameter: Propeller diameter is very important because the
larger the diameter the more force will be needed by
the motor to rotate the propeller. Moreover it will
drain more battery power and the battery will never
last long. When the motor have a too much pressure
regarding the extra force creating by the propeller, it
s still turning but in the mean time the system have
lost the motor efficiency. In here more forces
needed, more battery power, motor will worn out
and loss the efficiency.

67
2) Blade angle: Blade angle is the angle that will determine how
much amount of air that can be scoop with in one
rotation. The more angle of blade will be more
thrust that will produce by the propeller. However
even the greater blade angle can produce more
thrust, its still depend on the how effective is the
engine and the propeller. If the angle is too much the
engine will lost efficiency therefore if the propeller
have a less angle of blade and it can be rotate faster
by the motor it will make propeller will lost
efficiency.

3) Direction of rotation: Engine direction of rotation is depend on how the
connection of the electric speed control and the
engine. If the motor is rotate clock wise the propeller
must be made by the rotation of the clockwise and
vise versa. However the user must know the aircraft
is using what kind of engine is either tractor or
pusher. This will also determine what kind of
propeller needed.

68
 APPENDIX

BENCH TEST

ELECTRIC MOTOR

69

BATTERIES

70
 PULLEY SYSTEM

71
 PROPELLER

PROPELLER MOUNTING

72
 TRIKE DESIGN

73
 COMPLETE TRIKE

74


75
Abbreviation

1. Bldc = brushless direct current
2. A/c = aircraft
3. Esc = electric speed control
4. Etc = et cetra
5. Rpm = revolution per minute
6. UAV = Unman Aerial Vehicle
7. KG = Kilogram

76

3.2 SURVEY QUESTION

Questionnaire

1. Do you agree Paramotor is very dangerous because of the weight and the heat that
produce from the combustion engine?

a. yes
b. no

2. Do you agree that combustion engine from paramotor will produce a very loud
sound which can disturb the communication between pilot with other pilot or pilot
with ground crew?

a. Yes
b. No

3. Do you agree that the smoke produce from the combustion engine can be a
substance that pollutes air.

a. Yes
b. No

4. Do you agree paramotor can fly more then 1 hours but the pilot could not sustain
the vibration, sound and heat produce by the combustion engine.

a. Yes
b. No

5. Do you know that electrical paramotor can fly more then 3hours, lighter, less
vibration, no sound, no heat, no pollution and cheaper then combustion engine.

a. Yes
b. No

77
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78
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79