Optical sensors available for Astro, Turnigy, etc.

[Burtie]

Not complete kits, but pcbs, application notes and encoder images, to enable you to put together your own optical sensor setups

Rotary board (inside Astro or external shaft fitment).jpg (170.57 KiB) Viewed 2540 times

Linear board (for outrunners)

Misc encoder parts.jpg (248.23 KiB) Viewed 2670 times

Descriptions and demo videos of the parts are in the opto thread here:
viewtopic.php?f=2&t=28966&start=30#p434772

Sorry I can not walk though each individual installation with people, but
download the application notes /fitting guides here and have a go :

Astro (internal)

Fitting Astro optos.doc

(1.29 MiB) Downloaded 164 times

External rotary:

Fitting rotary opto sensor.doc

(1.83 MiB) Downloaded 166 times

Linear, for fitting to outrunners:

Fitting the linear opto sensor.doc

(1.39 MiB) Downloaded 207 times

The prices:

a) Rotary/Astro board 22 GBP
b) Linear (outrunner) board 18 GBP

I also have
c) 40mm metal disc and balsa spacer material to help with Astro installation @2 GBP
d) 40mm nylon discs and spacers to help construct your own external encoder wheels to work with a) @ 2GBP

Postage (no tracking) 5 GBP



PM me if you want any, we can sort the funds with Paypal. EDIT May 2013 --> Sorry, currently no boards available
Opto encoder images are available in the post below

Burtie

[Burtie]

Rotary encoder images for 8, 14, 20 and 24 magnet motors

Download the full size image (click to expand it -should get 937x1465 pixels), save it, and print it A4 on a Laser Printer using 'best fit to page', should get you pretty close.
Not sure about american paper sizes
You need to fix the image to a 40mm disc to work inside an Astro, I probably have some 40 mm metal discs with a 13mm (1/2 inch) hole if you need.
I also have various nylon parts (spacers +discs) which can be combined to make hubs to for external rotary encoders.

Note
1) You need to use a laser printer, inkjet printouts will not work with these IR sensors, the black portions are too reflective.

2) The black segments are deliberately a few degrees wider than the white ones. This is to compensate for the slightly uneven characteristic of these sensors in this application.



Here is a set of images for the linear encoder, for 14 magnet outrunners

7set.jpg

Linear (Strip) encoder images for 14 mag outrunners

(54.59 KiB) Downloaded 4 times

For the 80mm Turnigy outrunners, resize the image using your printer options -try the printer settings below:
(Landscape, custom size: 26.50 wide, 18.90 high)

Printer settings strip.jpg (119.8 KiB) Viewed 2589 times

For different size outrunners, you will have to work out how to resize it yourself

Single linear images:

Linear14.jpg

Linear encoder image for 14 mag outrunners

(28.59 KiB) Downloaded 4 times

For 80mm motors, print Landscape 3.7cm high x 25.71cm wide
For 63mm motors, print Landscape 3.7cm high x 20.28cm wide

Linear20.jpg

Linear encoder image for 20 mag outrunners

(26.46 KiB) Downloaded 4 times

Linear24.jpg

Linear encoder image for 24 mag outrunners

(28.79 KiB) Downloaded 4 times

here is a link to a linear28 image for 28 magnet outrunners (thanks Tsjoechov)
viewtopic.php?f=2&t=28966&start=75

Have fun,
Burtie

[STGMT]

Can you make a "kit" with the encoder, sensors board, fixing and all stuff for the turnigy 80-100 ? I want one!

[liveforphysics]

Burtie- I love your work! Optical is so immune to the flux-noise issues and hall distance issues. This is so great! You are really a major contributor here, solving issues one after another with clever solutions. I am so fortunate to have you here Burtie. You rock!

[grindz145]

Hell yeah! Just made off the shelf outrunners that much more viable. Woohoo!

[Arlo1]

Thanks burtie!!!!

[Burtie]

Thanks for the encouragement guys!

Can you make a "kit" with the encoder, sensors board, fixing and all stuff for the turnigy 80-100 ? I want one!

I think most of what you need is now here my friend, I have added the encoder images in the 2nd post.

Burtie

[addicted2climbing]

Hello Burtie,

Wow this is great to see and I was just about to design in some external hall sensors to my outrunner. However after seeing this, I may change that. I could easily fit your external version, but curious if it would be possible to fit an internal version or a smaller version of your design. I have attached a Jpeg that shows where I would like to fit one of your boards. I am pretty sure I could not fit your stock one, but any chance I could get one specially made to fit between my motor and sprocket? I could design my own mount to hold the black and white flags, and then give you a PCB size with sensor locations to fit in a pocket I machine in the swingarm... I am sure you dont have time for customs,but curious if one could be made with prototyping boards...

If not, can I get a dimension of your external board so I can design it in... Only thing I fear is the external one woudl have issues with dirt on the motor and this will be used in the dirt... Having it hidden in the swingarm would be a much cleaner environment..

The motor is an Aeleon 6354-250KV...

Take care,

Marc

[Burtie]

Hello Burtie,

...I could easily fit your external version, but curious if it would be possible to fit an internal version or a smaller version of your design. ... I am sure you dont have time for customs,but curious if one could be made with prototyping boards...

If not, can I get a dimension of your external board so I can design it in... Only thing I fear is the external one woudl have issues with dirt on the motor and this will be used in the dirt... Having it hidden in the swingarm would be a much cleaner environment..

The motor is an Aeleon 6354-250KV...

Hi Marc,
I can't do 1 off pcbs because of the time/cost, but I can give you the measurements of the ones I have:

Linear board is 51mm x 24mm (could be trimmed down to 43mm x 24mm)

Rotary board is about 51mm square with a 25.4mm (1 inch) hole in the centre


You probably need to protect your outrunner motor from water/dirt to make it reliable, so external linear sensor may not be a bad idea?

Best regards,
Burtie

[mwkeefer]

Burtie,

You are the MAN! After some trial and error on an old (expendable) motor, I finally got the optical solution working quite nicely and now here I find the optical for my Turnigy and Hyperion motors... Excellent!

-Mike

[Burtie]

Good to hear you got it working ok Mike


I have added some more encoders to the 2nd post in this thread, to support 20 and 24 magnet motors.

Burtie

[Burtie]

Just a bump to keep the thread alive..

I just made up a few more boards if anyone wants one to play with, they are ready to go

green things.jpg (94.5 KiB) Viewed 2071 times

Burtie

[Arlo1]

Just a bump to keep the thread alive.

I just made up a few more boards if anyone wants one to play with, they are ready to go

green things.jpg

Burtie

Uhmmmm... Im broke But I have decided this is the way to go for hi power BLDC! So You will be hearing from me soon.
DO you have something with timing avalible for WYE for colossus instead of Delta? Or something that can be switched back and fourth?

[Burtie]

DO you have something with timing avalible for WYE for colossus instead of Delta? Or something that can be switched back and fourth?

Arlin, sorry to hear you are broke, --being broke sucks ballz

The sensors and encoder are the same for delta or wye configurations. The only thing that changes is the ideal position of the sensors relative to the encoder.

To get best efficiency in both modes you could use two sets of linear sensors positioned at different points, reading the same encoder strip.
Or two rotary sensor boards, reading both sides of an encoder disc.

The switch between one set to the other could be accomplished using simple logic gates.

[Arlo1]

DO you have something with timing avalible for WYE for colossus instead of Delta? Or something that can be switched back and fourth?

Arlin, sorry to hear you are broke, --being broke sucks ballz

The sensors and encoder are the same for delta or wye configurations. The only thing that changes is the ideal position of the sensors relative to the encoder.

To get best efficiency in both modes you could use two sets of linear sensors positioned at different points, reading the same encoder strip.
Or two rotary sensor boards, reading both sides of an encoder disc.

The switch between one set to the other could be accomplished using simple logic gates.

Yeh I was thinking one board with 6 sensors on it. 3 for WYE and 3 for DELTA , Hmmm I need to learn to make pcb! Ok thanks Burtie. And I wont be broke for long. Just till a little while after christmass this is my slow season fixing motorcycles, the ATVs and Snowmobiles help but there is less of them.

[Burtie]

Bump to stop the sale thread timing out....

[comradegerry]

Nice work Burtie, your contributions to the Sphere are legend.

PM Sent.

Gerard

[dumbluck]

Awesome work I will take some. pm sent

[Burtie]

Thanks very much for the appeciation



While testing out boards for some orders recently, I made this short clip showing how the sensors are affected differently by flourescent and incandecent light.

http://www.youtube.com/watch?v=s0T_YolNWy8


Burtie

[www.recumbents.com]

I'm working on adapting the burtie board to an Astro 3210, using a MKII-LYEN EDITION-12 FET 3077 MOSFET controller. Battery will be 44V LiPo.

I used a polycarbonate plastic washer that I made as a spacer for the washer that the black and white timing image is mounted to, and glued it all together with JB weld. My motor did not have a balancing blob, or if it did it is gone now, so I didn't need to worry about clearance for that. Hopefully balance will be ok. I used a punch to reduce the ID of the washer rather than using tape to fill the slight gap. I'm working on wiring it all up now. I'll post pictures and stuff when I have something working.

Started a new thread to document the build: viewtopic.php?f=28&t=39035

-Warren.

[Burtie]

Would be great to see your work Warren.

New thread might be best to document your project. These threads in the sale section are a bit temporary and dissappear if not regularly used.




Edit:
Warrens thread is here
viewtopic.php?f=28&t=39035

[wojtek]

im very exciting to get one and try to install on my 4 turn wye 3220 as i was unlucky with HV160 controller

[kevo]

Bertie,
I would like to order two of these when the next batch is available (Astro 3210 10t).

[wojtek]

i have received the sensor board! paid on Friday and got it on Monday!

many thanks for fast shipping much appreciated!

the board is sent with heavy duty envelope and additionally protected with cartoon box inside. Great job!

[MattyCiii]

Burtie,
Are these back in stock? I'd love to order one or more if so.