Electric Belite!

Discussion in 'The light stuff area' started by Farfle, Jul 14, 2017.

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  1. Jul 14, 2017 #1

    Farfle

    Farfle

    Farfle

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    Hello all, I purchased a Belite Ultracub in Feb of this year, and now that I have some progress, I am posting up some pictures, Enjoy!

    Specs:
    Motor: Zero ZF75-5
    Hp: 41hp cont, 54hp 5min
    Tq: 78 ft/lbs
    Base speed; 5808 RPM
    Reduction: 65-30 8mm toothed belt drive (2.2:1)
    Controller: Sevcon Gen4 size 4
    Battery: Farasis 29Ah pouch in 28S4P configuration for 12.0 Kwhr of storage

    Boxes! Very professionally packaged, and Old dominion freight did an excellent job of treating the boxes nicely from Wichita to Moscow, ID.

    [​IMG]

    [​IMG]

    Clecos everywhere!


    [​IMG]

    Cabin and tail temporarily mated:

    [​IMG]


    Temporary landing gear:

    [​IMG]

    More pics to follow
     
  2. Jul 14, 2017 #2

    Farfle

    Farfle

    Farfle

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    Reduction drive machining:

    [​IMG]

    Propshaft bearing tube. .065 wall 2.5" 4130 tubing holding a pair of 2" OD Tapered roller bearings.

    [​IMG]

    Prop mount flange:

    [​IMG]

    DIY rotary welding table makes good results! 4130 shaft welded to 4130 flange with 4130 filler rod. Will be sent out for heat treat and shot-peening.

    [​IMG]







    Mount flanges attached:

    [​IMG]

    Finished Re-drive:


    [​IMG]


    Spring-gear painted and installed:


    [​IMG]
     
    Last edited by a moderator: Mar 20, 2019
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  3. Jul 14, 2017 #3

    Farfle

    Farfle

    Farfle

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    Wing coming together:
    [​IMG]

    Wing temporarily mounted up! Looking more like an airplane at this point!

    [​IMG]

    Door!


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    Battery module one of two installed:

    [​IMG]


    Battery module two of two lives behind the seat:


    [​IMG]

    Both packs, we will see where the CG ends up. The front pack has some fore and aft movment, and the rear pack could be rotated 90 degrees if weight needs to move rearward.

    [​IMG]
     
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  4. Jul 15, 2017 #4

    Victor Bravo

    Victor Bravo

    Victor Bravo

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    Dude! Congratulations on a magnificent project and great progress!
     
  5. Jul 15, 2017 #5

    cheapracer

    cheapracer

    cheapracer

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    Nice.

    What does the Zero motor weigh please?
     
  6. Jul 15, 2017 #6

    Farfle

    Farfle

    Farfle

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    This zero motor (short stator, 5cm vs 7cm) weighs 29.5lbs with the cooling holes as shown.
     
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  7. Jul 15, 2017 #7

    Farfle

    Farfle

    Farfle

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    Thanks! Now just waiting on the machined parts. Belite is being slow about them :(
     
  8. Jul 15, 2017 #8

    saini flyer

    saini flyer

    saini flyer

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    Great project. Looking forward to see the first flight report. Good luck

    The Zero info I am providing is a few years old but good for reference.
    I dont think you can just buy a powertrain from Zero anymore. You need to be a dealer.
    Zero motor and controller spec sheet.jpg


    Zero Battery pack information.jpg


    Zero complete powertrain kit.jpg
     
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  9. Jul 15, 2017 #9

    cheapracer

    cheapracer

    cheapracer

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    Thanks for the reply, you're English is excellent!
     
  10. Jul 15, 2017 #10

    BJC

    BJC

    BJC

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  11. Jul 15, 2017 #11

    Farfle

    Farfle

    Farfle

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  12. Jul 15, 2017 #12

    cheapracer

    cheapracer

    cheapracer

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    :gig:

    From Idaho you say?

    Well in that case your English is outstanding!
     
  13. Jul 19, 2017 #13

    Authmion

    Authmion

    Authmion

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    Cant wait to see more progress! Especially with the Zero motor. I've heard of people using them, but never seen them in action. I also want to do electric.
     
  14. Jul 21, 2017 #14

    Richard6

    Richard6

    Richard6

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    Wow, great welding.

    Good luck with your project.

    Richard
     
  15. Oct 2, 2017 #15

    Farfle

    Farfle

    Farfle

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    The motor is up and running! Its angry!

     
    Last edited by a moderator: Mar 20, 2019
  16. Oct 7, 2017 #16

    etard

    etard

    etard

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    Haha, I thought I would find you over here. Great group of guys on here, very similar to ES.
     
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  17. Oct 9, 2017 #17

    Farfle

    Farfle

    Farfle

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    Got the first round of thrust testing and burn-in complete! Forgot to edit an amperage limit after a last minute firmware upgrade, so I left about 20% more power on the table. Will be headed back for more testing this weekend or next. Thrust was 600+ lbs at 9 degrees, but thats pitched for ~40mph. thrust decreased to 220 lbs at 14 degrees, so we settled at 12 degrees and 280lbs of thrust.

     
    Last edited by a moderator: Mar 20, 2019
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  18. Oct 9, 2017 #18

    Victor Bravo

    Victor Bravo

    Victor Bravo

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    Those numbers are about the best case I've ever seen for a controllable pitch propeller!

    600 pounds of thrust for takeoff on what is probably a 600 pound airplane, is just too good to pass up. You can give Dead Stick Steve a run for his money, by taking off uphill from the same hilltop he takes off downhill. THAT will be a "mic drop" moment! The youtube video revenue will pay for your airplane :)

    But if you can have a high pitch position that allows you to use a lot less current in between those VTOL maneuvers, that would give you some usable range for the type of back country flying that this aircraft will be used for.
     
  19. Oct 9, 2017 #19

    Farfle

    Farfle

    Farfle

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    Sadly its only a ground adjustable prop. Variable pitch would be awesome, although i am not sure if anyone makes a small variable pitch prop in this size range. It would be pretty easy to implement though, as the reduction drive could easily have a hollow shaft.
     
  20. Oct 9, 2017 #20

    Victor Bravo

    Victor Bravo

    Victor Bravo

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    Ivoprop and others have built electric variable pitch propellers. No hydraulics, no oil passages, nothing. Just electricity.

    Beech-Roby propellers are still around, you might pick up a used one of those and put in newer composite blades on their hub. I believe they are mechanically (manual) operated.
     

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