ESC Survival Guide: Preventing Failures for Ultimate R/C Performance
Electronic Speed Controllers (ESCs) are, as we know, essential components in the world of remote-controlled vehicles .The main function of an ESC is to receive signals from a control source, such as a radio transmitter or a microcontroller, and then adjust the power supplied to the motor to regulate its speed and direction. ESCs are essential components in these systems, allowing precise control and smooth operation of the motor.
ESC’s are typically composed of several electronic components and may vary in their specific design and construction:
Printed Circuit Board (PCB): The main structural component of an ESC is the PCB. It serves as the platform for mounting various electronic components and provides the necessary electrical connections. The PCB is often made from fiberglass with copper traces to conduct electrical signals.
Microcontroller: ESCs contain a microcontroller or microprocessor that handles the control algorithms, interprets signals from the input device (such as a receiver in remote-controlled applications), and regulates the power supplied to the motor. This microcontroller can be a central component of the ESC.
MOSFETs (Metal-Oxide-Semiconductor Field-Effect Transistors): These are electronic switches that control the flow of current from the battery to the motor. They play a crucial role in modulating the speed and direction of the motor. The number and quality of MOSFETs can vary depending on the ESC's power handling capability.
Capacitors and Other Passive Components: Various capacitors, resistors, and inductors are used to filter and stabilize the electrical signals, reducing electrical noise and ensuring smooth motor operation.
Connectors: ESCs have connectors for power input from the battery and motor output connections. The type and size of connectors can vary based on the specific application and voltage requirements.
Heat Sink: Many high-power ESCs, especially those used in high-performance RC vehicles, may include a heat sink to dissipate heat generated during operation. This helps prevent overheating and ensures the ESC functions efficiently.
Protective Casing: Some ESCs are enclosed in a protective plastic or metal casing to shield the electronics from environmental factors and physical damage.
Wiring and Solder Joints: Various wires and solder joints are used to connect the components on the PCB. These connections need to be well-designed and robust to handle the electrical currents and voltages involved.
Even with the use more durable and efficient components ESCs can fail for various reasons and understanding these failure points is crucial for both beginners and experienced hobbyists. In this blog post, we'll delve into the common causes of ESC failures and discuss how to prevent them.
Battery Polarity Reversal:
One of the most common reasons for ESC failure is connecting the battery leads in reverse. This mistake can lead to a short circuit that can damage the ESC's internal components. Always double-check the polarity before connecting your battery.
One easy way to help avoid battery polarity reversal is to label your batteries: Use a permanent marker to label your batteries clearly. Write "+" and "-" signs on the batteries themselves. This will make it easy to identify the polarity.
We’ve also found these cool polarity stickers via Google: https://www.rccarstars.com/rc-maintenance-blog/the-importance-of-polarity-stickers-on-inboard-lipos
Excessive Current Draw:
Excessive current draw in an RC (radio-controlled) car setup refers to a situation where the electrical components in the vehicle are pulling more current (amperage) than they are designed to handle. This can have several negative consequences, including:
Overheating: Excessive current draw can lead to overheating of the electrical components such as the motor, ESC (Electronic Speed Controller), and battery. Overheating can cause permanent damage or reduce the lifespan of these components.
Reduced Efficiency: Drawing more current than necessary can reduce the overall efficiency of the RC car. This means that the power from the battery is not being used as efficiently as it could be, resulting in reduced performance, increased strain on electrical components, and shorter run times.
Battery Stress: High current draw can put stress on the battery, which can cause a short in the battery (and fire!), or excessive heat which will shorten the lifespan for the battery. It can also cause a drop in voltage, affecting the performance of the vehicle.
Reduced Run Time: Excessive current draw can lead to shorter run times on a single battery charge, which can be frustrating for RC enthusiasts.
Component Damage: Prolonged and repeated excessive current draw can lead to damage or even failure of electrical components, including the motor, ESC, and other electronics in the car.
Safety Concerns: In extreme cases, excessive current draw can pose safety risks, such as the risk of fire or other electrical hazards.
DEEP DIVE: What exactly causes excessive current draw??? It is caused by various factors, let’s review them:
Mechanical Resistance: Excessive friction in the drivetrain, such as dirty or damaged bearings, or a misaligned transmission, can lead to increased current draw as the motor has to work harder to overcome the resistance.
Binding or Sticking Components: Any components that are binding or sticking, such as suspension parts, axles, or gears, can cause the motor to draw more current than normal.
Low-Quality or Worn Out Components: Low-quality or worn-out parts, including tires, shock absorbers, and bushings, can increase rolling resistance and result in higher current consumption.
Incorrect Gear Ratio: If the gear ratio is not appropriate for the type of driving you're doing (e.g., off-road versus on-road), it can cause the motor to work too hard, drawing excessive current.
Overloading the Vehicle: Adding extra weight to the RC car, such as larger batteries, can increase the current draw, as the motor has to provide more power to move the added mass. Or using too small of a motor, battery and/or ESC.
Battery Issues: A worn-out or damaged battery with a reduced capacity can cause the motor to pull more current to achieve the desired speed or performance.
Motor and ESC (Electronic Speed Controller) Mismatch: Using a motor and ESC combination that is not properly matched can result in excessive current draw, as the ESC may not be able to handle the power demands of the motor.
Electronic Issues: Faulty electronics, such as a malfunctioning ESC, receiver, or servo, can cause erratic behavior in an RC car and lead to increased current draw on the ESC’s BEC.
Tire Selection: Using the wrong type of tires for the terrain can result in poor traction and increased current draw as the car struggles to maintain grip. Increasing the tire diameter or weight will increase current draw.
Driving Style: Aggressive driving, rapid acceleration, and constant full-throttle operation can cause higher current draw, especially if the motor and battery are not designed for such demands.
It's important to consult the manufacturer's specifications and guidelines for the motor, ESC, battery, and other components to ensure that you stay within their recommended current limits. Additionally, monitoring the temperature of these components (Keep ESC and motor temps UNDER 200°F, preferably 180°F or lower; LiPo batteries should not exceed 130°F) during operation can provide a practical indicator of whether excessive current is being drawn, as overheating is often a visible symptom of this issue.
**It is always useful to have one of these infrared thermometers on hand, they are specially designed for use with R/C engines, motors, battery packs, battery chargers, electronic speed controllers, as well as hundreds of other applications. To use, simply aim the infrared thermometer at the target and press the measurement button to quickly and easily display the surface temperatures.
High Battery Voltage:
Using a battery with a voltage higher than the ESC's maximum rating (IE: running a 6s pack with a 4s capable ESC) can result in catastrophic failure. Always match your ESC's voltage rating with the battery voltage to avoid overloading the ESC. (Exceeding a motor’s voltage rating can result in overheating, or even catastrophic motor and/or ESC failure.)
Insufficient Cooling:
Heat is the enemy of electronics, and ESCs are no exception. Inadequate cooling can cause the ESC to overheat and fail. Ensure proper airflow and consider adding additional cooling mechanisms like heat sinks or fans for high-power setups. High-quality batteries, optimal gear ratio, added ventilation and proper maintenance (dirt and debris removal) can help ensure a cooler running vehicle as well.
Excessive Ripple Voltage/Current:
High ripple voltage or current in the power supplied to the ESC from the battery can lead to instability and ESC failure. To minimize ripple, use high-quality batteries with a low internal resistance and ensure your power connections are secure and free from interference.
Many of the Castle controllers have the ability to measure and record battery voltage at the beginning and end of the FET cycles and display that voltage swing in terms of volts in the Castle Graph Viewer program on a Windows PC (or mobile phone). Ripple voltage should be 5% or less during normal operation and 10% or less during extreme maneuvers. Anything over this is too high. To measure this, divide the ripple measured by the ESC by the nominal voltage of your battery pack.
Note the nominal battery volts is 22.2v (6s), but ripple voltages spike to 3.68v; this is ripple over 16%, which will stress the capacitors on the ESC and shorten the life expectancy (3.68 / 22.2 = 16.57%)
Long Battery Leads:
Excessively long battery leads can increase resistance and result in voltage drops, reducing the ESC's efficiency. Whenever possible, keep all wires, especially those between the motor and the ESC, as short as possible. We recommend that you do not exceed more than 18 inches of total wire between the battery and ESC (this includes the wire already on the ESC and battery).
Improper Wire Gauge and Connectors:
Using wires that are too thin or connectors that cannot handle the current can lead to voltage drops and overheating. Always use the recommended wire gauge and high-quality connectors for your setup.
Poor quality battery connectors can be a roadblock to performance. Avoid the common “white plastic” connectors seen on many battery packs. A high-performance brushless setup will draw many times the power that these connectors can safely handle. Invest in connector sets made for high-powered electric systems such as our CC Bullets, Castle Polarized Connectors, or QS8 antispark connectors. .
High strand count silicone coated copper wire is essential with higher power electric power systems. Castle Creations' wire is lower resistance than the same diameter of solid copper, meaning more power gets from the batteries to the motor with less wasted as heat. The ultra-high strand count and silicone coating means the wire is very flexible which prevents work hardening and breakage with use.
Bottom line: Use the best batteries and connectors that you can find. The better the batteries, the more punch, runtime, and the more power to the ground your Castle system will have.
Improper Soldering:
Poor soldering can cause intermittent connections or shorts, leading to ESC failure. Make sure to use the correct soldering techniques and inspect your solder joints for any issues.
When soldering connectors ensure of the following:
1. Use a high-quality soldering station. Soldering stations usually have a variable temperature control which lets you set the right amount of heat to be used. Too little heat will result in a cold solder joint; too much heat can seriously damage a component. The key factors in quality soldering are time and temperature. For most R/C projects we are in the 350° - °400 C (660° F - 750° F) -degree range; 100+ Watts is recommended.
2. Use a high-quality rosin core solder. The rosin core solder is infused with flux which helps clean the surfaces you are soldering for better adhesion.
3. Do not exceed more than 18 inches of total wire between the battery and ESC (this includes the wire already on the ESC and battery).
4. Do not solder wires directly to the circuit board. Doing so will damage the ESC and void the warranty.
5. Our wire is available for purchase and this link provides the appropriate wire gauge for your Castle ESC. http://www.castlecreations.com/wire-application-chart
Let us know if you’d like to see a video tutorial on soldering!
Exceeding BEC Limits:
The Built-in Battery Eliminator Circuit (BEC) in many ESCs provides power to the receiver and servos. Exceeding the BEC's limits by connecting too many high-power servos or devices can cause voltage drops and affect the ESC's performance.
If you're experiencing brown-outs, glitching, or slow actuating servos it may be time to try an external BEC (Battery Eliminator Circuit). This scenario can occur in an application which uses high powered servos (or additional torque increasing modifications), where the ESC does not have an internal BEC, or the existing internal BEC is simply inadequate.
A BECs primary purpose is to draw voltage from the motor batteries and drop it to a voltage level that is suitable for your receiver and servos. Simply put, an external BEC will provide clean and constant power and ensure you are not underpowered.
Installing a BEC is pretty easy, assuming you don’t mind a little soldering. Our BECs include wiring instructions.
What to know a quick test to ensure your external BEC can safely operate everything you have it powering?
Step 1: Disconnect the motor.
Step 2: Turn on your transmitter and plug in a freshly charged battery pack (the same one you’re going to use the CC BEC with).
Step 3: Exercise all servos (turn on/off other devices) simultaneously for 20 seconds. If you see the servos slow down to a crawl or stop, or the LED on the CC BEC is flashing rapidly, you are exceeding the current level the CC BEC can safely handle.
You can learn more about Castle BECs here: https://home.castlecreations.com/becs
Conclusion:
Electronic Speed Controllers are critical components in RC vehicles and drones and understanding what makes them fail is essential for a smooth and enjoyable hobby experience. By avoiding common pitfalls such as reverse battery connections, excessive current draw, high voltage, and improper cooling, you can extend the lifespan of your ESCs and enjoy trouble-free operation. Always refer to the manufacturer's documentation for specific guidelines and recommendations related to your ESC model and take care to follow best practices when setting up your electronic speed controller for your RC adventures.
By surviving a 12-hour minimum event, the COBRA 10 earned the coveted “Recon G6 Certified” emblem!