Saturday, January 28, 2017

EMG-6 "Shop Notes" January 2017

"EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.



January 30, 2017

For the last 16 days straight we have been engaged in a light sport repairman maintenance class.  This is one of the smallest classes that we've ever had. Four of the students that signed up for this class had to pull out for various reasons just before the start of class. The wintertime classes are always limited to  a maximum of 12 to accommodate the facilities during the cold winter months. As it turned out the best day, weather wise, of the entire class was the last day. All of the students graduated with flying colors and will now move on to utilize their FAA light sport repairman maintenance certificate in different ways. Although this was a small size class of only 8 students, they came from pretty much every corner of the United States. And unlike a normal class, we had no foreign students this time. The next class will be in May and is already starting to fill. This is the 1st class that we have taken the class photo with a drone.



Brushless DC Motor (How it Works) Videos

Brushless DC Motor (How it Works) Videos







Sunday, January 22, 2017

Low Cost Hydroforming (Video)



Low cost hydroforming on the Rainbow Aviation Video channel with your host Brian Carpenter. In this episode were going to be taking a look at a low cost way  to manufacture your own aluminum hydro-formed  parts. This is a companion video for technically speaking article published in the May 2016 sport aviation magazine

Saturday, January 14, 2017

Dan Kokenge Design

An email came across my desk today. Thought I'd share it. Innovative ideas going all over the place these days.

January 26, 2017



Wow! I saw your video. I thought I was the only one working on this. 
I agree that electric is the way to go. The military has pretty much said that all new craft will be electric.

Friday, January 13, 2017

Builder Ed. Santucci S/N 16-027 North Carolina

  Builders  Ed. Santucci S/N 16-027 North Carolina


January 13, 2017

Ed's latest Pictures




Tuesday, January 10, 2017

Lift Strut Attach Fitting (Video)

53-10-50 Lift Strut Attach Fitting Video

In this video we go through the installation process of the lift strut attach fittings on the fuselage frame.

Monday, January 9, 2017

Seat Support Tubes (Video)

Seat Brace Tube Installation

P/N 53-10-02-106  and P/N 53-10-02-107 Tube installation onto the fuselage frame.



Sunday, January 8, 2017

Ultraflight Batteries Donald Lineback

 "Donald Lineback" Batteries


  Donald Lineback and his latest E-Mail.

 January 7, 2017

  News about what to buy: 

 Before looking at batteries - consider the voltage current demand. Let’s compare voltage to gasoline. One gallon of gas contains 33.7kWh energy according to EPA or 33,700Wh. How big of battery would that be? An NCM Lithium-Ion pack would be 33.7kWh, 172 cells, 635v, 107Ah and weigh 927 pounds. If you factor in the fact that the average car only gets 23% of that energy - the battery pack would still weigh: 213 pounds. So adding a big current demand is not good. Nor is it a good idea to equate the battery pack weight to 5 gallons of fuel in ultralights. ("apples to apples”)

For Sea-Kite.com the number one incentive was to build a highly efficient motor and use less energy. It has been easy for some motor designers to make high kW demanding motors. The problem - airplanes just couldn’t carry enough batteries. Big motors also disqualify themselves to be used with solar and other power supplies like fuel cells. 

What is the best battery and what on the “drawing board?” As for the future - higher energy batteries can be made, but they are only good for 3 or 4 charges and need to be scraped. The batteries that Tesla has been using, sourced from Panasonic, for its Model S electric cars are mostly likely a lithium-ion battery with a cathode that is a combination of a lithium, nickel, cobalt, aluminum oxide. The battery industry calls this an "NCA battery" and they've been around - and made by Panasonic, LG and Samsung - for many years.

Typically, lithium-ion NCA batteries use a combination of 80% nickel, 15% cobalt and 5% aluminum. (The anodes in these traditional lithium-ion batteries is usually a graphite combination, which acts as a host for the lithium ions.) The addition of the aluminum to the NCA battery makes it more stable.
For a home battery grid - Musk said that Tesla will use a lithium-ion battery with a nickel, manganese, cobalt oxide cathode called an NMC (or NCM) battery. Many traditional NMC batteries use one-third equal parts nickel, manganese, and cobalt.

Where do we stand among all the choices? NCM still reigns as king for safety and it works great for cars that handle the slight increase in weight. We have found a new source for the NCA which offers the weight savings needed in aviation. As soon as we have all the numbers - they will be posted on our website. Our new motor has an advantage because with a slower charge time, lower discharge demand and our new Active BMS - the safety went way up. 

Here is some info to help in your calculations:
Note: 1kW = 1000W. To find Ampere hours - Watt hours ÷ Voltage.  
kWh (1000Wh) is unit to measure total energy stored in battery and it can be calculated as battery voltage multiplied by Ah (V*A*h = Wh). In general kWh is unit to measure energy used.
Voltage is similar to water pressure like the height of the dam or water tank.
Current is the flow-rate of water.  
A battery rated for 100 amp hours will provide 5 amps for 20 hours.
If we have a 12 volt battery, we multiply 100 by 12 and determine that the battery will provide 1200 watt hours.
To apply the metric ‘kilo’ prefix, we divide the result by 1000 and determine that the battery can supply the 1.2 KW hours.
In the case of our 1200 Watt Hour conversion, we need to understand that what is really being said is that the battery will provide 60 Watt Hours for 20 Hours.

Sunday, January 1, 2017

Top 10 apps for the aircraft builder. Sport Aviation / Experimenter "Technically Speaking" Article December 2016

Top 10 apps for the aircraft builder


“There’s an app for that.” This overused cliché becomes more and more apropos every day. Even for the aircraft builder, we now have a virtual toolbox in our pocket that has become indispensable. We have reached the point in technology where it is now the norm for an aircraft manufacturer to publish maintenance manuals, parts manuals, and all other documentation, for that matter, in a digital format. If you’ve grown up on paper, the transition to digital can sometimes be difficult, but the rewards are well worth the effort.


#1 The PDF Reader App:(Figure: 1) The Rotax manuals, for example, consists of literally thousands of pages spanning more than a dozen different manuals. The ability to use a search function on a 500-page manual can really speed up the process of locating the information that you’re looking for. In our shop, we have a library of aircraft maintenance manuals accumulated over the last 40 years.