Finding matching motors for the selected power supply and propeller
Comparing motors and propellers

The user may select either a constant voltage or specific cells as the 'Power supply'. If 'Constant voltage'
is selected, the voltage is entered into the volts 'V' input box by highlighting the default voltage number,
typing the desired voltage and pressing the Enter/Return key or the Tab key. The voltage may also be
changed by dragging the mouse cursor in the diagram area.
The type of cells making up a battery pack may be selected from the popup menu list. Once a specific cell
type has been selected, the number input box changes to 'cells'. The number of desired cells is entered into
the 'cells' input box. When specific cells are used, the voltage under load and combined weight of the cells
appears to the right of the 'cells' input box.
When a battery type has been selected from the menu and the number of cells entered into the input box,
Drive Calculator will display the wide open throttle (WOT) flying time. Your mileage may vary, of course,
according to the type of plane and the pilot's flying style. With a light plane and an efficient drive you may
easily achieve much longer flying times. At half throttle the power consumption is usually less than a
quarter of that at
full throttle.
The Total weight indication will be computed from the cell weight and the number of cells, the weight of the
ESC, the motor, and the gear box, if the information is available in the database. If no weight information is
indicated in the respective component's area, it will also be missing in the total weight. Propeller, hub,
connectors, cables, and mounting parts are not included.

Users, who are not familiar with the metric system, may prefer to have the values converted to
imperial/English units. Drive Calculator will convert grams, mm, cm, m, km, degrees C, etc. to the
appropriate units upon a right mouse click on the respective number. In addition, a bi-directional converter
is accessible
in the Drive Calculator 'Tools' menu. Symbols you may not be familiar with are explained in a
help tag that opens on mouse rollover.
The output data may be viewed in two different graphs displaying either the motor data or propeller data.
When the radio button to the left of the motor popup list menu is selected, the graph displays motor data.
When the radio button to the left of the propeller popup list menu is selected, the graph displays propeller
data. A third graph view, also displaying propeller data, becomes available once the 'Match prop...' button
has been selected. It provides a second propeller graph with special functions that can be used to select
and compare motors (see Finding matching motors for the selected power supply and
propeller below).
The check boxes in the 'Motor' and the 'Propeller' areas provide access to the filters that can be applied to
the database. The first two filters in each row are additive and when activated include the items. All other
filters are subtractive. When activated these filters exclude items from the selection and limit the choices to
make selection easier. The grayed numbers on the left of the filter rows indicate how many entries have
passed the respective filter bank.
The propeller selection can always be limited to props matching the selected motor, 'Match motor', in its
current configuration. It is possible to have filter combinations that leave no entries; Drive Calculator then
tries to disable the last filter setting.
To save a motor configuration, including its power supply, gearbox, ESC and propeller, press Ctrl-S
(Command-S on the Mac). A red dot on the right of the motor popup list menu indicates that the current
motor
configuration has not yet been saved. In the Preferences dialog window, accessible in the Drive
Calculator menu, you can choose to have any configuration saved automatically. It will be restored any time
you select the motor again. To keep a battery, gearbox, or prop setting different from that in the saved
configuration activate the respective Hold check box.
Finding matching motors for the selected power supply and propeller
Select a power supply and propeller. Start the database scan run by clicking on the 'Match prop ...' button
below the 'Propeller' area. In the example below, the search has been limited to the results of the 'Measured
only' filter, which excludes the motors without loaded measurement data. In the Preferences dialog window,
accessible in the Drive Calculator menu, you may choose the option to always include all motors, regardless
of the filter settings.
The results of a scan run is a list of motors that fit the selected power supply and propeller. The motors are
available in the motor popup list menu and are presented in the new propeller graph view:

Each of the grey dots on the graph represent one of the chosen motor's operating point. The green dots
show the selected motor's operating point. To choose a motor and have its data displayed, either select it
via the motor menu or click one of the grey dots on the graph. The dots on the 'Eta' bar on the right show
each motor's efficiency at the computed operating points. You can also click on these points and select a
motor by its efficiency.
The scan result filter 'Match prop name' in the 'Motor' section is automatically activated after the scan run.
Switch it off if you do not want the limited motor selection. Once a scan has been run, the 'Current limit'
filter can be accessed.
Sometimes you may want to exceed the limits specified in the database or at least see what might
happen if you did. In the Preferences dialog window, accessible in the Drive Calculator menu, you can
choose the option to exceed the maximum current specified for the motor, the peak current specified for the
battery, or the maximum rpm specified for the propeller by an amount of up to 50%.

Choosing one of these options means that Drive Calculator will include the respective components in the
computation and display the results. You may see warning messages, in red, if you select one of the over-
stressed components. Please remember that exceeding the specified limits with real world motors, batteries,
ESCs, and propellers can destroy the components and may result in personal and property damage.
You can bookmark any motor or propeller, while it is selected, by pressing Ctrl-D (Command-D on the Mac).
You may want to use the 'Bookmarked' filter for the components that you own or are considering
purchasing. To edit the bookmarks, select the Edit item in the Drive Calculator menu and then 'Edit
bookmarks'.
The sliders at the bottom right of the application screen are not meant for controlling any options. They are
used to display the computation and the data quality.

The reliability rank for motors depends upon several factors:
1. The difference between the computed current values and the measured values
2. The difference between the operating voltage and the measured voltage range
3. The number of measurement points
4. The spread of the measured data (ideally for the loaded operating point voltages should be the same
while
loads should differ strongly; for a second no load operating point the voltage should differ by 10 to 20
percent).
The reliability rank for propellers depends on how many independent sources have contributed plausible
data
for the computation of the propeller constants. With only one data source, the reliability is set to 50%.
If the data
is not fully plausible the indication will be lower than that.
Comparing motors and propellers
Up to up three motors at a time can be compared by clicking the little selection arrows on the right side of
the
motor list popup menu.

With the motor radio button selected, clicking the down arrow once allows a second motor to appear in the
graph. The popup list menus can then be used so that each motor can have its own power supply, gearbox,
and even prop settings. By click on the down arrow once again, a third motor will appear. Select any of the
three by clicking the little arrows. Selecting the first motor and click upward once again makes the third motor
disappear. One more upward click and the standard motor graph reappears.
For the purpose of comparison you may prefer to have the horizontal diagram axis referring to the electrical
input power instead of the current. Click on the diagram title 'I [A]' to change it to 'Pin [W]'.
In the same manner you can compare up to three propellers in the diagram. As you see, there is also a little
arrows control in the Propeller area.
Please note the propeller rpm warning in the picture above. Drive Calculator may display similar warning
messages, in the color red, if the current is too high for the battery or for the ESC.
The warning messages depend on the entries in the database. If there is no limit specified in the database,
there will be no warning. Since many entries in the database are incomplete, you should never rely on Drive
Calculator; i.e. the calculated rpm may lead to the destruction the prop and cause extreme
danger, even if
no warning message appears.
In all cases you should refer to the manufacturer's specifications.
In the Tools menu of the application are some useful tools for motor builders. The Simple prop calculator
computes the static thrust based on the constants in the propeller database. It can also give a rough
estimation of
the motor efficiency. This is useful if you have measurement data at only one operating point.
The Rotor calculator computes rotor dimensions and magnet distance, based on the stator dimensions and
the desired airgap. If you are lucky enough to have a lathe for making
motor parts, you may like this tool.

The Wire calculator deals with the mechanical and electrical properties of the winding. It computes the wire
section and respective diameter for multi-wire winds. It also gives a recommendation for the maximum burst
current. If you put in some stator dimensions, especially the size of the slots, it approximates how many
turns can be accommodated.
The Reconfigurator very roughly estimates the effect of modifications on the winding and the stator height
of the selected motor. If you select it from the Tools menu, additional text edit fields and controls will appear
at the bottom of the application page. The modified parameters are entered into the appropriate edit fields
and then a third pair of little arrows is used to change between the original and the modified motor.

Drive Calculator 3.0 comes with a SQL database that contains separate tables for batteries, ESCs, gear
boxes, motors, and propellers. To inspect or modify the data and to enter new components you can open
a dialog window for each table via the 'Edit' item in the main menu.
To enter a new component, select 'New...' in the component's popup menu list or click on the 'New' button
in the component's dialog window. Selecting 'New' clears all fields in the dialog window and starts a new
database record.
If a similar component is already in the database, the component's record can be copied to save retyping
a lot of the information. To copy a component, hold down the Shift key while clicking on the "New" button.
The contents are copied to a new record and the word "copy" is added to the component's name.

A motor record with very few entries is displayed above. The minimum information to be entered is Kv,
Rm, no load voltage (U0), and no load current (I0). Usually these data points are only sufficient for a very
rough estimation of the motor characteristics.
The motor analyzer part of Drive Calculator is designed to approximate the motor's characteristic data
based on real world measurements. If you have measured data, there is no need to fill in the Kv and Rm
fields, since Drive Calculator will do its own calculation and overwrite these entries anyway.
Up to six sets of measured data may be entered. The minimum amount of data that should be entered is
two sets. The first set should contain the no load data including rpm. If you do not have the no load rpm, you
may just enter the no load voltage and the no load current in the first row. (You must always enter no load
data in the first row.) If the no load data does not include the rpm, then you will need to enter at least
one more data set that includes the rpm value.
The more measured data that is entered; the better is the computation accuracy. Ideally, you should provide
two no load data sets at voltages differing by 15%, along with four data sets measured at a voltage in
between, with strongly differing loads that cover the full current range you want to use.
The computation is based on a simplified model of the DC motor and is applicable to brushed motors and
brushless motors. But expect no miracles, since the model does not consider all factors , i. e. the interaction
of the ESC with the BL motor. Even if careful measurements with good equipment are provided, the
calculator results may sometimes deviate substantially from reality.
As an accuracy check the difference between the measured and computed current values is shown at the
bottom of the main window. However, if only two rpm values are provided, the calculator cannot compute a
meaningful indication and it will not be displayed.
If differences of more than 3% arise, examine the measured data and repeat the measurements, if possible,
or select alternative data (with different voltages or loads). It is advisable to record additional measurements
during the motor testing so that alternate data is available if needed. The calculator is particularly sensitive
to discrepancies in the no-load data.
All measurements must be made at full throttle. Perform the no-load measurements at operating
temperature. The idle current of the ESC must be subtracted from all current data.
When entering new data, please make sure to use a unique name for each component, so that the
component can be identfied in the menu lists. Using a unique name will also make the merging of the data,
via
the online data exchange, safer and easier. I am also asking
that motor builders adopt the naming
convention for custom made motors that is used in the database. Each motor name starts with a set of
numbers that indicate the most important parameters, followed by a unique name string, i.e.
242x144 13D630 Quadro
in which
242 is the stator diameter in millimeters x 10
144 is the stator height in millimeters x 10
13 is the number of turns of the winding
D stands for delta termination (Y indicates WYE termination)
630 is the wire diameter in millimeters x 1000 (respective diameter in case of
multiwire windings).
Remember, there is still a Remarks field for individual notes and comments.
Drive Calculator 3.0 supports data acquisition by means of the Hyperion EMeter.

Connect the device to the serial port of your computer. Switch it on. Select the device name from the popup
list menu. Select the serial port in use from the menu on the right. Radio buttons appear next to the edit fields;
push one of them to select the row into which the measured data is to be written. If you want to repeat a
measurement in the same row, click the radio button once again to enable the edit fields.
If you choose to have a log file written by checking the box at the bottom, you will be prompted to enter the file
name and destination.
Drive Calculator will guide you through the measuring procedure. It is advisable to fill in all fields and select
the propellers before starting the measurement, since some information goes into the log file.

In the Preferences dialog window you configure general program settings and register your connection
profile for the online data exchange:
Save configurations automatically: Any changes of the drive configuration, including the power supply,
the ESC, the gear box, and the selected propeller, will be registered in the database. If the respective motor
is selected, the configuration will be restored. If you deactivate this option, you can still save any
configuration by pressing Ctrl-S (Command-S on the Mac). To keep a battery, gearbox, or prop setting
different from that in the saved configuration activate the respective Hold check box in the main window.
Include motors without weight data: This options controls the function of the weight limit filter in the main
window. Some motor records in the database do not provide the weight information. If the option is
deactivated, motors with no weight listed in the database will be excluded from the filter result.
Include all motors in "Match prop": On a fast computer this option should be activated, so that the
database scan run includes all motors. You can then apply any motor filter to the resulting motor list. On a
slower computer you may prefer to deactivate this option, so that only the filtered motor list is scanned.
'Exceed...' settings: See section Stretching the limits
Participate in online data exchange: This is the master switch for both, automatic download of updates,
and the submission of measurement data. The data to be entered in the edit fields on the right side are the
same as in your web browser and your mail client software, respectively.

Once you have entered new data, you may be asked to confirm the submission via your email connection,
when you close the dialog window. Whether or not you will be asked, depends on the online data
exchange option selected in the Preferences dialog window.

If 'Look for updates, when I'm online' was selected in the Preferences dialog window, Drive Calculator will
look for new items on its home server whenever you are online.
Upon confirmation, the database update will be loaded and merged into your database. You will see a
detailed report of what is added to your database in a protocol window.
A database update may contain new records, that are added to your database, or it may contain
modifications of existing records. In the latter case, you will be prompted for a confirmation, before any
change is made. A dialog window showing the contents of the existing record and of the new record
will open. You may as well opt for rejecting the changes or adding the new record with a different name.
...
Please send questions this manual failed to answer to christian@drivecalc.de