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Author Topic: question on battery cooling  (Read 2862 times)

steven yampolsky

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question on battery cooling
« on: September 22, 2010, 07:05:28 PM »
This might sound like a dumb question coming from someone still trying to learn about e-flight but please bear with me.

From what I understand, it's important to keep batteries cooled during flight. At the same time, battery packs consist of several smaller batteries(cells?) linked together. That kind of cooling would only cool one side of the outer most cells. I seems to me it makes sense to split the pack and put distance between cells for the air to flow between the cells. So here's the question: how come this has never been done or considered? Am I missing something?


Steve

Offline Dean Pappas

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Re: question on battery cooling
« Reply #1 on: September 22, 2010, 09:12:12 PM »
Hi Steve,
Hmmm ... yes and no.

1)The price to produce a pack with spacers, or for you to buy 2S packs and tie them together with spacers and solder all the bits together would be substantially  higher.
2) With cell resistances coming down as they are, our 7~8 "C" average and 10~11 "C" peak loads are no problem at all, provided the battery does get cooling.
The thermal conductivity of the cells themselves is surprisingly good.
The RC Pattern guys want 17 or 18C peaks, and until recently, I considered the hassle of putting gapped packs together as worthwhile.
This last generation of light-weight and medium high current cells are coming down with maybe 20 or 25 F rises compared to ambient, in hot weather.
It's no longer worth the bother, in either event.
3) In cold weather you actually want to launch with the batteries warmed to at least body temp, and you'd like to land with them at at least 100F. This means battery cooling paths that are segregated from the motor/ESC so that this path can be partially blocked in cool weather.
4) On the other hand, it is traditional to make Stunt fuselages by bolting the rails to the intended engine, and gluing fuse sides on ... no fat planes can ride here! This has to change. There are plenty of examples of poor cooling design, and hopefully as we move away from conversions to purpose-designs we will fix this one.
Motors and ESCs just get happier the cooler they are.
later,
Dean P.


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Offline Wynn Robins

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Re: question on battery cooling
« Reply #2 on: September 22, 2010, 09:12:54 PM »
Steve,
the top and bottom of each cell are exposed (pretty much anyways) and get air over each

Batteries do not need to be cooled as much as you might think - they run best at 50-60 degrees celcius (sorry I dont know the F measurement)  which is actually quite warm.

you run into problems if they Exceed this - or run too cold......so on really cold days  - you can actually pre-warm your packs and block off venting on your model to keep the packs at "operating" temp

In the battle of airplane versus ground, the ground is yet to lose

Offline Tim Wescott

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Re: question on battery cooling
« Reply #3 on: September 22, 2010, 10:33:16 PM »
3) In cold weather you actually want to launch with the batteries warmed to at least body temp, and you'd like to land with them at at least 100F. This means battery cooling paths that are segregated from the motor/ESC so that this path can be partially blocked in cool weather.
4) On the other hand, it is traditional to make Stunt fuselages by bolting the rails to the intended engine, and gluing fuse sides on ... no fat planes can ride here! This has to change. There are plenty of examples of poor cooling design, and hopefully as we move away from conversions to purpose-designs we will fix this one.
Motors and ESCs just get happier the cooler they are.
I see no reason not to stack the cooling ductwork over/under, with the motor ducting on top just below the spinner (or around it) and the battery ducting below.  Like the ductwork on the P-47 Thunderbolt, where the top opening cooled the engine and the bottom opening took air back to the intercooler.  They couldn't use the warm engine cooling for the intercooler, because the target temperature is too low.

And if you played your cards right, you could make it a styling element in the front view of your airplane.
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The problem with electric is that once you get the smoke generator and sound system installed, the plane is too heavy.

Offline Dean Pappas

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Re: question on battery cooling
« Reply #4 on: September 23, 2010, 09:14:20 AM »
I'm all over that styling element aspect!
Turboprop exhaust ducts would be just right for motor air egress.
Dean
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Offline Tim Wescott

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Re: question on battery cooling
« Reply #5 on: September 23, 2010, 10:56:46 AM »
I'm all over that styling element aspect!
Turboprop exhaust ducts would be just right for motor air egress.
Dean
I haven't done it yet, but I have been tempted (after hacking yet another ugly hole behind the wing of an RC ship) of designing a ducting system that brings the air in the front, loops it around, and exits somewhere close to the front again.

I hadn't thought of fake turboprop exhaust ducts, but on the right plane they'd certainly look good.  There's no reason you couldn't do something similar with the chin radiator on a P-40 or a Hawker Typhoon.

With a stunt ship there's no reason you couldn't have the duct exit at a "natural" point and still look good -- I'm thinking of the step in the bottom of a Nobler fuselage, which looks like an exit duct already, and only needs the right structural work to actually be one.
AMA 64232

The problem with electric is that once you get the smoke generator and sound system installed, the plane is too heavy.

Offline John Witt

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Re: question on battery cooling
« Reply #6 on: September 23, 2010, 05:36:20 PM »
Keep in mind that the exit hole needs to larger in area than the entrance. A good rule of thumb is 1.5 to 2 times the area. This is to account for the velocity drop from the internal drag.  Also another thing to remember is that the internal drag of the ducting/machinery is added to the total drag of the airframe.  This is why real airplanes have "nice" ductwork that is carefully sized for the required airflow. Probably overkill for us to use fluid modeling to size the ducting, though Howard might.   LL~

As PT Barnum said, "This way to the egress".

John
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Offline Dennis Adamisin

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Re: question on battery cooling
« Reply #7 on: September 23, 2010, 06:08:48 PM »
Keep in mind that the exit hole needs to larger in area than the entrance. A good rule of thumb is 1.5 to 2 times the area. This is to account for the velocity drop from the internal drag.  Also another thing to remember is that the internal drag of the ducting/machinery is added to the total drag of the airframe.  This is why real airplanes have "nice" ductwork that is carefully sized for the required airflow. Probably overkill for us to use fluid modeling to size the ducting, though Howard might.   LL~

As PT Barnum said, "This way to the egress".

John

Maybe Johnnie Taylor was singing about COOLING:

Shake it up, shake it down
Move it in, move it round, disco lady
Move it in, move it out,
Move it in round about, disco lady
Shake it up, shake it down
Move it in, move it around, disco lady
Denny Adamisin
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Offline Tim Wescott

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Re: question on battery cooling
« Reply #8 on: September 23, 2010, 06:11:57 PM »
Keep in mind that the exit hole needs to larger in area than the entrance. A good rule of thumb is 1.5 to 2 times the area.
As an engineer, I've learned to be both deeply suspicious and profoundly thankful for rules of thumb.

Profoundly thankful, because when you use them in the context for which they were formulated they save a lot of work -- sometimes work you cannot do, for lack of things like wind tunnels.

Suspicious because when you take them out of the proper context they become meaningless at best, and harmful at worst.

It'd be nice to see a comprehensive study done of this stuff.  Including measures of the entrance and exit holes on cooling paths of 'the big boys'.  I'd like to see some rules of thumb about how far to space the ductwork from the important stuff so the air goes where it'll do good instead of just setting up a situation where you have hot stuff sitting in a stagnation point with cold air blowing by 1/4 of an inch away.  Then add to that just how many square inches you need for how many watts at what speed, etc.

An easy-to-make windtunnel design that I could use to test cooling would also be -- well -- cool.
AMA 64232

The problem with electric is that once you get the smoke generator and sound system installed, the plane is too heavy.

Offline Dean Pappas

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Re: question on battery cooling
« Reply #9 on: September 23, 2010, 09:57:49 PM »
I have a bone to pick with that rule of thumb too!
 S?P
Dean P.
Dean Pappas

Offline Dean Pappas

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Re: question on battery cooling
« Reply #10 on: September 23, 2010, 10:07:11 PM »
Maybe Johnnie Taylor was singing about COOLING:

Shake it up, shake it down
Move it in, move it round, disco lady
Move it in, move it out,
Move it in round about, disco lady
Shake it up, shake it down
Move it in, move it around, disco lady


Now I am going to have that tune in my head ... Deeeenniiiiiis!

later,
Dean
Dean Pappas

Online Howard Rush

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Re: question on battery cooling
« Reply #11 on: September 23, 2010, 11:56:34 PM »
An easy-to-make windtunnel design that I could use to test cooling would also be -- well -- cool.

I'd use an automobile.
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Offline Tim Wescott

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Re: question on battery cooling
« Reply #12 on: September 24, 2010, 09:26:24 AM »
I'd use an automobile.
You mean a "Rabe windtunnel".
AMA 64232

The problem with electric is that once you get the smoke generator and sound system installed, the plane is too heavy.

Offline John Witt

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Re: question on battery cooling
« Reply #13 on: September 24, 2010, 10:16:18 AM »
It would be useful to know where the low pressure and high pressure areas are on the surfaces of a "generic" stunt model, at least maybe on the front third where exit holes are likely to be.

John Witt
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Re: question on battery cooling
« Reply #14 on: September 24, 2010, 10:30:37 AM »
I had a cooling hole on the bottom of my cowl.  I wanted to replace it with a cooler-looking NACA duct, but I didn't know whether the air went in or out of the hole. 
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Offline Tim Wescott

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Re: question on battery cooling
« Reply #15 on: September 24, 2010, 11:17:36 AM »
I had a cooling hole on the bottom of my cowl.  I wanted to replace it with a cooler-looking NACA duct, but I didn't know whether the air went in or out of the hole. 
The NACA duct is made to scoop air into the airframe.  At the very least you'd want to turn it around backwards.  In general you want the outlet to be at a low pressure point.  I couldn't tell you the best places to look, other than it's probably at or behind the fattest part of the fuselage.
AMA 64232

The problem with electric is that once you get the smoke generator and sound system installed, the plane is too heavy.

Offline Tim Wescott

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Re: question on battery cooling
« Reply #16 on: September 24, 2010, 11:22:36 AM »
Another thought that I have on this whole cooling thing:  In full size aircraft practice folks are often asking "how can we get effective cooling with the minimum drag" -- this has motivated cowling design from the Townsend ring, the NACA cowl, all the way up to the modern flat-engine cowl with itty bitty round holes in the front.

(I'm stretching my neck out here, because I'm not that good of a flier yet -- I'm regurgitating what I've heard and read, so take it with an appropriately-sized grain of salt).

But for CL stunt, to some extent, people seem to want a bit of drag on the airframe, to keep the plane from speeding up on the downward lines in maneuvers.  If this is true, then there's no reason not to spend some of that drag budget on cooling.  Even if you can get the whole job done with a 3/8" diameter hole just under the prop, it way well be that a gaping maw with over one square inch of area makes the plane look better, and doesn't have an appreciable effect on the actual flight performance of the plane (and would probably ease the requirements on the interior duct work, to boot).

Just a thought...
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The problem with electric is that once you get the smoke generator and sound system installed, the plane is too heavy.

Online Howard Rush

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Re: question on battery cooling
« Reply #17 on: September 24, 2010, 11:32:33 AM »
The NACA duct is made to scoop air into the airframe.  At the very least you'd want to turn it around backwards.  In general you want the outlet to be at a low pressure point.  I couldn't tell you the best places to look, other than it's probably at or behind the fattest part of the fuselage.
I'm familiar with NACA inlets; we use them where I worked.  My airplane cooled just fine.  I tufted the hole to see which way the air went.  It went in, so I put an NACA inlet on the cowl.  It cooled just fine with it, too.
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Online Howard Rush

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Re: question on battery cooling
« Reply #18 on: September 24, 2010, 11:47:04 AM »
Another thought that I have on this whole cooling thing:  In full size aircraft practice folks are often asking "how can we get effective cooling with the minimum drag" -- this has motivated cowling design from the Townsend ring, the NACA cowl, all the way up to the modern flat-engine cowl with itty bitty round holes in the front.

(I'm stretching my neck out here, because I'm not that good of a flier yet -- I'm regurgitating what I've heard and read, so take it with an appropriately-sized grain of salt).

But for CL stunt, to some extent, people seem to want a bit of drag on the airframe, to keep the plane from speeding up on the downward lines in maneuvers.  If this is true, then there's no reason not to spend some of that drag budget on cooling.  Even if you can get the whole job done with a 3/8" diameter hole just under the prop, it way well be that a gaping maw with over one square inch of area makes the plane look better, and doesn't have an appreciable effect on the actual flight performance of the plane (and would probably ease the requirements on the interior duct work, to boot).

Just a thought...

Sounds good to me.  We may want to consider drag a little more on electrics than on IC engines, but I'm too lazy to make a lot of cowls, so I'd err on the side of drag.  I like Bob Hunt's idea of using baffles to duct the flow where it's needed, too.

This reminds me of a story, as so many things do.  I once attended a technical review of a human-powered airplane our AIAA section was funding.  One of the reviewers, the chief of aerodynamics of the local airplane factory, spent about half the time grilling the designer on his cooling duct inlet sizing.  I concluded it must be a big deal.
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Offline John Witt

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Re: question on battery cooling
« Reply #19 on: September 24, 2010, 05:24:07 PM »
What I know of NACA boundary layer ducts, from my race car days, is that they are only used for inlets. Also, they have to be located where the boundary layer is mostly laminar and relatively thin, thirdly, there is a fairly specific set of dimensions/rules for their shape.  If done correctly, an NACA duct can actually decrease the drag by thinning the boundary layer downstream of the duct opening.  I haven't read anything much about exhaust ports, though, to know if there is an equivalent.  It is a problem in impedance matching both entry and exhaust to the surrounding atmosphere.

I once had the chance to ask Paul McCready whether the front end shape of a vehicle or the downstream end was more important from a drag viewpoint. He said the entry shape was the most important. FWIW.

Maybe we need automatic speed brakes for the down lines. Howard, Igor...?

John Witt
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