/BugWiper2_0

Bug Wiper Controller for Sailplanes Version 2 with Arduino Nano

Primary LanguageC++Apache License 2.0Apache-2.0

BugWiper

This project is an open source electronic bug wiper system.

Old Version

Version 1

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Problems:

  • Motor Driver had a high voltage drop, which reduced the motor power
  • Motor was not enough torque for higher speeds
  • Motor was to easy to rotate when powered off. The spring in the bug wiper wings pulled the cable out a bit.
  • The GFK spring pulled out the cable after stopping the motor and turned the motor backwards
  • the GFK spring is not only bending as intended, but although twisting dependent on the spooling direction of the cable drum. This results that the outboard stop switch is reached at 5-6 kg in one direction and at 2-3 kg in the other direction. So that in one direction the Motor not automatically stops when the bug wiper wings reaching the fuselage and in the other direction the motor stops all the time in the middle of the wing.
  • The high pull force of the cable tightens the cable sometimes so strong, that at the next winding out the windings are pressed so strong together, that the spool is pulling the wings back inwards after a couple of rotations

Version 1.1

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Features:

  • new higher geared motor for more torque and more resistance when powered off
  • new high power motor driver

Components:

Problems:

  • new motor is very slow
  • still the same Problems with the cable and the GFK spring

Panel

  • one LED per Wing
  • one two-way toggle-switch Image

New ESP32 Version (Ideas):

New mechanical design:

  • ESP32 instead of 8bit Atmel controller
  • no more end stop switch
  • no big spring for the end stop
  • encoder for the cable spool

New software design:

  • motor current sensor and motor position decides when to stop the BugWiper motor
  • programmable cable length with the motor encoder
  • direction change of the motor at the wingtip. Motor turn every time the same direction for in and out.
  • slow down the motor before reaching the fuselage to reduce the force at the stop.
  • auto retighten the bug wipers if they loosen from the fuselage in flight
  • ground modus to loosen the bug wiper just bit and no full cleaning process
  • WiFi Hotspot with web browser to configure the BugWiper system before flight

Used IDE and Settings:

  • Arduino IDE2.3.2
  • selected Board: ESP32S3 DEV Module

Board Pinout:

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Board Settings:

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Installed Librarys:

Used Hardware:

Motor Tests:

SRA58SW-555B / 5840-555 Worm Geared Motor

https://www.bringsmart.com/pd.jsp?id=110

similar to https://nfpshop.com/product/12v-24v-metal-gear-worm-gear-model-nfp-5840-555-en ???

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Motor Parameters:

  • 12 Volt
  • 30 Watt
  • 470 rpm
  • self locking worm gear
  • 17:1 Gear ratio

Testing

Cable drum with 24mm Diameter made out of CHANCS Aluminium Alloy Double V-Groove Belt Pulley 40 mm OD 8 mm Fixed Pulley for Motor Shaft Bore 6 mm: https://www.amazon.de/gp/product/B0CRR4KS3J

Forwards:

Load Current Speed
1kg 2.2 A 0.55 m/s
2kg 3.4 A 0.44 m/s
3kg 4.6 A 0.39 m/s
4kg 6.2 A 0.32 m/s
5kg 8.3A 0.23 m/s

Backwards:

Load Current Speed
2kg 4.6 A 0.4 m/s
3kg 6.4 A 0.37 m/s

--> Time for the cleaning process of one wing around 28 seconds

Result:

Positive:

  • self locking
  • high Torque
  • integrated Encoder
  • fast

Negative:

  • high power consumption
  • bad efficiency
  • high noise
  • higher losses when turning backwards

ZGB37RH31

https://www.amazon.de/gp/product/B00T48KC1Q

https://www.zhengkemotor.com/product/Zhengk_DC_Brushed_Motor_RS555__EccentricShaft_37mm_Gearhead_RoundFlange_ZGB37RH.html

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Motor Parameters:

  • 12 Volt
  • 30 Watt
  • 200 rpm
  • self locking worm gear
  • 31.1:1 Gear ratio

Result:

Positive:

  • higher efficiency

Negative:

  • not self locking, but could be enough resistance

Open Source Software Declaration

The Webserver part is based on https://github.com/smford/esp32-asyncwebserver-fileupload-example and licensed under Apache 2.0 license