Very nice initiative. There is so much work for a solo man and in perpetual evolution that I have a suggestion. Why not using a mind map tool or a huge WIKI ? The writing could be parallel. A few people could help you out. You could create commits… in a pdf format if you like.
Best solutions have emerged like the forced flow watercooling through a pod nose inlet that cancels the pump need thus simplifying the wiring diagram thus the electric case (see @michion v2 board simplicity)
Then there is the matrix of options not easy to translate into a single pdf
1 - Board fully home-made or modified existing board ? Electric box: external plastic case or internal ? With or without hinged lid ?
2 - Electrical aspects
2.1 Wiring diagram: the minimum setup is: a motor, an ESC, a remote receiver, a battery and a protection system (fuse or ). A switch can be added to disconnect the battery during the transport. Possible sensors: temperature, water detection, etc
2.2 Wires and connectors tbc
Wire gauge AWG8 or AWG6, … 8mm connectors, AS150 (AS = Anti spark), XT90,
3 - Drive train,
3.1 motor: we have a wide choice of possibilities today
Inrunners : sold waterproof: Flying Rodeo or 6516x 100 and 120kv from Reacher / Flipsky / Maytech?
Outrunners : need DiY waterproofing : 80100 replaced by the 63100 (both APS) …6384 from FLIPSKY
3.2.1 Fixed or folding
3.2.2 DiY (3D printed, cast) or commercial (Flying Rodeo, Russian manufacturer, Solas, Chinese, new comers)
4 - ESC:
- 4.1 position: above the mast for simplified electric box (FliteB, Pegasus, Mantafoils, Waydoo One, …)
- 4.2 VESC or non VESC, max voltage 6, 10, 12 or 14s ? ESC with included BEC and anti spark solution
Lowcost Flycolor 60usd type, middle cost Flipsky 12s waterproof VESC, or SEAL 300A 14s non VESC, quality: Trampa 75/300 or TeamTriForce , high end MGM Compro 500usd+, …
- 4.3 ESC programming + modes (BDLC, FOC, ) + main brand user-guide links
_VESC (motor-batt-ABS current, throttle calibration, ramping time, stator compensation, …)
Trouble shooting guide: symptoms/error code and solutions in a esc/motor use-case matrix (see @User1 10 - Trouble Shooting guide below )
As your esc/motor/wire length /connectors setup is unique, rerun a motor detection in suitable conditions : unloaded motor, so no lip seals; cable lengths in final configuration
non VESC: …
VESC: list of error codes with solutions, list of symptoms with solutions see ch 10 - Trouble Shooting guide below )
5 - Battery : commercial or DiY so far Li-Ion but Supernova should unveil their much awaited LTO cell based solution on the 2020/06/18 - probably 6s
6 - Hydrofoil front wing choice:
Commercial OR DiY : which surface, footprint and airfoil section?
Trend: new large surface high AR low thickness ratio (UniFoil / Windfoil wings / RL efoil wing / Gong Veloce 8%) should open a new way to low consumption drive trains using 6s batteries and low cost 6s ESC’s (see 8-Budget efoil here below).
7 - Remote control:
Commercial (MAYTECH, Waydoo (possibly August ) ) or DiY (Yahef, samisin, yours, new to come, …
8 - Budget efoil chapter (sub 1000USD) : a summary of the best practices
The 6s phylosophy by @JetboardCologne (60kg rider): set up for E Foil under 450usd :
Motor: waterproofed outrunner Flipsky 6384 120kv (avoid APS)
ESC: 6s 150A Flycolor boat: http://www.flycolor.net/index.php?c=category&id=149
Battery: Turnigy 6s 12Ah x2 in parallel = 6s 24Ah
DiY Propeller: 2 blades, 170mm (instead of 140-150mm in 12s with a 100-120kv inrunner)
Source @V_S 140mm increased to 170 and z-axis multiplied by 1.3
Amps and power drawn: take-off / flight: 80 A / 32 - 35A - Power: 1775 / 720W
Ride time: 35 - 40min
Front wing: Bic Techno windfoil 85cm span, 1300cm2 (Kerfoil design)
for heavier riders needing 120A to take-off who want to keep amps low:
a foot push rod along the mast to lower a flap to double the lift (at constant speed) and trigger a board take-off at 40A instead of 120A ? Should allow the use of a low cost 6s 60A ESC or 70A MK3 VESC ? The wing must be flat see Taaroa iUP thread.
9 - Buiilding and using your battery charger
10 - Future developments
IMU - Artificial Intelligence for which use ?
11 - Trouble Shooting guide
Motor-ESC use cases.
(1) User1 use-case VESC ESC figures for 65162 motor + Flipsky FSESC 200A VESC
(2) List of issues and solutions that have worked in the past
With Flipsky FSESC 200A waterproof
Reminder: as your esc/motor/wire length /connectors setup is unique, rerun a motor detection in suitable conditions : unloaded motor, so no lip seals; cable lengths in final configuration
Error 1 (Err1): ABS_OVER_CURRENT
Sol Err1.1: Abs Max current has to be a lot higher than motor current. Set Abs Max current to 200A and max motor current to 160A. Enable slow abs max current.
Sol Err1.2: install no_HW_limit driver if available
Sol Err1.3: check … increase
Error 2 (Err2): R0 is 1
Sol Err1.1: tbc
Issue 1 (Iss1): motor cogging and stalling during startup
Sol Iss1.1: check that motor is running on 3 phases instead of 2
Sol Iss1.2: Modify “Stator Saturation Compensation” from stock 0% to 10%, from 10% to 0%
12 - Advanced Trouble Shooting guide
Structure of a MotorConfig.xml configuration file
… and so on.
200621: added 9 - Buiilding and using your battery charger