Good evening everyone.
As I had previously anticipated, I will explain how this simple circuit works, for those who are interested because they want to make it or out of simple curiosity.
The first diagram is simpler, it is used to understand the logic of operation, there is only one relay equipped with four contacts.
The second scheme is the one I actually used having two relays available.
UNDERSTANDING THE TWO PHASES OF THE CIRCUIT
COIL NOT ENERGIZED
In the first image (simplified diagram with a single relay) you can see what happens when I operate the radio control lever in forward gear.
In this case the current flows in the coil (which has a circuit [electrical mesh] in parallel with the ESC) but the voltage is not yet sufficient to excite it.
If the coil does not energize the contacts are not activated (i.e. modified), therefore the "normally closed" contacts will remain closed and the "normally open" contacts will remain open.
In this condition, only the current from the ESC circuit will reach the motor.
The conventional direction of the electric current (not real electrons) from the positive pole to the negative pole is displayed by the arrows.
The large arrows (red and black) indicate the ESC mesh current, while the small arrows (red and black) indicate the current path in the coil.
In the second image (simplified diagram with a single relay) you can see what happens when I operate the remote control lever in reverse.
Due to the diodes placed only in the electrical mesh of the coil it will not energize.
The conventional direction of the electric current (not the real one of the electrons) is visualized by the arrows.
The large arrows (red and black) indicate the ESC mesh current which is reversed compared to the previous situation.
The 12 volt circuit will not be able to operate even at the maximum negative voltage that can be delivered.
In the third image (real two-relay diagram) you can see what happens when I operate the radio control lever in forward gear.
The situation is the same as that of the first image but more faithfully reflects the practical tests recorded in the attached videos.
Measuring instruments (voltmeter in parallel and ammeter in series) and fuses have also been added. In the simplified diagram they have been omitted to facilitate understanding.
COIL EXCITED
In the fourth image (simplified diagram with a single relay) you can see what happens when I operate the remote control lever in maximum forward gear.
In this case the current flows in the coil (which has a circuit [mesh] in parallel with the ESC) and the voltage is sufficient to excite it.
If the coil energizes the contacts are activated (i.e. changed), so the "normally closed" contacts will open and the "normally open" contacts will close.
In this condition, only the current from the 12 volt battery circuit will reach the engine.
The conventional direction of the electric current (not the real one of the electrons) is visualized by the arrows.
The large arrows (red and black) indicate the 12 volt mesh current, while the small arrows (red and black) indicate the current path in the coil.
The circuits are not in parallel, they are galvanically separated.
I omit the complex two-relay scheme for reverse (it is superfluous).
In the fifth image (real two-relay diagram) you can see what happens when I operate the radio control lever in maximum forward gear.
The situation is the same as that of the first image but more faithfully reflects the practical tests recorded in the attached videos.
Measuring instruments (voltmeter in parallel and ammeter in series) and fuses have also been added. In the simplified diagram they have been omitted to facilitate understanding.
PROBLEM OF THE CORRECT COIL EXCITATION THRESHOLD
The theoretical operation has been described so far, but in reality there is a problem. I thought of solving this problem by placing diodes on the electrical mesh of the coil.
What's the problem?
The coil is nominally 6 volts but in reality it is able to energize (electromagnet effect capable of modifying the electrical contacts) with much lower voltages.
In this way the system will still work, but the excursion of the lever in forward gear will be very reduced, because it will be enough to raise the voltage on the coil by a few volts to energize it and trigger the 12 volt circuit.
Thus we could not exploit the entire 6 volt range (or slightly less) available.
Placing the diodes in series before the coil causes a voltage drop.
Yes, I'm not using diodes in the most classic way but I'm exploiting them for another feature.
Each diode has an electrical voltage drop across its terminals (if I remember correctly these have a drop of 0.7 volts).
By increasing this voltage drop it is necessary to supply more voltage to energize the coil. The coil will not energize right away.
The more diodes I put in, the more voltage is needed to excite the coil.
In short, the more diodes I put in, the closer I get to the maximum threshold of 6 volts, exploiting the entire range before the circuit switches.
To understand this, remember that the diodes are placed on the coil circuit only so their overall voltage drop will not cause any effect on the voltage the motor receives.
What happens if the voltage drop is too high because I placed too many diodes?
It simply will never energize the coil and never switch the 12 volt circuit, so I have to gradually remove a diode to gradually reduce the voltage drop.
With these small adjustments I find the ideal threshold.
REFERENCE AND EXPLANATION OF THE VIDEOS
In all the videos you can see the test of the two relay circuit.
You may notice that there are three multimeter testers.
The first blue tester on the left is used as a voltmeter (see the diagram in the sixth image).
It is connected directly to the motor so it will detect the voltage that reaches it. Just by looking at this instrument we will be able to understand which circuit we are using.
From the number of volts we will understand (as well as from the obvious change in engine speed) which circuit is working, at 6 or 12 volts.
The center tester, black in color, is used as an ammeter and is in series in the six volt circuit (immediately at the ESC output). It detects the sum of the currents flowing in the esc/motor circuit plus the small current flowing in the coil.
Blue/black arrow and blue/red arrow of the two relay circuit.
The larger yellow tester on the right is used as an ammeter and is placed in series on the 12-volt battery circuit.
In the videos you can see that the remote control lever is gradually moved forward.
At the same time you can observe the gradual increase in voltage on the blue tester.
At the same time you can see the current rising on the black tester.
Instead, on the yellow tester the display shows 0 Amperes, a clear sign that the 12 volt circuit is open and therefore not active.
As soon as the voltage, measured on the blue tester, exceeds a certain threshold, we see that:
the 12 volt motor starts to turn much faster,
the blue tester directly indicates just under 12 volts,
the black tester shows a few milliamps (not zero) because it continues to detect only the current of the coil circuit (current no longer flows in the ESC circuit),
the yellow tester measures the absorption of the current passing through the 12 volt circuit.
I made more videos to show you how, as I added diodes, the voltage drop increased.
In this way you can see how the activation threshold of the coil goes from 3.61 volts in the first video to 4.29 in the last video.
I could have continued to increase the voltage drop up to the maximum threshold but I stopped because I believe that this way the concept is understood well.
In the last video you can see the reverse gear being activated.
The blue tester shows negative voltage.
The black tester shows a reverse current.
The twelve volt circuit which is only fast forward never engages (and thank goodness!)
ADVICE FOR POSSIBLE PRACTICAL IMPLEMENTATION OF THE CIRCUIT
Always use fuses.
Consider the currents at play.
In this case they did not exceed 2 amperes even at 12 volts but the motor axis was free. With a propeller in water things change, absorption increases.
Pay attention to how much current, especially the relays, must support.
If you want to cause the voltage drop in a different way, remember that at least one diode is useful to not energize the coil in both directions.
Imagine a backward march which, if done too quickly, can become a sudden and disastrous forward march.
If you use two relays, make sure they are identical and do some tests. A single realis guarantees the simultaneity of the commutation.
The blue tester (not really mine, buy your own, hahahahahah) will be used to calibrate the coil's intervention threshold correctly and to your liking.
Don't be scared by the tangle of cables I made.
Work well done on a breadboard requires little space.
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