It started from the basics. It is a totally new light weight composite motor for aviation.
Safety is #1, then efficiency with a good price.
A lot of little improvements all add up to make good products.
Special knowledge is NOT needed to enjoy the benefits
of silent flight.
Understanding Lithium battery cells:
The 3 types to choose from are : Prismatic, Pouch and Cylindrical
Without a long explanation - we do not recommend the Prismatic. The second type to run from are the NCR with only 500 cycles times (or charges). These are the dangerous cells we here about on the news that are starting fires.
For safety, everyone is changing over to the NCM chemistry. Now we can look at the 2 best design choices.
In 1995 the pouch cell surprised the world with a radical new design. For aviation we can fit these into almost any space. We recommend no more than 3 layers laid in a flat area. For our flat pack dimensions scroll down to the bottom. Our proprietary method for attaching the battery connectors to the tabs eliminates corrosion, welding or clamping. The process is faster which lowers the cost and allows more freedom to fit any compartments in an airplane. These cells can be customized up to 200Ah.
These big cells can go up to 100Ah with 1,500 cycles. They are ideal for storage in the wings - the same as fuel tanks for weight distribution. They are connected by terminal nuts as they slide into a track in the wings. The metal casing is replaced by a stronger composite to save weight. The 16 inch cells do not need cooling fans when in use, but it should be noted that any battery will have a longer life span when stored in an environment free of excessive heat.
NOTE: Is it really possible to get 8,000 to 10,000 charges or cycles from NCM cells?
Yes it is, but only if you charge and discharge at no more than 1 amp. Of course that is not reasonable in aviation. So Don't be fooled by unreasonable claims. The quality of our batteries is based on chemistry and not price. Our chemist has made special improvements for us because of our need for aircraft quality and safety.
Efficiency needs 3 things for success:
The correct motor design with a variable Pitch Perfect Prop
The best battery chemistry with the epower charging system
An active battery cell balance management system
Why do we need a balance system? Simply put - most battery packs runs at least 30% less efficiency then what they should be running at. The best way to understand this balance problem is to illustrate batteries with water. Free flowing water describes volume or amps. Water forced through a valve creates pressure or volts. Barrels of water can be the cells. If you filled each barrel individually (in parallel) there would not be a problem of balance between the cells, but you would only have a total voltage of 4.2 for the pack. You need more cells (or barrels) in series to get the voltage high enough to power the motor. Each barrel feeds into the next one so the pressure will vary when filling or draining.
An active balance system is needed at all times to allow this pressure (or voltage plus amps) to freely go back and forth to balance all the cells perfectly. Without these computer chips - the pack will continue to go out of balance potentially up to 50%. Two things happen: The pack is only as good as the the weakest cells' performance and not from the total. Some cells could even overcharge which will damage those cells. A smart charger can only try to burn off the excess voltage - while a balancer uses that excess to flow into the lower cells keeping them all equal. When weight is critical, we recommend running from any system that relies on a BMS without an active balancer.
Cylindrical and flat cell layout
All of our new battery cells will be INR LG 18650 MJ1
This cell has the highest energy storage per pound of any battery cell on the market today.
There are new batteries "on the drawing board" but so far, all attempts to make improvements have created other problems. We highly recommend looking at our onboard charging system as an alternative to adding more cells and weight.
We have standard sizes to keep the cost down. We do offer any custom size needed. Contact us for a quote for your application.
Note: Never use a battery management system that is not the active type. Packs are in series so they can get the high voltage needed. Each cell is carefully selected at the factory so the pack starts off balanced. But when charging or discharging - each cell does not except the same voltage. The reason is the resistance or capacity may except a higher voltage or it may be lower. An active BMS diverts the higher voltage to the lower cells until all the cells are perfect. That is why our charges last longer and you get more cycles.
The industry is slowly changing over to the safer cobalt cells and more and more BMS producers are offering the Active BMS systems for high voltage packs. Our goal is to provide the better performance that you can see and experience at the same cost.
The cylindrical cells work best for wing mounting.
They can side on a rack into one end in pairs of 2
with the end crossed over. That means the Poss
and negative are close to the controller with short
The pouch type is great for easier access to your
cells. Any configuration can be made and there is a variety of cells to choose from. No cooling fans are needed with the NCM type.
One - step
3 types of lithium batteries: Cylindrical Prismatic Pouch What are the differences?
Note: Spot welding or solder have many disadvantages. Our advanced system:
- Eliminates corrosion, worry about heat, the need to pre-punch, drill or align holes
- Reduces weight, assembly time and component cost
- Pierces and attaches the connections in one step
- Rivets can be extracted if needed
- Joins dissimilar and plated materials
- Ensures permanent assembly
- Excellent mechanical strength and fatigue performance
- Self-sealing joints that can be air- and water-tight
Let us help you with your battery storage needs.
Our entire system can be tested on most LSA and ultralight planes at no cost for the test.
Sail planes or motor gliders can be retro fitted with a single or twin installation.
Solar is great for for long term charging but lacks the amps needed to sustain flight.
Hybrid implies 2 power sources. We recommend electric for the primary and a charging system for sustaining flight. (possibly up to 4 hours.
The 110v AC charger can be carried on board. The epower can be added to use in flight or as a portable device with 4 fuel choices.
We are the only supplier of non welded battery cell tabs.
Pick your pack size:
The sample sizes below are based on 1, 2 or 3 layers. The 3 layers are the maximum for flat
packs. With the vents - the largest pack is 2" thick when using 12 cells in each layer.