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V-Control Switches & Lost Power - Crash

Posted by 3D Dave 
V-Control Switches & Lost Power - Crash
May 19, 2021 04:09AM
So I had another incident with a NEO over the weekend.

Flipped to inverted, and lost power from about 30 feet up. I'm 99% sure I hit rescue (V-Control classic) at that instant and it just kept falling.

I'm posting a few logs here for some dissection and discussion to see if someone can shed some light. The last log (16:42:14) is the crash.

VBar Start -- Oxy 5 6s -- 16.05.2021 -- 14:43:01 (Good Flight)
14:43:02;1;Reset Reason: Power On
14:43:02;2;Bank 2 Loaded
14:43:02;1;Motorswitch Motor Off
14:43:03;1;Motorswitch Idle Bailout
14:43:08;2;Calibration Finished
14:43:17;1;Batt sel manually: PUL #1 6s5000 Old
14:44:21;2;Bank 1 Loaded
14:44:23;1;Motorswitch Idle Bailout
14:44:26;1;Motorswitch Motor On
14:44:39;2;Raised Vibration Level
14:45:09;2;Raised Vibration Level
14:45:19;2;Raised Vibration Level
14:46:05;2;Bank 2 Loaded
14:48:01;2;Raised Vibration Level
14:48:22;2;Raised Vibration Level
14:48:32;2;Raised Vibration Level
14:48:52;2;Raised Vibration Level
14:49:02;2;Raised Vibration Level
14:49:22;2;Raised Vibration Level
14:49:33;2;Raised Vibration Level
14:49:53;2;Raised Vibration Level
14:50:03;2;Raised Vibration Level
14:50:33;3;High Vibration Level
14:50:43;2;Raised Vibration Level
14:50:54;3;High Vibration Level
14:51:06;1;Motorswitch Idle Bailout
14:51:07;1;Motorswitch Motor Off
14:51:14;2;Raised Vibration Level
VBar Logfile End -- 16.05.2021 -- 14:53:09


VBar Start -- Oxy 5 6s -- 16.05.2021 -- 15:21:31 (Good flight but 6 extreme vibration level warnings)
15:21:31;1;Reset Reason: Power On
15:21:32;2;Bank 2 Loaded
15:21:32;1;Motorswitch Motor Off
15:21:33;1;Motorswitch Idle Bailout
15:21:35;2;Calibration Finished
15:21:50;1;Batt sel manually: PUL #2 6s5000 Old
15:22:54;2;Bank 1 Loaded
15:23:01;1;Motorswitch Idle Bailout
15:23:02;1;Motorswitch Motor On
15:23:16;2;Raised Vibration Level
15:23:26;2;Raised Vibration Level
15:23:37;2;Raised Vibration Level
15:23:47;2;Raised Vibration Level
15:23:57;3;High Vibration Level
15:24:07;2;Raised Vibration Level
15:24:17;3;High Vibration Level
15:24:27;4;Extreme Vibration Level
15:24:37;4;Extreme Vibration Level
15:24:48;4;Extreme Vibration Level
15:24:57;4;Extreme Vibration Level

15:25:08;2;Raised Vibration Level
15:25:18;2;Raised Vibration Level
15:25:28;2;Raised Vibration Level
15:25:38;2;Raised Vibration Level
15:25:48;2;Raised Vibration Level
15:25:58;2;Raised Vibration Level
15:26:08;2;Raised Vibration Level
15:27:09;2;Raised Vibration Level
15:27:30;2;Raised Vibration Level
15:27:40;2;Raised Vibration Level
15:27:50;3;High Vibration Level
15:28:00;2;Raised Vibration Level
15:28:02;2;Bailout Start
15:28:04;2;Bailout End
15:28:04;2;Bailout Pilot Oversteer
15:28:10;4;Extreme Vibration Level
15:28:20;2;Raised Vibration Level
15:28:30;2;Raised Vibration Level
15:28:38;1;Motorswitch Idle Bailout
15:28:38;1;Motorswitch Motor Off
15:28:51;3;High Vibration Level
VBar Logfile End -- 16.05.2021 -- 15:29:41


VBar Start -- Oxy 5 6s -- 16.05.2021 -- 15:44:54 (Good flight but 3 extreme vibe warnings)
15:44:54;1;Reset Reason: Power On
15:44:55;2;Bank 1 Loaded
15:44:56;2;Bank 2 Loaded
15:44:56;1;Motorswitch Motor Off
15:44:56;1;Motorswitch Idle Bailout
15:44:58;2;Calibration Finished
15:45:07;1;Batt sel manually: Din #1 6s5000
15:46:16;1;Motorswitch Idle Bailout
15:46:18;1;Motorswitch Motor On
15:46:30;2;Raised Vibration Level
15:46:38;2;Bank 2 Loaded
15:46:50;2;Raised Vibration Level
15:47:00;3;High Vibration Level
15:47:10;3;High Vibration Level
15:47:20;3;High Vibration Level
15:47:30;3;High Vibration Level
15:47:40;3;High Vibration Level
15:48:01;2;Raised Vibration Level
15:48:21;2;Raised Vibration Level
15:48:31;4;Extreme Vibration Level
15:48:41;2;Raised Vibration Level
15:48:51;3;High Vibration Level
15:49:02;3;High Vibration Level
15:49:12;3;High Vibration Level
15:49:22;3;High Vibration Level
15:49:32;4;Extreme Vibration Level
15:49:42;3;High Vibration Level
15:49:52;3;High Vibration Level
15:50:02;3;High Vibration Level
15:50:12;4;Extreme Vibration Level
15:50:23;3;High Vibration Level
15:50:33;2;Raised Vibration Level
15:50:43;3;High Vibration Level
15:50:53;2;Raised Vibration Level
15:51:03;2;Raised Vibration Level
15:51:12;1;Motorswitch Idle Bailout
15:51:12;1;Motorswitch Motor Off
15:51:13;2;Raised Vibration Level
15:51:23;2;Raised Vibration Level
VBar Logfile End -- 16.05.2021 -- 15:52:15


VBar Start -- Oxy 5 6s -- 16.05.2021 -- 16:06:30 (Good flight but 5 extreme vibe warnings)
16:06:30;1;Reset Reason: Power On
16:06:31;2;Bank 2 Loaded
16:06:31;1;Motorswitch Motor Off
16:06:32;1;Motorswitch Idle Bailout
16:06:34;2;Calibration Finished
16:06:42;1;Batt sel manually: Din #2 6s5000
16:07:31;2;Bank 1 Loaded
16:07:35;1;Motorswitch Idle Bailout
16:07:36;1;Motorswitch Motor On
16:07:45;2;Raised Vibration Level
16:07:55;3;High Vibration Level
16:07:56;2;Bank 2 Loaded
16:08:05;2;Raised Vibration Level
16:08:15;3;High Vibration Level
16:08:26;3;High Vibration Level
16:08:36;3;High Vibration Level
16:08:46;3;High Vibration Level
16:08:56;2;Raised Vibration Level
16:09:00;2;Bank 3 Loaded
16:09:06;3;High Vibration Level
16:09:16;4;Extreme Vibration Level
16:09:26;4;Extreme Vibration Level
16:09:36;4;Extreme Vibration Level
16:09:47;4;Extreme Vibration Level
16:09:57;4;Extreme Vibration Level

16:10:07;3;High Vibration Level
16:10:17;3;High Vibration Level
16:10:27;3;High Vibration Level
16:10:37;2;Raised Vibration Level
16:10:47;3;High Vibration Level
16:10:57;3;High Vibration Level
16:11:03;2;Bank 2 Loaded
16:11:07;2;Raised Vibration Level
16:11:18;3;High Vibration Level
16:11:28;2;Raised Vibration Level
16:11:29;1;Motorswitch Idle Bailout
16:11:29;1;Motorswitch Motor Off
VBar Logfile End -- 16.05.2021 -- 16:12:51


VBar Start -- Oxy 5 6s -- 16.05.2021 -- 16:42:14 (Lost power while inverted, no recovery)
16:42:14;1;Reset Reason: Power On
16:42:15;2;Bank 2 Loaded
16:42:15;1;Motorswitch Motor Off
16:42:16;1;Motorswitch Idle Bailout
16:42:18;2;Calibration Finished
16:42:23;1;Batt sel manually: Din #3 6s5000
16:43:38;1;Motorswitch Idle Bailout
16:43:39;1;Motorswitch Motor On
16:43:49;2;Raised Vibration Level
16:44:00;2;Raised Vibration Level
16:44:01;2;Bailout Start
16:44:02;3;The Cyclic Ring is active
16:44:02;3;The Cyclic Ring is active
16:44:02;3;The Cyclic Ring is active
16:44:03;3;The Cyclic Ring is active
16:44:03;3;The Cyclic Ring is active
16:44:03;3;The Cyclic Ring is active
16:44:04;3;The Cyclic Ring is active
16:44:04;3;The Cyclic Ring is active
16:44:04;4;Elevator Sensor Value out of Range
16:44:05;3;The Cyclic Ring is active
16:44:05;1;Motorswitch Motor Off
16:44:05;3;The Cyclic Ring is active
16:44:05;3;The Cyclic Ring is active
16:44:06;2;Bailout End
16:44:06;2;Bailout Pilot Oversteer
16:47:46;3;The Cyclic Ring is active
VBar Logfile End -- 16.05.2021 -- 16:55:01


I'd really appreciate it if someone can tell me what's going on. Unfortunately, this exact same thing happened 2 years ago (different NEO), and 1 year ago (another different NEO).

I know extreme vibe warnings can be common in hard 3D moves, but I'm not sure if there's a connection with the problem.

I'm starting to wonder if maybe it's an issue with my V-control (switch malfunction or, really user error). I don't see how 3 different NEO's could produce the same reaction.

I've had the V-control for 6 years now, so maybe a switch (or switches) are the culprit.

I'm thinking about replacing the switches I use the most.

Thanks for your help.

PS, I will add a pic of my TX and switch assignments.



Edited 4 time(s). Last edit at 05/19/2021 04:22AM by 3D Dave.
Re: V-Control Switches & Lost Power - Crash
May 19, 2021 04:17AM
I changed the switch positions on the top right back when the TX was new (2015)

Here's a pic of my V-Control showing the switch positions and assignments for the last 6 years.


Re: V-Control Switches & Lost Power - Crash
May 19, 2021 09:11AM
Hi Dave,

sorry to hear.

About the vibration warnings, they are not critical _if_ it doesn't affect flight (like drift on one or more axis).
They are measured at the gyros as always, and they cover a frequency range of 0...500 Hz (0...30,000 1/min 'shaft rpm', whatever is spinning at that speed, this is also what you see in the graphic vibration analysis).
Vibration doesn't cause a power loss, unless it causes wires to chafe/get harmed, or connectors to disconnect.

In the last log, there is no evidence for a motor-off from the VBar (switch action) or a loss of radio link and subsequent fail safe.
Means, the VBar was constantly outputting a throttle signal to the ESC.
Also, no low voltage warnings, no warm start, so the power supply was good all the time.

The conclusion can only be, there was something else going on or going wrong, ESC disconnected, wire harmed and a short circuit, a glitch on the ESC's signal line, or the ESC simply quitting on you. I mean, it sounds threadbare, but the sky is blue, the water is wet, ESCs sometimes just quit on you.
Still I would check the NEO's ESC signal output, with home tools, connect a servo, wiggle/press/squeeze and see if it goes limp or acts erratic, with an oscillocope, also check the voltages and signal, if they drop.

What comes then substantiates this:

You hit Rescue, the VBar tries to upright the model, but it can't, has not much authority left, with the quickly dropping head speed.
Tell tales are the cyclic ring entries, means, the VBar outputs full cyclic and runs into it's own internal electronic limits, because the model doesn't come around.

Then, like a leave in the wind, then the the impact, sensors out of range, you switch off the motor, and already on the ground, 4 secs (of timeout) later, the VBar ends the Rescue because it was not able to upright the model, and it even 'rats you out' smiling smiley that you tried to help, that you were working the sticks at that time, too.

In my opinion, and per the log, all your switch operations came through—I mean, the log entries are generated by the VBar NEO and are subsequently Morsed back, it's not the radio just writing it and maybe not sending it. If there's a log entry, it happened _on the model_, if there isn't, there was no situation to raise the alarm.

I can not tell about the other incidents, but honestly, hardly any two are the same, even if it always looks the same: oops, drop, crash, sh*t.

That's my interpretation, and with that, I would pretty much rule out the NEO and almost absolutely rule out the radio.

So ... motor, wiring, ESC, wiring, connectors, insulation, load of the ESC during that flight ... if the ESC has internal logging, that could help.
If there was a U/I Log, that could help. Both could e.g. show that there was a PWM signal to the ESC all the time, but that it quit anyways, or they could even have warnings, like over current, over temperature, whatever there is.

Or, even simpler, something just let go in the power train, pinion, a set screw, the one way bearing.

—Eddi

Born to fly ...
forced to work.
Re: V-Control Switches & Lost Power - Crash
May 19, 2021 04:45PM
Hi Eddi.

So the ESC is an old Heli Jive 120HV. I don’t know if it has an issue, but it has seen lots of use.

Since the heli damage was fairly minimal (cracked lower frame), I tried cycling power and spooling it up for just a few seconds to see if it would, and it did. I shut it down right away though as I didn’t want to have a 2nd incident with worse damage.

I will go over it thoroughly during repair and see if any wires are chaffed or damaged, but I don’t think so.

I also try to keep power wires and data wires separate on all my helis. Also, the one way is a heavy duty sprag (Oxy 5) and the pinion seemed fine but I will double check those too.

That said, I think I’m also going to swap new switches in the TX for motor off/run and momentary rescue just for piece of mind.



Edited 1 time(s). Last edit at 05/19/2021 04:46PM by 3D Dave.
Re: V-Control Switches & Lost Power - Crash
May 19, 2021 04:51PM
Hi Dave,

good calls, all of them.

Fingers crossed you find something, always bad if doubts remain :-/

Best,

Eddi

Born to fly ...
forced to work.
Re: V-Control Switches & Lost Power - Crash
May 31, 2021 05:55AM
Hi Eddi.

So I replaced the short 3 position switch (motor run/idle/off) and the long 3 position/momentary (used for rescue) with new switches. I had previously physically switched the positions of those however, having the long one in the front and short in the back as I much preferred that way with how I hold the radio (and wanted the rescue switch easier to reach).

One thing I noticed in the old momentary switch, was that one of the wires going into the white connector had about 1mm if bare wire exposed. Under a 30x magnifier I see 2-3 strands broken right at the connector. I don't know, but I guess maybe that was causing the issue. I don't know how they broke, as the wires seemed secure, with no tension where they were routed.

In putting the new ones in, I decided to put them back in their original factory positions.

I have now flown 4 flights and tested rescue (on a Goblin 500) about 20 times and all were successful.

The thing is, I'm not comfortable with the rescue switch in the back. I'd rather have it back on the front where the short switch is. I'm trying to get used to it, but I'd prefer to have it back the way I had it.

That brings me to a question, but I'll start a new thread as I'm sure I'm not the only one that has physically moved a switch on the TX.
Re: V-Control Switches & Lost Power - Crash
May 31, 2021 09:45AM
Hi Dave,

thank you for your feedback.

Hard to tell, with the exposed/frayed wire. In the radio, there is no vibration or constant wear, so the only thing I can imagine is that it can happen if you pull the plug by the wire, not by the connector.

You can move the switches, on the radio. The only hitch is, the top ones are ergonomically tilted forward, which makes the finishing cap hard to grab (without risking damage to the surface of the case).

Then, the 3x3 connectors on the mainboard need careful handling, if you only pull the wire, you can easily leverage them off—hold them between thumb and index finger and apply some force against the mainboard, then you can safely unplug.

—Eddi

Born to fly ...
forced to work.
Re: V-Control Switches & Lost Power - Crash
May 31, 2021 10:29PM
Hi Eddi.

Yes, I was careful to pull on the connector housing when I unplugged the switches.

It is very hard to grasp them however.

Maybe I should try using something like micro tweezers next time.

Anyway, all seems good for now.

Thanks for your help!
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