@Alex-Kushleyev
Thank you for your continued support and assistance with this investigation.
Please find attached the system architecture diagram (power flow) of our platform for your review.
We would appreciate it if you could review the architecture and advise whether there are any potential concerns related to the power distribution, grounding scheme, wiring, connectors, ESC installation, or any other aspect that could contribute to the behavior we observed with the VOXL FPV ESC.
Additionally, we would like to highlight a few observations from our testing activities.
The abnormal ESC behavior was not present during the initial flight tests. The aircraft completed multiple successful flights before the failures began to occur. This leads us to believe that a direct short circuit caused by the frame, enclosure, or mounting arrangement may be less likely, as such an issue would typically manifest from the beginning of testing rather than after several successful flight cycles.
To further isolate the issue, we replaced the VOXL FPV ESC with a third-party NeutronRC X-CLASS 4IN1 ESC (70A). Following the replacement, the aircraft has been operating normally and has successfully completed multiple flight tests without any motor shutdown events or ESC-related failures.
At present, the third-party ESC continues to function correctly, and we have not observed any of the symptoms previously encountered with the VOXL FPV ESC. Motor operation, flight stability, and overall system performance remain normal.
This observation is particularly important because the remainder of the system configuration has remained largely unchanged, including:
VOXL2
Flight Controller V2
Power distribution architecture
Motors
Propellers
Battery configuration
Airframe and enclosure
Given that the issue is not reproducible with the third-party ESC, we are trying to better understand whether there may be any specific factors related to the VOXL FPV ESC installation, operation, thermal conditions, configuration, or hardware that could have contributed to the failures we observed.
For reference, the ESC installation includes:
An aluminum heatsink mounted beneath the ESC
Thermal interface material between the ESC and heatsink
Nylon spacers providing electrical isolation
A dedicated 3D-printed mounting structure preventing contact with the aluminum enclosure
Based on the current mechanical arrangement, we do not believe there is any direct electrical contact between the ESC and the enclosure.
We would greatly appreciate your guidance on any additional troubleshooting procedures that you would recommend for the VOXL FPV ESC, including:
Hardware inspections
Diagnostic tests
Additional logging parameters
Thermal validation methods
Power system checks
Known failure modes or common causes for the symptoms observed
If there are any specific measurements, logs, or test procedures that would help narrow down the root cause, we would be happy to perform them and share the results.
Thank you once again for your continued support and technical guidance.
We look forward to your recommendations on the next steps.
Thank you
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