Thank you for providing detailed description of the tests. I just requested access to the logs.
Please see the following comments:
ESC temperature: the VOXL FPV ESC is rated for pretty high operating temperatures. For example, the MCUs are rated to run at up to 125C MCU temperature. I would not recommend running the ESC above 100C, however I am confident that the ESC will perform fine even above 100C. We typically recommend designing the system such that ESC temperature does not exceed 80C under normal flight conditions - this gives plenty of margin before a failure would occur. Did you take note of the ESC temps of VOXL ESC? VOXL FPV ESC reports two types of temperatures: two of the IDs (ID 0, 3) are measuring the ESC temps from separate temperature sensors located on top and bottom of the ESC. IDs 1 and 2 are reporting the MCU temps (the temperature of the MCU silicon). The MCU temps at steady state are typically a bit higher (5-7 deg C higher) because the MCU itself generates a little heat internally. VOXL ESC not responding after a crash : the likely reason is mechanical damage as a result of the crash. Components can be knocked off during the crash. If the ESC powers on briefly (you see the leds blink initially, but then the ESC turns off), then the likely issue is some kind of short or high load on one of the regulated ESC power rails (5V or 3.3V) -- the high current drain (due to some issue) results in the voltage regulator to turn off due to over-current, resulting in the ESCs shutting down. If only 3 out of 4 LEDs blink, then it is possible that one ESC channel has some sort of a short (due to mechanical damage) and it does not turn on, eventually causing the power rails to be disabled due to over-current. motor suddenly stopping in flight: this is often a result of a mechanical issue related to mounting the motor to the frame. Sometimes the motor mounting screws are too long and they can penetrate the motor windings and cause intermittent failures just like this. We have experienced this ourselves several times when long screws were used and were touching the motor windings. Alternatively, something could be touching the ESC itself and intermittently affecting operation of the ESC once I see the px4 log with the FPV ESC, i can check if one of the motors was operating abnormally before it stopped spinning. There is some additional information in the log that can tell us if a particular motor requires more power to spin (compare to the others).Questions:
do you have px4 logs of the VOXL ESC with one of the motors shutting down in flight? is it possible that the aluminum enclosure is making contact with the ESC components, causing some kind of short? especially during crash, perhaps the ESC is making contact with the enclosure? did you check if the motor temperature was OK after successful flights? what was the total current draw during flight when the failure occurred? (should see that in the px4 log)Alex