2023-07-09-Series 2 Controller Development

We have decided that we will build a series 2 version of our Controllers. The objectives are two:

1. fiver Controllers – Reduce cost and assembly complexities of the fiver by right-sizing the relays. 10-12A relays will be perfectly suitable to model rockets. Smaller relays may be PCB mounted and this may be used to reduce parts counts and assembly steps.
2. HPR Controllers – 24v Console power will extend the range of these controllers significantly and further differentiate them from the fiver controllers. With an added internal battery bank, voltage to the Console will be at least doubled. Extensions of 600 ft or more may be practical – even with multiple pads selected for launch. The Controller power bus will still be at 12v.

I had been toying with the idea of a relay board with less costly relays. Keeping up with events and building controllers as we sold them meant no progress on this front. We have been profitable for several months in a row. This month we decided to bite the bullet and devote some time to this project. I have selected a couple of smaller relays and designed PCBs for them. I ordered relays and boards on July 8th and 9th of 2023. Testing and integration take time. We hope to have the Series 2 fiver design wrapped up and in production by October.

I have also been investigating LiON battery options for the HPR controllers. A friend introduced us to 18650 cells. I like these a lot. I looked at a lot of LiPo cells and the limitations and caveats with their use.

These cells have a great life rating and I can ship a charger for them with each controller. 4 x 3.7vdc is