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Worker & Aluminium Flywheels
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Boff
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Post Worker & Aluminium Flywheels  Reply with quote
NOTE: This is the technical article, if you want something more human readable and closer to a review check this blog article.

Flywheel technology has come to be a critical component of the modern super-stock foam combat space. Technological improvements over the last 2 to 3 years with the proliferation of better wiring practices and battery choices has created a field that is competitive and still safe. The advent of the Rhino 130 motor as a standard for 130 upgrades has solved the supply problem that has plagued upgrade motors. Plentiful access to wiring kits and other commercially available upgrade kits offers the end user a lower threshold of entry than in previous years.

However, there are still improvements to be made. It has been noted by several sources that poor quality flywheels are a problem. With several sources reporting flywheels walking off motor shafts at high rotational velocities and others reporting issues surrounding the trueness of the wheels themselves, it has become apparent there needs to be a solution.

Aluminium flywheels have long been discussed as an alternative to the Delrin flywheels supplied by Hasbro stock. The Dr Snikkas machined flywheel cage was one solution to this but as others have noted, it introduced too many variables to fairly and accurately assess its efficacy. Aluminium flywheels from Taobao are available by mail order. This design fits to the motor shaft using a pair of 2mm grub screws. This solves the problem of flywheels removing themselves from the shafts and offers a very effective means to balancing flywheels as it is possible to alter the balance of the system by altering the physical location of the grub screws. The flywheels procured through the Taobao website were a pair of machined flywheels with a roughened, surface. It is proposed that this will impede flywheel foam build up that has been shown to be beneficial in factory stock versions.

A further option is plastic 'Worker' flywheels that have a concave, toothed design illustrated in the picture below. The premise of this design is to increase the surface area between the dart and flywheel in order to raise muzzle velocity and output power. These flywheels offer a much thicker wall than the factory versions and are less prone to warping and bending when subject to hand-held stresses. While these wheels may not offer any sort of increase in velocity, it is projected they will reduce the spread of results as indicated by a smaller standard deviation. This effect is expected because of the lack of deformation during flywheel spinning and a more consistent contact surface.

 Given previous work done by this author it's easy to assess their  efficacy as it is possible to change one variable at a time and assess  the output.

It's important to note that these trials focus on muzzle velocity data as the sole indicator of performance. It is understood that this is not the sole indicator of performance and that the human will indeed be at the centre of the Nerf hobby, irrespective of the hardware they have access to.

Method:
Flywheel fitting:

Worker flywheels:


Worker flywheels are a simple push fit

These are a simple push fit but require noticeably more force to press them into place compared to the stock flywheels.

Aluminium flywheels:
These required a little more work. Push fit the flywheels initially to the motor shafts. Then, using the hex key provided, screw in the grub screws to their respective threads. The package contained spare grub screws to make up for loss which is fairly simple as they are tiny and difficult to see when dropped. Ensure equal numbers of turns are made to the screws so they protrude the same distance from the motor shaft thus balancing the flywheels as best possible.

Muzzle Velocity Data Collection:
Data collection for the Falcon 130 motors themselves was done using a Competition Electronics Pro-chrono Digital shooting chronograph with custom lighting rig, placed on a tripod. Shots were fired over the chronograph at a rate of 2/s (unless otherwise specified in the specific protocols). Each trial is run twice with 50 darts per trial for a total of 100 data points.

Flywheel masses:
Each flywheel was weighed on a standard weighing scale prior to fitting. The masses are listed in the images below.

Stock:


A single stock Stryfe flywheel complete with foam build up weighs 3.96g

Worker:


A single Worker flywheel weighs 3.87g but has no evidence of foam build up

Aluminium:


A single Aluminium flywheel weighs 8.28g.


Flywheel foam build up:
Prior to muzzle velocity trials, 5 18 dart magazines loaded with Voberry pattern foam darts were loaded and fired in rapid succession through the Stryfe while powered by a 3S 1000mAh for testing purposes. This process was repeated 4 times for a total of 360 darts. The aim of this test was to give an indicator of the foam build up on flywheels. This process was performed for both sets of flywheels prior to testing.

Comparative Data Sourcing:
Data for factory flywheels were sourced from previous work to study Falcon 130 motors on 3S LiPo.

The 2 3S Stryfe trials form the benchmark data for comparisons with this trial.

Stryfe Configuration
Batch number: 42484

The Stryfe was rewired using a Blastersmiths UK solid state wiring kit and switches. In the place of a micro-switch, a IRF44ZN MOSFET was used to control the flywheels using the stock harness. The same batteries were used for all trials so the LiPo was held outside the blaster using Velcro on this occasion.

The above configuration is same configuration as detailed in previous work done to assess the [uel=http://britnerf.co.uk/about1954.html]efficacy of Falcon 130 motors.[/url]

Constants:
Darts: Koosh (eBay seller BabyGiraffe, sourced August 2015) All darts are pack fresh and have not been fired prior to testing.

3S LiPo: ZIPPY Compact 2200mAh 3S 25C Lipo Pack

Results:
Aluminium Flywheels:
Aluminium flywheel complete results can be found here

Aluminium flywheel trial: #1
Mean Muzzle Velocity: 117.49FPS
Standard Deviation: 9.17

Aluminium flywheel trial: #2
Mean Muzzle Velocity: 120.40FPS
Standard Deviation: 9.62

Worker Flywheels:
Worker flywheel complete results can be found here

Worker flywheel trial: #1
Mean Muzzle Velocity: 128.5FPS
Standard Deviation: 14.43

The test protocol was altered after this trial to add a set of diffused photography studio lights around the chronograph in an effort to over-come the possibility of high reads from incorrect lighting conditions. Trials #2 and #3 were performed using this altered set up.

Worker flywheel trial: #2
Mean Muzzle Velocity: 131.96FPS
Standard Deviation: 16.16

Worker flywheel trial: #3
Mean Muzzle Velocity: 124.42FPS
Standard Deviation: 10.11

Flywheel Foam Build Up:
The flywheels were photographed after all trials had been completed to show if there had been any foam build up on them. While not providing any form of quantitative information, it is seen as a useful yard stick in the community for how a flywheel system might perform.

Stock flywheels{/b]


This photo is included for reference. The flywheels pictured above have been in use through a Green Cloaks season and have been used in many different trials and events. It is provided to illustrate the amount of foam build up that occurs on a stock of factory flywheels so as to offer a point for comparison below.

[b]Aluminium flywheels:



Notice the minor tracks of foam build up but the flywheels are otherwise clean.

Worker flywheels:


Notice the complete lack of foam build up on these flywheels.

Analysis:

Stock Flywheels:
For reference, the aggregated data for the stock flywheels performance (data can be sourced here) is listed below.
Stock Mean Muzzle Velocity: 112.86FPS
Stock Standard Deviation: 15.87

Worker Flywheels
Aggregated Mean Muzzle Velocity:128.19FPS
Aggregated Standard Deviation:13.99
Aggregate formed from Trial #2 and #3

t-test vs stock data: p = 1.18E-11

The Worker flywheels demonstrated a marked velocity increase over the stock flywheels with an average output of 128.19FPS compared to  aggregated datasets of Trial #2 and #3. There was a slight drop in the aggregated standard deviation from stock indicating a marginal increase in the consistency of data but further trials will be needed to fully explore this effect. Given such a small difference, it is difficult to say whether this effect is statistically significant and warrants further study.

The comparative difference between the Worker flywheel data and the stock data is clear and statistically significant as demonstrated by the t-test value.

Aluminium Flywheels
Aggregated Mean Muzzle Velocity: 118.78FPS
Aggregated Standard Deviation:9.46
Aggregate formed from Trial #2 and #3

t-test vs stock data: p = 0.001

The Aluminium flywheels also showed a marked increase over the basic stock flywheels but but fell short of the mean velocity of the Worker flywheels. The standard deviation for the aggregated data set is smaller than either the stock or the Worker flywheels, indicating a more consistent muzzle velocity output. Further work is required to determine what real-world effective this might have.

The comparative difference between the Aluminium flywheels and stock was significant at p=0.001 while the difference between Worker and Aluminium was very significant with a t-test result of 9.51E-8

Discussion:
Both sets of after market flywheels offered a performance improvement of the stock counterparts. The reasons for these differences should be taken in turn.

The improvement in muzzle velocity with the Worker flywheels is likely down to the increased rigidity and larger contact surface area compared to the smooth stock flywheels. Prior concerns about dart damage and friction due to air resistance from the grooves cut into the flywheel appear to be unfounded. While there is not a vast difference in the Standard Deviation of the data sets (15.87 for stock and 13.99 for Worker), it is worth noting for further study. Additional studies into the real world impact these flywheels have is also warranted.

The Aluminium flywheels show a marked decrease in standard deviation compared to the other 2 data sets. While only offer an average of 6FPS increase over stock flywheels, it would appear this flywheel system can offer a more consistent output power than the other 2 systems trialled in this study. Further work to determine the real world effect, including on accuracy will determine if this difference is a freak of statistics or an actual effect that comes from one of the various intrinsic properties of the aluminium used.

It is important to highlight the presence of high reads in of these data sets. Conventional wisdom for the Nerf community is that a flywheeler will struggle to hit past 130FPS. In all of these data sets there are numbers above 150FPS. These have been left in the analysis to offer complete openness in terms of the data gathered. Enhanced data analysis might opt to introduce a clear cut-off for higher results. This is a tricky area, however as while these results might be outliers, it is hard to say whether they are an instrumentation or protocol defect as they are within a few standard deviations from the mean. Wildly high reads on the order of magnitude or other such obvious problems are not present. In turn, it is very difficult to tease out if these high reads are the result of error or simply pure luck where dart, flywheel and motor come to perform a perfect shot that produces a higher than expected muzzle velocity.

Given the unexpected result from the Worker flywheels, other testers are invited to attempt to replicate these results. If there are any enquiries on protocol then please use the appropriate means of contact for the location of this article.

Disclosure:
The author is an employee of Blastersmiths UK Ltd and owns shares in the company.


A note on data ethics and publication bias:
I'm committed to the principle of All Trials which essentially means that all the tests I do get published; not just the successful ones or the comparative ones. If I've done it it'll be here on BritNerf. The more data we have, the more useful things we can determine by analysing it. Something I might miss, someone else might notice because of the data I've published. Yes, I'll use the successful data when I'm promoting a mod or upgrade but the bad stuff will be here, too.

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Last edited by Boff on Sat Jan 09, 2016 4:16 pm; edited 1 time in total
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old_man_nerf
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Post Reply with quote
TL / DR worker wins?

Actually good article. Will actually upgrade my fly wheels now if the improvements are that good.


Last edited by old_man_nerf on Sat Jan 09, 2016 7:56 pm; edited 1 time in total
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Boff
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Post Reply with quote
Yup, tl;dr Worker wins - OldNoob and I have some humble pie to eat after our ragging on them back in December. I was genuinely surprised by the results.

Of course, others are invited to replicate the data to see if I've made a mistake somewhere. Always happy to be proved wrong.

If you're after a link for them, they can be had from eBay here.

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Aldegar
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Post Reply with quote
Thank you for testing them, I like that they are lighter and more precise than the originals. Any observations on sound or spin up time?

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Aldegar
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Post Reply with quote
Thank you for testing them, I like that they are lighter and more precise than the originals. Any observations on sound or spin up time?

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Boff
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Sound is more even and less rattly than stock, no change in spin up time - it's instantly on in both cases. I have a feeling Falcon 130s have torque in excess so there's no difficulty there. Smile

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OldNoob
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Post Reply with quote
Happy to suck a bit if humble pie. My major beef with them was that there was no decent data and lots of bull/assumptions around them. Also still no true test against a fully balanced stock set, I will try and replicate that for you all.  I have had near that overall performance on elites with Stryfe flywheels, so still not convinced that they represent the ultimate solution. I still maintain the teeth are an error, but I will need my own design out to prove it.

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Big_Poppa_Nerf wrote:

Boff whats the damage? I have spent over 3 times my Nerf budget this month already. Part of me is trying to be a responsible parent/husband/house owner. The other half is just says 'Ahhhh, Screw it!'.
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Aldegar
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Also, there is a newly designed nipple j dart that is supposed to be optimized for these flywheels.
http://world.taobao.com/item/5251...00824.w4002-11859455456.12.qSZcrk

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OldNoob
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Those are just FVJ 2.0, the MTB guys have tested a load of the purple, nothing special about them afaik. They won't be UK war legal either. Solid vinyl heads are stupid and need to go away. We need a decent silicone type head, like a heavier Koosh.

The worker final stage pusher is supposedly to help get the dart into the deeper centre of the concave fly's though, which I hadn't considered.

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Big_Poppa_Nerf wrote:

Boff whats the damage? I have spent over 3 times my Nerf budget this month already. Part of me is trying to be a responsible parent/husband/house owner. The other half is just says 'Ahhhh, Screw it!'.
Sat Jan 09, 2016 9:08 pm View user's profile Send private message Send e-mail
super gripper
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Post Reply with quote
Fantastic lot of data, top job.

I have been using the Worker fly wheels in a lot of my builds. Super impressed with them and the marked increase in dart velocity.

Having done quite a few commissions and recommending the Worker fly wheels people have been super happy.

I currently have two stryfe's built and ready with these fly wheels on ebay or come direct to me to get them a bit cheaper.

http://www.ebay.co.uk/itm/Nerf-St...item3d0c9520eb:g:WOMAAOSwZ1lWeXiZ
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Aldegar
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OldNoob wrote:
Those are just FVJ 2.0, the MTB guys have tested a load of the purple, nothing special about them afaik. They won't be UK war legal either. Solid vinyl heads are stupid and need to go away. We need a decent silicone type head, like a heavier Koosh.

The worker final stage pusher is supposedly to help get the dart into the deeper centre of the concave fly's though, which I hadn't considered.


I was talking about the orange nipple darts which looks like are not there anymore. FVJ's hold up much better than koosh, work well in any blaster, and are dirt cheap. Replacing barrels and re-glueing tips are not on my list of fun activities.

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OldNoob
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They are still useless. We need a flat ended Superstock dart like the one the Aussies have, with a tip that isn't rock hard. I can't use FVJ in any indoor venue because of fixture damage and given that my outdoor kit already generates a split lip at 10ft with Koosh (ask CarrierII) I wouldn't want to use a harder tip compound. The weight distribution and foam quality isn't an issue, it's the lousy cheap and offensive tip. The darts linked are definitely a solid vinyl tip.
If I wanted to come home covered in welts I would play paintball. You will never see FVJ at an event I run, regardless of who is playing. I want to have minimal injuries, a system that is inclusive, doesn't need a full face mask and honestly if I have to throw away 10% of my darts every game to achieve that, fine.
We are reaching the point where 110-130fps is commonplace in some systems, these flywheels are taking us closer to easily shooting a 130 average for under $100 all in which means ammunition safety has now got to be considered.
Koosh isn't a permanent solution, there are as many things wrong with them as there are with FVJ, they just damage people and property less.

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Big_Poppa_Nerf wrote:

Boff whats the damage? I have spent over 3 times my Nerf budget this month already. Part of me is trying to be a responsible parent/husband/house owner. The other half is just says 'Ahhhh, Screw it!'.
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Boff
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Post Reply with quote
OldNoob wrote:
Koosh isn't a permanent solution, there are as many things wrong with them as there are with FVJ, they just damage people and property less.


Curious to hear your alternatives. Koosh are pretty ideal from where I'm standing for all the reasons you've stated. They have the added advantage of being nice and distinctive in eBay listings so you know what you're getting. As a safety planner for what is probably the largest regular organised Nerf event in the UK, that makes my life so much easier. For Green Cloaks, 2016 is basically going to boil down to Koosh or Elite me thinks.

Which dart is that the Aussies use? The blue silicone ones that Brisbane Nerf wars use?

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McRex
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Post Reply with quote
Boff wrote:
OldNoob wrote:
Koosh isn't a permanent solution, there are as many things wrong with them as there are with FVJ, they just damage people and property less.


Curious to hear your alternatives. Koosh are pretty ideal from where I'm standing for all the reasons you've stated. They have the added advantage of being nice and distinctive in eBay listings so you know what you're getting. As a safety planner for what is probably the largest regular organised Nerf event in the UK, that makes my life so much easier. For Green Cloaks, 2016 is basically going to boil down to Koosh or Elite me thinks.

Which dart is that the Aussies use? The blue silicone ones that Brisbane Nerf wars use?


Really, get blue Koosh if you want it on the cheap, get genuine elites if you have the money.
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OldNoob
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Yeah, the flat tip ones. I was thinking of a tip weight of around 1-1.2g, a good stiff full length foam and a soft rubber tip, like a full length Amior. Essentially the weight balance and ballistic shape of Koosh without the tip overlapping the foam and a touch more tip mass for greater stability over 120fps. ACC darts are heading in the right direction tip compound wise but shape, adhesion and quality are all crap.
I can almost live with gen 3 Koosh but they still fail in use and the inconsistency of the foam is still there from the older ones.
How many misfires did you get in your test? I had no Koosh dart tip failures in my Koosh Vs ACC shootout, despite the huge torque on hand from the URP.

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Big_Poppa_Nerf wrote:

Boff whats the damage? I have spent over 3 times my Nerf budget this month already. Part of me is trying to be a responsible parent/husband/house owner. The other half is just says 'Ahhhh, Screw it!'.
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Aldegar
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Post Reply with quote
Its the rainy season here and we have been playing in the house a lot lately. My kids are 11 and 7, we all have fully modded stryfes and strictly use fvj's. Nobody has been injured beyond what an elite dart would do and there has been no property damage. I dont consider them dangerous at all in superstock blasters but understand the concern as you run more public games.
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SSGT
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Post Reply with quote
I'd definitely like to see another dart alternative. Koosh are great all-rounders but are no good in long sealed barrel setups unless you go through your box of darts and remove the outer ring of bristles from every single one. Unless FVJs are allowed at that particular game that means you're pretty much stuck with Elites or Voberries - neither of which I'd want to use at superstock velocities. Homemade darts are an option but I really can't be arsed finding the materials and sitting down and making 500-1000 darts at a time before every game (I now tend to go into games with the expectation that I'll lose most of my darts - either through physical loss or damage/wear). At that point I might aswell go back to modifying Kooshes.

The only issue with darts that have more mass is what you then do about velocity limits. If 130fps is the Elite/Koosh limit you'd need a lower limit for a dart with a greater mass (unless the tip design is comparatively "safer") as the dart with more mass will have/transfer more energy than a dart with less mass at a given velocity. Generally a blaster will fire a dart with more mass at a lower velocity anyway but that isn't always the case - the foam of the dart with more mass may be better suited to the barrel/flywheels of the blaster than the dart with less mass and may achieve the same velocity.

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OldNoob
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The tip mass increase keeps the whole dart below 1.5g, foam is typically 0.3g for a standard full length. Koosh is too light for upper end. 130 is only the GC limit, it's not an absolute but I picked it because 110-130 is where the majority of UK blasters are shooting.



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Big_Poppa_Nerf wrote:

Boff whats the damage? I have spent over 3 times my Nerf budget this month already. Part of me is trying to be a responsible parent/husband/house owner. The other half is just says 'Ahhhh, Screw it!'.
Tue Jan 12, 2016 8:01 am View user's profile Send private message Send e-mail
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