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[WIP] Hooligan Flywheels - Stock Cage & Artefact Red Cag

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[WIP] Hooligan Flywheels - Stock Cage & Artefact Red Cag
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The Dealer

Joined: 08 Dec 2012
Posts: 3411
Fav. Blaster: (Modified) Stampede ECS
Location: Bristol, UK

Post [WIP] Hooligan Flywheels - Stock Cage & Artefact Red Cag  Reply with quote
I'm back with another one of my long technical articles on the latest hotness in the flywheel community. This one's not terribly human readable but it does the job. If you find more data and analysis anywhere else, I'd like to see it. Smile


Flywheel technology has become the de facto standard in the UK and wider Nerf community. The ready availability of upgrade motors and wiring looms has resulted in a proliferation of flywheel blasters. Semi-automatic and fully automatic options are now game-play staples and the result is a more fluid, tactical game that relies more on the player than the hardware. However, there are still areas where the hardware can be improved.

One of the key areas is the lack of a good quality, consistently machined flywheel. Stock Hasbro wheels leave a great deal to be desired in terms of consistency. They are often weight mismatched, poorly shaped and improperly aligned. Worker wheels have been explored before and have provided an amount of improvement but a high precision CNC machined wheel would be the next step up. were the first to produce such a wheel but its dimensions were found wanting. The testing done here on this forum shows their smaller size results in poorer performance. More recently, Hooligan Blaster Co out of Dayton, Ohio have presented the Hooligan Flywheel as a a full size CNC machined piece of equipment.

Hooligan Flywheels are CNC machined plastic and are still push fit. The shaft fit is tight so the wheel must be handled and fitted warm. The consistency of the machining and weighting ought to result in better consistency than a traditional Hasbro flywheel. The slight change in dimensions may also lead to a higher dart 'crush' which may improve velocity by imparting more force to the dart.

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.

Flywheel fitting:

Flywheels were heated for 15s with a 1600W hair dryer held 3" from the wheel, braced with a screwdriver so it didn't blow away on the workbench. Once warm, the wheel was pressed to the shaft and slotted on. The fit was checked so that each wheel was the same distance from the back of the cage with a variance of +/- 0.2mm. In this event, the measured distance between the back of the wheel and the cage was 2.5mm in both cases.

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.

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.

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=]efficacy of Falcon 130 motors.[/url]

Darts: Koosh (eBay seller BabyGiraffe, sourced May 2017 & Milocos, sourced May 2017) All darts are pack fresh and have not been fired prior to testing.

3S LiPo: ZIPPY Compact 1000mAh 3S 25C Lipo Pack

This spreadsheet contains all the Hooligan flywheel data including the Artefact Red Cage data.

In the following analysis, a standard mean has been taken and the standard deviation of the population calculated. A student's t-test is then used to compare the difference between stock and Hooligan flywheels data.

Hooligan Flywheels, Stock Cage, Falcon 130s:
Trial #1
Average: 123.14FPS
Standard Deviation: 3.05

Trial #2
Average: 123.48FPS
Standard Deviation: 2.40

Trial Aggregate (2 trials):
Average: 123.31FPS
Standard Deviation: 2.75

t-test versus stock data (trial #1) - 9.02E-04
t-test versus stock data (trial #2) - 1.76E-07

Hooligan Flywheels, Artefact Red Cage, Falcon 130s:
Trial #1
Average: 131.72PS
Standard Deviation: 2.96

Trial #2
Average: 131.40FPS
Standard Deviation: 2.73

Trial Aggregate (2 trials):
Average: 131.56FPS
Standard Deviation: 2.96

Flywheel Foam Build Up:


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
Worker flywheel data can be sourced from prior work done here and the spreadsheet of results is here.
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

This is a restatement of the prior work done in order to then compare and assess the differences between these datasets going forward. There is a clear difference in terms of output velocity between the Hooligan and the Worker wheels. The Hooligan wheels are much more consistent as per their consistently smaller standard deviation whereas the Worker wheels produce a higher muzzle velocity. It is inferred that the greater mass of the Hooligan flywheels (7g as opposed to Worker's 4g) is the reason for this. The machining process and construction quality of the Hooligan wheel also means that it produces a more consistent shot.

Hooligan Wheels: Stock & Artefact Cages
To compare the stock flywheel cage performance with the Artefact Red flywheel cage, a student's t-test was performed on the aggregate data sets.

[b]Stock Flywheel Cage Data:

Aggregated Mean Muzzle Velocity:131.56FPS
Aggregated Standard Deviation: 2.85
Aggregate formed from Trial #1 and #2

Artefact Red Flywheel Cage Data:
Aggregated Mean Muzzle Velocity:123.31FPS
Aggregated Standard Deviation: 2.75
Aggregate formed from Trial #1 and #2

Aggregate t-test: 2.12E-51

Clearly there's a velocity increase from using the Artefact Red Cage and the t-test finds it exceptionally unlikely that it was a fluke. The reasons for this increase are unclear as, on paper, the stock Stryfe cage and Artefact Red cage are similar. It might be there are some dimensional differences and more work is needed in this area.

Interestingly, the standard deviation of the two aggregate samples appears to have not altered all that much. Indeed, a t-test (admittedly not the best test for this but I'm at the limits of my statistics at this point) showed there to be no difference between the SD sets of the stock and flywheel cages. This points to the idea that the quality of the flywheel is more important than the quality of the cage. Further work ought to be done in this area to explore this.

The Hooligan wheels are an impressive piece of engineering. Their quality is obvious from the outset and it's clear from the results that the CNC machining process is indeed what the community has needed for some time.

There are some caveats, however. The wheels themselves need to be fitted warm. Their shaft fit is great but they cannot be fitted without expanding the shaft hole and resetting them. Additionally, it is likely that these are a one use thing and reinserting them onto multiple motor shafts will result in a degradation of shaft fit and flywheel walking. This is not in of itself an inherently bad thing, just something that needs to be borne in mind during builds. The tighter shaft fit is indeed an asset with the advent of higher 'crush' flywheel cages as seen with the Open Flywheel Project and other 3D printed cages. The tighter fit will reduce the risk of higher torque motors causing damage to the flywheel shaft.

Interestingly, the higher mass of the flywheel did not impede muzzle velocity too much. The aluminium flywheels from Taobao assessed here were in excess of 8g and were also producing muzzle velocities in the 120FPS region. It is a testament to the torque output of Falcon 130s that they can output darts at that velocity without issue.

The community has needed a CNC machined flywheel for a long time now. These wheels provide the best performance consistency of any known dataset. With Standard Deviations below 3.5, the shot consistency from these wheels is second to none.

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.

Boff: Managing Director, Blastersmiths UK & BUZAN Founder (formerly)
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Mon Jun 12, 2017 1:21 pm View user's profile Send private message Visit poster's website
Foam Data Collector

Joined: 07 May 2013
Posts: 4886
Fav. Blaster: Xtreme 180 Rapidstrike
Location: In the Boonies

Post Reply with quote
Also worth noting that the higher crush of the red cage needs more torquey motors. Anyone considering running those with 130's would be well advised to get either high torque 132's or 180's as they will be wasting the potential of the cage.
I will be doing a comparison set of data on Elites with 3240 motors this month. Thanks for doing those Mike!

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!'.
Mon Jun 12, 2017 2:03 pm View user's profile Send private message Send e-mail
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