rcgldr said:
When trying to optimize for speed, how do you choose between pitch and gearing? I'm assuming diameter is fixed since it's just one prop. The maximum speed is related to the overall reduction factor from ground speed to prop wash speed, but the forces involved are related to the prop thrust and opposing ground force used to drive the prop, and I assume that any force greater than the minimum required to overcome drag and rolling resistance increase losses in the drivetrain, but I don't know if those losses are linear.
Also assuming the prop doesn't have a one way clutch, how diffcult is it to slow the cart down via the brakes (how much of the momentum is in the prop)?
To make a very long story short, we do two things... we make research what kind of numbers we think we're capable of in terms of rolling resistance, prop efficiency, aero drag, etc. With those numbers we simulate the system and come up with the optimal parameters (pitch, gearing, etc.). From there we can vary the prop pitch on the fly to optimize a bit further.
If this were a high budget project with a real purpose, we'd re-optimize based on the real-world data, perhaps make a 2nd, 3rd, and 4th prop, change gear ratios, and even find the optimal parameters for any given wind speed.
As it happens, our initial parameter guesses were close enough to allow us to achieve better than 2.5X wind speed. So just adjusting prop pitch (which doesn't adjust TRUE prop pitch) is enough to satisfy us. When someone else breaks our record by a few percent, the next guys are going to have to do all that stuff to beat theirs - and we'll be long gone onto the next silly project.
Our prop does have a freewheel mechanism, but it's still incredibly effective in braking. It's the same as a helicopter in autorotation. No torque is put into the shaft, but it still slows the heli's descent drastically.
ETA: The momentum in the prop is a TINY fraction of the overall momentum in the cart. When we run the prop on the dyno, it slows down very rapidly when we stop powering it. It's trying to push a LOT of air.