Item 0473

OTHER: Helicopter - Outside - Intermeshing - Kaman - K-MAX

Locations of specific Information:

This Web Site:

DESIGN: SynchroLite ~ Rotor - Disk - Lead-Flap Coupling, for Intermeshing Helicopter

Use search engine, located on initial page, to find all locations in this web site.

Other Web Sites:

 Rotor:

The rotor hubs are attached to the transmission output shafts with horizontal teeter pins incorporating a 30-degree offset.

 Yaw Control:

From HDW on PPRuNe ~ April 19, 2006

DIRECTIONAL CONTROL SYSTEM: POWER-ON

Up to now, the intermesher rotors reacted in much the same manner as any helicopter. However, in the directional system the similarity ends. Due to the counter-rotating rotors, as explained in previous paragraphs, rotor torque is nullified. It is important to keep in mind that this is true only if both rotors receive equal pitch changes. So far in our discussion, we know how to fly vertically and in any given direction. To make turns, the rudder pedals are linked mechanically to the collective and fore-aft cyclic systems. Turning the intermesher is brought about by intentionally changing the torque relationship between the rotors with the application of the pedals.

When the pilot applies pedal, both differential collective and differential cyclic are applied to the rotors. For example, when right pedal is applied, the left rotor increases in pitch and the right rotor decreases in pitch (see fig. 5). This action is known as differential collective and causes the left rotor to produce more torque reaction and the right rotor less, thus turning the helicopter to the right.

Conversely, the pitch and torque reaction of the right rotor increases and that of the left decreases when left pedal is applied causing the helicopter to turn and roll to the left. It must be remembered that these effects occur while the helicopter is in powered flight.

As differential collective is induced in the rotors, another action as differential cyclic, takes place simultaneously. Application of right rudder pedal not only causes the left rotor to increase in pitch and torque reaction, but also tilt forward,(see fig.6). the right rotor decreases in pitch and tilts aft. This action tilts the left rotor forwards and the right rotor aft , causing them to „ push and pull „ in the turn. Thus an aerodynamic force is induced wich assists the helicopter in the turn to the right. The action of differential cyclic may be compared to the use of oars in turning a row boat. When in a right turn, the oarsman facing the stern uses the oar in his right hand to pull the boat around in the direction of the turn and either pushes with his left oar or allows it to drag in the water to assist in turning. Application of left rudder pedal in the helicopter causes the right rotor to „ push „ and the left rotor to „ pull or drag „ and the left rotor to „ pull or drag „ turning the aircraft to the left.

My thoughts re cross-couplings: The opposed longitudinally cyclic will not stop the roll that is induced by the differential collective and the 'V' angle between the masts. Unless perhaps, if the rearward longitudinal cyclic was greater than forward longitudinal cyclic. Too much difference in the longitudinal cyclic may impart a reverse force on the craft.


DIRECTIONAL CONTROL SYSTEM „ POWER OFF „ ( AUTOROTATION )

As described in previous paragraphs during power-on flights ( engine driving the rotors ), the differential torque reaction helps turn the helicopter. We have learned that in the intermesher configuration, in powered flight, the greatest torque reaction is produced by the HIGH lift rotor. During autorotation the rotors are driven by an external force, the flow of air up through the rotors produced by the helicopter`s rate of descent. Again, due to the characteristics of the intermesher configuration, the rotor having the HIGHER pitch now provides the greatest reaction due to transmission friction and causes the fuselage to turn in the same direction as the rotor. Consequently, application of right pedal would apply more pitch on the left rotor, which would cause the helicopter to yaw to the left-an undesirable situation! The solution is in the incorporation into the controls a mechanism known as the „ reverser. The purpose of this devise is to maintain a consistent relationship between the application of pedal and direction of turn. This is accomplished by reversing the differential collective in the rotors while in autorotation thus by reversing the differential collective in the rotors while in autorotation thus making the inside rotor in a turn the high pitch rotor and the rotor ( see fig. 7 ). The helicopter then turns in the desired direction.

REVERSER

To accomplish the above, the reversing mechanism is installed in the control module between the pedals and collective system. Ist only purpose is to reverse the differential collective to the rotors when in descending flight 0 - 10 percent collective position and autorotation. The reverser mechanism is a self - contained unit consisting of three control connections - input from the rudder pedals output to the collective systems, and control input from the collective lever.

The reverser never needs adjustment other than initial rigging. It is designed to mechanically and automatically reverses the differential collective input to the rotor from the pedals as required between power - on flight and descending - autorotation. The reverser has two main control positions, „normal" and „reverse". During normal power-on flight, the reverser is in the normal position. With application of right pedal, the left rotor increases pitch and the right rotor decreases pitch.This causes the helicopter to turn to the right. On entering descents while maintaining the same amount of right pedal, the pilot lowers his collective lever to the full „ down „ position, and the signal rod from the collective lever automatically and mechanically causes an overcentering lever in the reverser to shift. This moves the output side of the reverser in the opposite direction from that applied by the right pedal. This action reverses the pitch between the rotors, decreasing pitch in the left rotor, and increasing pitch in the right rotor. The direction of turn is now in the same direction as pedal applied and, so far, the reverser has accomplished what it was designed to do. However, as in most reversing mechanisms, there is a transition area which, in this case, occurs in a neutral area, which the reverser must pass through in order to reverse the control direction.

The neutral area exists at approximately the 25 - 30 percent collective position. As the pilot lowers the collective lever from a normal power-on flight condition to the full „ down „ position for descents, the reverser shifts from normal to reverse. During this time, at some intermediate collective lever position, the reverser passes through this neutral area. There are times in flight when the pilot may fly at this intermediate collective stick position (partial power flight during a descent). If a pilot were to apply rudder pedal with the reverser in this area, there would be no differential collective output and all the pilot would be relying on for a turning force would be differential cyclic. Consequently, the directional control power would be less due to the lack of differential collective.

To augment this neutral area characteristic, a control linkage has been added to the differential cyclic system to augment the differential cyclic control. This is called the differential cyclic shifter.

DIFFERENTIAL CYCLIC SHIFTER ( D.C.S.

The primary purpose of the DCS linkage is to increase the output of the already present differential cyclic control (more fore / aft tilting of the rotors) so there will be adequate directional control whenever the reverser is in, or near, the neutral area.

The result of all this mechanical mixing is that the pilot just pushes the pedal in desired direction to get normal aircraft response. Larger pedal inputs may be required, with the collective in the neutral area, to get the same aircraft response. More pedal response can be achieved by moving the collective control up or down out of the neutral area.

The pedals are also connected to the rudder, which moves in direct proportion to pedal input. The rudder reduces pilot workload by increasing directional stability in forward flight.

 Transmission:

The engine is derated from 1,800 shp to 1,500 shp for takeoff and 1,350 shp maximum continuous.

Input speed 6,600 rpm

Output speed 271.4 rpm

Total reduction ~ 24.32:1

 3 gear reduction stages

Power splits after first reduction

Design objective was infinite life at fatigue design torque

No yielding at the limit design torque. (150% of fatigue design torque)

No rupture at the ultimate design torque (150% of limit design torque, 225% of fatigue design torque).

An additional 10% asymmetrical load distribution of the intermeshing components (I.e. after the input reduction) was added to the fatigue design torque.

Input Reduction:

Pitch ~ 4.80

Gear reduction ration of 1.89:1

Pinion ~ 28-tooth

Gear ~ 53-tooth

Cross shaft Reduction:

Pitch ~ 4.516

Pinion ~ 19-tooth

Gear ~ 59-tooth

Gear reduction ration of 3.106:1

Accessory - Spiral Bevel gear:

Gear ~ 28-tooth

Pitch ~ 4.80

Face Width ~ small

Planetary Final Reduction:

xx

Fan Drive - Spur Gear:

Gear ~ 52-tooth

Pitch ~ 12

Face width ~ 0.355", Scaled

Power ~ 13 hp maximum continuous

Speed ~ 6096 rpm

Allowable contact stress = 180000, Assumed

Allowable bending stress = 36000, Assumed

from Hamilton Spur Gear Selection:

Durability 45.6 hp

Strength = 28.4 hp

 

Design torque = [load torque ~or~ normal torque ~or~ continuous torque] * service factor. [from outside sources]

Note that the final reduction has the pinion above the gear.

Housing:

The nine housings are cast from ZE41A-T5 (AMS 4439) magnesium alloy and machined to accept 4340 CEVM (AMS 6414) alloy steel bearing liners. ZE41A magnesium was selected over other available magnesium casting materials due to it higher fatique strength, good casting characteristics and its good weld repairability.

This information is from 'K-Max Intermeshing Rotor Drive System' 53rd Annual Forum Proc., AHH, 1997. I have hard copy

FORM: Hamilton Bevel Gear Selection.

Input Reduction:

The following calculations are based on the above information and noted assumptions.

 

 

Input: (primary)

X-shaft: (intermediate)

 

Pinion Speed [rpm]

6600

3492

 

Catalog Pinion Pitch Dia. [in]

5.8333

4.2073

 

Pitch Line Velocity [fpm]

10087

3849

 

Diametral Pitch

4.80

4.516

 

Face Width [in] These are scaled from picture & drawing.

1.61" & 1.49" = 1.56"

2.0" & 2.18 = 2.1"

 

Allowable Contact Stress (1)

190,000

190,000

 

Allowable Bending Stress (1)

30,000

30,000

 

Elastic Coefficient

Pinion & Gear - Steel

Pinion & Gear - Steel

 

Load Distribution Factor

Both straddle mounted

Neither straddle mounted

 

Geometry Factor [I]

.115

.134

 

Geometry Factor [J]

.300

.298

 

Durability [hp]

1402

605

 

Strength [hp]

1270

689

(1) These are assumptions.

 

This results in a Durability SF

1402 / 1350 = 1.04

605 / (1350 / 2) = 0.90 (2)

 

This results in a Strength SF

1270 / 1350 = 0.94

689 / (1350 / 2) = 1.02 (2)

These results do not take into account any of the above safety factors. This situation is similar to my reverse engineering on the Mini 500 and Ultrasport. OTHER: Helicopter - Outside - Single (1seat) - Revolution - Mini-500 ~ Transmission There must be a reduction for life rating or something.

(2) This does not include the additional 10% asymmetrical load distribution of the intermeshing components

 Outside Information:

. http://oh1ninja.la.coocan.jp/details/KMAX/kmax_e.htm

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Last Revised: January 24, 2008