1664.html

Item 1664

OTHER: Helicopter - Inside - Intermeshing - UniCopter-UAV - Full-scale

I am not sure that this size of UAV is practical; since a fixedwing UAV will be more efficient.

Smaller scale and microlight rotary-wing UAV probable will be viable; particularly if they are considered disposable.

To Home Page ~ UniCopter-UAV

This project may be the design, development and possible construction of a full-size electric UAV UniCopter.

~ comprising ~

Intermeshing Configuration (bilateral symmetry and no tail rotor).

Large Chord and Low Tip Speed (including; 'Absolutely' Rigid Rotors, Pusher Propeller & Lifting Body )

Advancing Blade Concept (subset of the above)

Independent Root & Tip Control (probably utilizing the Floating Root Method)

Electric future ~ Pilotless future

The utility inventions on this site are openly and publicly disclosed on the Internet to negate an entity from patenting them, to the exclusion of all others whom may wish to use them. ~ Reference patent law 35 U.S.C. 102 A person shall be entitled to a patent unless - (a) the invention was known ... by others in this country, ..., before the invention thereof by the applicant for patent.

Consider the advantages of the Interleaving configuration.

Objectives:

To evaluate, possibly develop, and then possibly prototype an Unmanned Arial Vehicle based on the UniCopter except utilizing electric power and control.

To work toward the Probable Future Rotorcraft; through revolution not evolution.

To test a full size craft, which will have a number of significant features, without subjecting a pilot to risks.

Usage:

Search and Rescue (wild idea):

A group of full-size [1320 lb GW] UAVs might be used to go out to an area and search for a specific situation. When located the other UAV's could fly to the location and independently lower a basket to retrieve or deliver a person or object. The prone person or package will result in a very aerodynamic fuselage.

Concern: It does not allow for in-flight medical assistance.

Pilot in Prone Position:

For the fun of it, or for the above, see drawing 1664.dc.
The small aerodynamic fuselage acts as a lifting body.

Drawing:

Tractor Configuration:

The following are presently the 1/4 scale OTHER: Helicopter - Inside - Intermeshing - Electric UAV drawings.

Note that the 'fat' shape of the UAV fuselage will allow the rotors to have a large stagger and perhaps a smaller 'V' angle

Weight and Balance: Note that this is for a GW of 550 lbs, not 1320 lbs.

Taken from UniCopter_WeightAndBalance.html and crudely modified to get some idea about the weight of a full scale electric UniCopter UAV with the UAV 'squat' fuselage.

Item:	Full Name:	Wt. Ea.	Qty.	Length of Arm (in)			Moment (lb-in)
		Wt. Ea.	Qty.	X	Y	Z	X	Y	Z
1267	Control - Flight - Assembly - Final	20	1	-12	0	24	-240	0	480
1260	Control - Power Train - Assembly - Final	10	1	7	0	24	70	0	240
1261	Electrical - Assembly - Final	9	1	0	0	24	0	0	216
1270	Motor - Assembly - Final	28	1	10.25	0	25	3147	0	7675
	Motor Controller	10	1	36	0	18	360	0	180
1262	Equipment - Assembly - Final	11	1	-12	0	36	-132	0	396
1264	Fuel - Assembly - Final	17	1	2	0	42	34	0	714
1265	Instrument - Assembly - Final	5	1	-34	0	36	-170	0	180
1266	Landing Gear - Assembly - Final	15	1	13	0	72	195	0	1080
1268	Power Train - Assembly - Final	120	1	3	0	8	360	0	960
1268	Pusher Prop - Assembly - Final	40	1	29	0	29.5	1160	0	1180
1269	Rotor - Assembly - Final - VR-7b - 5.25"	140	1	0	0	0	0	0	0
	Empty Weight:	425		Empty Moment:				0
1271	Weight & Balance - Load - Test Equipment	75	1	-10	0	40	-1490	0	5960
1272	Weight & Balance - Batteries ⁽²⁾	??	1	-3	0	48	-150	0	2400
	Weight & Balance - Misc ⁽²⁾	50	1	-3	0	48	-150	0	2400
	Load:	125		Load Moment:				0
	Total Weight:	550 ⁽²⁾ ⁽³⁾		Total Moment:			xx	0	xx
				CofG from Origins:			xx"	0"	xx"
				Symbol:			x_CG	y_CG	z_CG

Dimensions are in inches and weights are in pounds.

Total weight is item quantity times item weight.

(1) The guestimate of an electric motor at 1 lb. for 2 hp. 55 hp = 28 lbs

(2) Same as the gross weight of the SynchroLite.

(3) The weight of most of the remaining components, such as rotors etc., have not been reduced from the full UniCopter weights. They may therefor be oversized for this application or, alternatively, they may remain so that batteries and a larger engine may be added in the future.

Motor:

Plettenberg Predator 30 Probably just for interest.

Note that there is a newer, more powerful Predator 37. ~ September 7, 2007

For more information on the Predator motor see; BUY: Electric - Motor - Plettenberg - Predator

For primary specifications see; [Ratio, HP, Torque & Losses].

Both the outer frame and the armature rotate. They drive against each other and therefore rotate in opposite directions. This opposed-rotation results in a 'free' 2:1 speed reduction when the propeller is rotating.

Consider a motor pack of 3 x 2 Predator motors. See drawing. If there is a desire to start using fewer motors just add weights to create a moment arm for each missing motor.

The motor pack might be mounted to the transmission frame.

Put differential inside central wide gear and do not have spinning 'cage' ????

Tesla Motors Inc.

The motor for a high-performance electric car requires a device that is simultaneously light, compact, and high in efficiency. The Tesla Roadster EV motor is just that. We accomplish this by starting with a well-optimized electromagnetic design and then using the lowest loss conductors and the highest quality magnetic steel possible.

The power of the motor is not only limited by how much power you put into it, but also by how fast it can be cooled, how hot it can operate, and how efficiently it runs. We addressed each of these in innovative ways. Our motor can operate continuously around 120°C, thanks to the array of air-cooling fins on our aluminum housing.

Without proper efficiency, our motor would convert electrical energy into heat instead of rotational energy. That's why we constructed it with specially designed, high-quality lamination steel that has very low eddy current losses, particularly at high rpm. The rotor is made with a proprietary process that produces a low resistance "squirrel cage" with large end rings using oxygen free copper. This allows the rotor to develop high current flows, and torque, with low resistance losses. The use of a small air gap allows tight inductive coupling which, combined with low loss magnetic materials, enables the development of high torque at high rpm. Together, these factors allow us to induce large currents, even at high rpm, producing much flatter power and efficiency curves from approximately 2,000 rpm to 12,000 rpm.

The sum of all these features is a single motor with efficiencies of 85 to 95 percent, power output of up to 185 kW, and a small footprint that measures just 250 mm (diameter) by 350 mm (length).

Type designation	3-phase, 4-pole electric motor
Max net power	185kW
Max rpm	13,500
Efficiency	90% average, 80% at peak power
Torque	see torque curve chart

Technologies M4:

Toronto

Zytek:

UQM Technologies, Inc.:

See; DESIGN: AeroVantage ~ Motor - Full-size - UQM - PowerPhase

IDAM - INA Drives & Mechatronics

From bill111 at Eng Tips Forum

INA may have what your looking for all developed. http://www.ina-dam.de/en/sub.php?page=16 Their main is impossible, but the link above should get you there (will these huge companies ever get a clue as to what the engineers need).
Read the descriptions carefully. They do have inside out brushless motors, of a fairly high power level.

Radial Engine: Rotapower:

If this engine can be supplied with output shafts at both ends then it might be (with rework) interchangeable with an electric motor with output shafts at both ends.

For an engine that may be somewhat interchangeable with an electric motor see the Rotapower engine at: Freedom Motors. Also see this sites web page; DESIGN: UniCopter ~ Engine

Energy Storage:

Large lithium battery storage; http://www.hymotion.com/products.htm. Lithium batteries. 160 lbs. 16" x 33" 10" high. 5 KW hours.

Ballard Fuel Cell; http://www.ballard.com/be_a_customer/transportation/fuel_cell_modules/mark_902#

Cooling of Motor:

Consider using the tail boom(s) as a radiator to cool the electric motors cooling fluid. The tail boom is always subjected to the downwash of the rotors when the motor is operation.

Evaporation cooling: Consider improving the cooling by using evaporation of some of the cooling water in a method similar to the canvas bag on the grill of a car. There is a United States Patent 4672817. Could porous Carbon composite be used, or something similar. Overlayed with a wicking material.

A header water tank will be required to hold sufficient water for recalculation and evaporation.
In winter, glycol could be used, if the glycol molecules were larger than the water molicules????
Search words?? ~ osmosis cooling water ("canvas bag" OR "canvas sack") evaporation.

It will probably be advantageous if the motor could be air-cooled. Consider compressing air at a remote location then letting it be ejected on select parts of the motor, where the expansion of the air will add to the cooling.

Engine:

If a reciprocating engine is to be considered as an alternative to an electric motor then the Limbach L2400 DT/ET should be seriously looked at.

Power Train:

For an understanding of the drive motor and drive train see; Inrunner+Outrunner_Motor

For primary specifications see; [Ratio, HP, Torque & Losses] below.

The outer frame drives the spiral bevel reduction unit and subsequently the rotors. The armature direct drives the propeller. Or the reverse?

Prop: 60 x ??

Rotors: 550 rpm (when the propeller is locked) and >277 rpm when propeller is turning freely. For primary specifications see; [Ratio, HP, Torque & Losses] below.

Transmission: Ratio ⁺/_- 8:1 For concepts see; 6-gear Spiral Bevel. Appears to be the best choice. It has the greatest efficiency and it allows for an angle greater than 90º between the masts and the propeller.

Autorotation: Synchronization is by two spiral bevel gear sets and ax X-shaft; with a high safety factor.

Ratio, HP, Torque & Losses Will eventually be on a separate web page.

From full size UniCopter 1510.html and then MODIFIED

The final reduction should be 3:1 and the secondary reduction should probably be 3:1

At Maximum Vertical Climb:

At Maximum Forward Velocity:

Speed:

Power:

Torque:

Speed:

Power:

Torque:

Ratio:

Loss:

Ratio:

Loss:

[Motor]

4800

rpm

ft-lb

4800

rpm

ft-lb

[Prop]

2400

rpm

(55/2)*0 = 27.5

ft-lb

Intermediate:

4800

rpm

ft-lb

2400

rpm

27.5

ft-lb

Secondary:

2.6

: 1

1.0

2.6

: 1

1.0

X-shaft:

1833

rpm

54.5

156

ft-lb

923

rpm

27.2

155

ft-lb

Final:

3.33

: 1

1.0

3.33

: 1

1.0

[Rotor]

550

rpm

53.9

515

ft-lb

277

rpm

27.0

512

ft-lb

Total:

8.65

: 1

2.0

8.65

: 1

2.0

The above [Maximum Forward Velocity] columns use an assumes speed distribution between the rotor and the propeller.

Controls:

These are options, which could be designed and possibly added at a later date.

Pitch change:

Consider High torque motors or linear actuators to change blade pitch.

Such as 'Limited-Angle Torque Motors'

Information http://www.electricmotors.machinedesign.com/guiEdits/Content/bdeee3/bdeee3_4.aspx

From the above: "Limited-angle torquers are currently available in ratings from 2.8 to 1,000 oz-in. The 2.8 oz-in. LAT, a two-pole motor, has a 90° excursion angle. Its stator is 0.7 in. in diameter, weighs 1.7 oz, and is rated for 80 W peak. The 1,000 oz-in. LAT, a 10-pole motor, has an 18° excursion angle. Its stator is 1.64 in. in diameter, weighs 45 oz, and is rated for 437 W peak."

The page http://www.unicopter.com/Independent_Root_Tip.html shows a maximum root pitch of +29.4º to -3.9º

The page http://www.unicopter.com/Independent_Root_Tip.html shows a maximum twist of +11.2º to -22.2º

Control wiring goes up center of masts.

Will require double or triple redundancy.

Consider all-electric, particularly if it will reduce the parasitic drag surrounding the rotors.

Speed Controller:

DESIGN: UniCopter ~ Pusher Prop - Variable Speed Rotors and Prop - Speed Controller

Propeller:

This is an option, which should be designed in a possibly added at a later date.

Could be coaxial for smaller diameter and to eliminate rolling force of single propeller.

Propeller to be folding, for ground clearance.

Features to Consider:

Locating the single gearbox lower will allow for more air to flow through to the upper quadrant of the propeller. The diameter of the final crown gear does not have to be so large and the mast can be longer than the primary UniCopter because wires not control rods will pass up into the rotor hub.

Increasing the mid-gear ratio and decreasing the final gear ratio will result in a smaller diameter final crown gear, a more aerodynamic fuselage and more room for the overrunning clutch.

The rotor hubs might be smaller with electric actuators. The mast will definitely be smaller.

Concerns:

Limited flying time with today's electrical storage technology. Offset by the almost certainty that electrical storage technology will significantly advance over the next few decades.

Power to weight ratio of today's electric motors and actuators. Offset by the almost certainty that electrical to mechanical power devices will advance over the next few decades.

How does cooling fluid get in and out of rotating motor stator? Use compressed air.

Will the gyroscopic precession of a single motor's fast turning motor stator cause problems. During cruise, the counter-rotating propeller and the reduction in the rpm of the stator may negate any problem.

Progressive Developmental Steps:

General overall arraignment:

Target the ultimate objective so that changes and modifications can be kept to a minimum .Start with the mock-up so as to have a perspective of the final objective.

Hover: Then purchase and modify off-the-shelf items or fabricate basic crude items, just to get a craft that will hover.

The frame could be initially tubular construction.
Keep the weight down by; no pilot, no or few batteries, and use ground based Genset with cables.
Initially, the gears could be conventional sliding worm and two wheels. They could be the open with a little grease or splash tray, since the flight duration will only be a couple of minutes.
The motor need not be particularly special.
The propeller need not be included and the shaft to it could be locked.

Improvements: Then start developing and installing the intended components such as;

Pusher Propeller.

Speed Controller.

Independent Root & Tip - Torque Tube Method rotor.

Electric flight controls.

Miscellaneous:

By using the UniCopter as the specification objectives, if advanced electrics takes too long to be realized there is always the ability to 'fall back' on the existing engine and power-train.

Other Electric Stuff:

This 'Electric UAV UniCopter', in 1/4 Scale: OTHER: Helicopter - Inside - Intermeshing - 1/4-scale Electric - UAV

Related; Electric Interleaving

More: See items in yellow blocks on OTHER: Miscellaneous - Thoughtless Ideas

Related Outside Web Sites:

Electric Aircraft Team Proposal

Goggle ["Lafayette" "E-Plane"] 415 hits

Initially displayed: June 9, 2006 ~ Posted on Rotary Wing; June 9, 2006 ~ Latest revision; December 29, 2009

The above utility invention is openly and publicly disclosed on the Internet to negate an entity from patenting it, to the exclusion of all others whom may wish to use them. ~ Reference patent law 35 U.S.C. 102 A person shall be entitled to a patent unless - (a) the invention was known ... by others in this country, ..., before the invention thereof by the applicant for patent.