Measurement of In-Flight Rotor Blade Loads of an Autogyro
Helmut Rapp, Peter Wedemeyer Institut für Aerospace-Technologie, Hochschule Bremen, Bremen, Germany Christian Teuber STN Atlas Elektronik GmbH, Bremen, Germany
Abstract go ahead in gyroplane development until there was Autogyros, or gyroplanes, are rotary wing aircraft extensive pressure due to military requirements. with no driven main rotor. The rotor keeps rotating In later stages their gyroplane was able to take only by the airflow resulting from the plane’s forward off vertically, to proceed the so-called "Direct Take- speed. Since WW2 there has been only a few investi- Off" over a 10 m obstacle and a vertical landing, if gations concerning the flying characteristics and per- required. Several gyroplanes were obtained by the formance of autogyros including blade loading. US-Military and a thorough research programme was This work covers both the theoretical and exper- undertaken at NACA-Laboratories compared to the imental investigations of rotor blade loading. The small research programmes done by the British, Ger- main parameters for the flapping moment are rotor man and French military. However, due to different speed and mass distribution of the rotor blades. For design the later developed Gyrocopter does not reflect the experimental investigations, a small telemetric the NACA results. In some short term research this system was developed. Up to four strains in the ro- type of aircraft was covered, even as a solution for a tor blades can be measured by using strain gauges. Mars-Landing-Vehicle and Pilot-Recovery-Systems. Wireless transmission of the strain data from the ro- Major design effort was put into gyroplanes for the tating rotor to a computer inside the fuselage is ac- civil market, reflected in the McCulloch J-2 and Um- complished by 433 MHz transceivers. A simple data baugh 18A, which is still in production as a fully cer- protocol to detect and correct faulty data was imple- tified aircraft. mented. In addition to the strain measurements, video In Europe, development was pushed forward, find- sequences of the rotor blade motion are recorded by a ing its success in the Fairey Rotordyne, as the prob- small rotor hub mounted video camera. ably most advanced aircarrier with 68 seats. Any further development targets were too ambitious and 1. Introduction therefore were unsuccessful, mostly due to fact that If someone talks about the technology of autogyros the designers’ and project leader’s requirements were this technology seems to be well known because of expecting to combine helicopter and gyroplane char- the commonly-known rotary wing aircraft i.e. heli- acteristics. copters. Since the 50’s or 60’s there scarcely has been Since these short studies it is not known about any further research in this particular kind of aircraft, any further research until during the last 6 years two especially with small gyroplanes. United States based Companies started to develop a The autogyro, a type of aircraft originally devel- competitor to the helicopter. They are called "Hawk" oped in Spain in 1920, made its first successful flight and "CarterCopter", both developments are sponsored on 9th January 1923 [1]. After a short period of work through indirect governmental sources. in Spain, major development was moved to the United In 1993 first steps were made to establish a gyro- Kingdom, where the military found much interest in plane aircraft class in the United Kingdom. Due to this particular type of aircraft. Very soon other coun- the number of complaints these regulations didn’t be- tries obtained the rights to use the patented designs for come effective. Meanwhile, several fatal accidents their particular developments. At this time the major with "AirCommand" gyroplanes lead the CAA to take research was done in the United Kingdom by Cierva direct action and started a research program at Glas- Autogiro Company of Juan de la Cierva and his team gow University [4] [5]. and also in the United States by the American Au- In 1993, a German programme to establish the gy- togiro Company of Harold F. Pitcairn and his team. roplane within the Ultralight-Aircraft class began and Both teams in 1937 were able to develop, build and was pushed until end of 1999. Despite notification fly prototypes of helicopters. of the requirements through the EC there has been no However, both companies were always aware that German progress, but France and Italy have made sev- the helicopter would be the more expensive to oper- eral decisions and pushed their regulations. ate solution for minor operations. This lead them to Since no progress has been in Germany, it was presented at the 26th European Rotorcraft Forum, 26 - 29 decided in 1997 to start a gyroplane research pro- September 2000, The Hague, Netherlands gramme at Hochschule Bremen, a university of ap-
101.1
plied sciences, supported by the director of ARROW Introducing λ into (1), together with the solidity ratio :
Engines (UK), Ltd., who at this time was fully in- (c0:7: blade chord at 0 7R) volved in the German activities. This at least gives
σ c0:7b =
: (5) a little bit of industrial support, and the Hochschule 0 7 πR Bremen need not obtain, maintain and handle a gyro- the rotor speed Ω of the autogyro with thrust is equal plane and a pilot just for the reason of research and
to weight T = W follows from
education.
Ú Ù
Due to European connections of ARROW Engines 1 Ù W
: Ω = Ù σ θ λ (6) (UK), Ltd., these research results will find their way Ø R 0:7a π 2ρ · R directly into safer designs and better performance of 2 3 2 light gyroplanes. In the present report, a thorough investigation, us- At least, the important vertical sink speed vvert of the
ing both theory and experiment, has been carried out, autogyro can be determined by Ú especially where blade loading is concerned. The ba- Ù
Ù W
= ; sic theory for calculating blade bending moments is vvert Ù (7)
Ù 2 CT π ρ shown. Telemetric equipment is developed to mea- Ø 2 R 2 CT 4λ · 1 sure in-flight blade loadings. 2λ2
CT denotes a thrust coefficient 2. Basic autogyro theory σ θ λ
Basic theory of pure autorotation is well known by he- 0:7a
: · CT = (8) licopter specialists [2], [3]. In the following the basic 2 3 2 equations are given. The theoretical results of these Table 1 shows basic data as well as the calculated ro- equations are to be verified later by flight measure- tor speed and vertical sink speed of the VPM-M16 ments. autogyro. 2.1 Steady autorotation Steady autorotation means that there is no forward Table 1: Data of the VPM-M16 autogyro speed with respect to the aircraft. The airflow is MTOW 450 kg strictly perpendicular through the rotor plane and the engine power 120 HP loading of the blade is independent of its angular po- maximum speed 78 kts sition. According to [2], total rotor thrust T follows minimum speed 22 kts
from integration of the local air loads along the rotor: radius of rotor 4115 mm weight of one blade 18.2 kg θ λ
1ρ Ω2 3 number of blades 2 · ; T = abc R (1) 2 3 2 precone angle β 2.0 Æ
pitch angle θ 2.5 Æ where ρ denotes the air density, a the slope of the lift curve, b the number of blades, c the blade chord and lift curve slope a 5.73 R the rotor disc radius. The blade section pitch angle profile drag coeff. CD0 0.012
θ is assumed to be constant over the rotor radius. For blade chord c0:7 250 mm
9 2 ¡ a given 1g flight condition, thrust must be equal to the flapping stiffness position 1 15:25 10 N/mm
9 2 ¡ known weight of the autogyro. flapping stiffness position 2 2:867 10 N/mm To determine the unkown rotor speed Ω and inflow inflow coefficient λ 0.0209 coefficient λ, rotor torque MT has to be considered solidity ratio σ 0.0339
(CD0: profile drag coefficient). rotor speed Ω 388 1/min
vertical sink speed v 9.6 m/s θ λ vert
1ρ Ω2 4 CD0 λ · : MT = bc R a (2) 2 4 3 2 2.2 Theory of blade loading The rotor of an autogyro is not driven so the overall In steady autorotation, the blade loading is indepen- torque has to be zero: dent of the angular position of the rotorblade. There is
no change of rotor loading with time. Figure 1 shows : MT = 0 (3) the principal out-of-plane loading of a rotor blade. For this investigation, in-plane drag is not considered. With this, equation (2) can be solved for the inflow The aerodynamic lift results from local airspeed
coefficient λ
µ ρ
v´r and the local lift coefficient CL ( air density, A
× reference area): θ θ 2
λ 1 a CD0 ρ · · :
= a (4) 2
µ= ´ µ : f ´r v r C A (9) 3 a 3 2 z 2 L
101.2 Static loading of rotor blade (blade weight) Aerodynamic lift fz (r’) 200 Deformation in mm Bending Moment in Nm
Q(r)
M(r) 0 fr (r’) Centrifugal Force β = 3.0 deg. N(r) β = 0.0 deg. w(r’)
β = 1.0 r −200 deg. r’ β = 2.0 deg. ra Deformation, Shear Force, Bending Moment
Figure 1: Loading of rotor blade −400 0 1000 2000 3000 4000
Rotor Radius in mm µ The centrifugal force fz ´r can be obtained by Figure 2: Flapping moment and deformation of the
¼ 2
µ= Ω ; fr ´r m r (10) non-rotating blade where m ¼ describes the local mass. The local airspeed While deformation of the non-turning rotor blade
β µ v´r follows from depends on the precone angle , the bending moment
does not. The bending moment changes when the
µ=Ω ; v´r r (11) rotor is turning due to centrifugal and aerodynamic forces. Fig. 3 shows the bending moment and the de- With consideration of Figure 1 the bending moment
flection of the rotor blade for four different precone µ M ´r is given by angles β. Precone angle is the built-in angle between r
Z a the rotor blade axis and the area of rotation of the
© ¨
¼ ¼ ¼ ¼ ¼
µ= ´ µ´ µ ´ µ[ ´ µ ´ µ] : M ´r fz r r r fr r w r w r dr whole rotor. r Blade Bending Moment for Different Cone Angles 600
Bending Moment µ The bending moment M ´r and the blade deforma-
500 µ tion w´r are dependent on each other. As the cen- trifugal forces are usually very high, therefore small 400 β = 0.0 Deg. deformations will have a large influence on the bend- 300 β ing moment. Hence, this influence must not be ne- = 1.0 Deg. Blade Deformation glected and geometrical nonlinear theory has to be 200 used. 100 β = 2.0 Deg. 2.2 Rotor blades flapping moments 0 There are different methods to solve this problem. Blade Deformation and Bending Moment Hollmann proposes in [7] the matrix method, de- −100 β = 3.0 Deg. scribed in [8]. In [6] this procedure is used. Besides −200 this, every other computer code for analysing geomet- 0 1000 2000 3000 4000 Rotor Radius in mm rical nonlinear structures can be used. The following results are obtained by the use of an iterative finite Figure 3: Flapping moment and deformation of the element method. Data of table 1 is the basis for the rotating blade and different precone angles following results. While all four deflection curves look very simi- Firstly, the static deflection due to blade weight lar, the curves representing the bending moments are
of the non-rotating blade is considered (Fig. 2). In quite different. The largest moment results from a
Æ Æ
this essential load case, the bending moment acts in Æ
β = : β = : cone angle of β = 0 . Between 2 0 and 3 0 the opposite direction compared to flight. For fatigue the sign of the bending moment changes. life besides other load cases the number of transitions from the non-rotating rotor to the rotating rotor and The aerodynamic load bends the rotor blade in the vice versa (the so called start-stop cycles) are impor- upwards direction (flapping), while the centrifugal tant. forces tend to diminish this deformation. As the bend- Static deflection is a geometrical linear load case ing stiffness of the rotor blade in flapping is rather (no centrifugal forces). Additional load factors have small, the blade is deformed like a string in this di- to be applied when the gyroplane is taxiing over a rection, resulting from aerodynamic and centrifugal rough taxiway, e.g. grass. Common load factors are forces. Therefore, the blade deflection and the bend- up to 2.5. ing moment in the outer part of the rotor blade is
101.3 Bending Moment and Blade Deformation, Cone Angle = 2.0 deg. 250 rotating rotor blade to the the fixed airframe. Profes- sional telemetric systems as well as slip-ring systems
Blade are ruled out from the beginning due to cost reasons. 200 Deformation ma/mi = 0.7 150 Bending ma/mi = 0.8 Moment ma/mi = 0.9 AD 7710 AD 7710 AD 7710 AD 7710 100 ma/mi = 1.0 Microcontroller HC12 Deformation, Bending Moment 50 RS232
Transmitter 433 MHz 0 0 1000 2000 3000 4000 Rotor Radius in mm Figure 4: Flapping moment and deformation of the rotating blade for different mass distribution Receiver nearly independent of the cone angle. Only at the PC (Laptop) RS232
cantilevered end of the blade can a difference in the Æ loading be noticed. For a precone angle β = 0 a rela- Figure 5: Principle of telemetric system tively large bending moment occurs in comparison to
β Æ To solve the task, a small four channel telemetric : the bending moment for a precone angle of = 2 0 . system was developed (Fig. 5). It consists of four
From this it follows that, for a stationary 1g flight, Æ
Æ highly integrated data acquisition systems AD7710 : the ideal cone angle lies between 2:0 and 3 0 .A
β Æ (Analog Devices [9]), each containing an amplifier : cone angle = 2 0 was chosen for the considered for the strain gauge signal and a 16 bit D/A-converter. rotor of the M16 Gyroplane. These four data acquisition systems are controlled by Another important parameter for the bending mo- a microcontroller 68HC12 (Motorola [10]). It con- ment is mass distribution along the rotor axis. More trols the data acquisition and the transfer of the data to mass in the inner part of the rotor blade decreases the a PC, located in the airframe. This data transfer is ac- centrifugal force and increases the maximum bending complished by a wireless data link. On the rotor side moment (Fig. 4). a small 433 MHz transceiver module (BiM-433, Ra- In forward flight, the bending moments are no diometrix [11]) is connected directly to the microcon- longer independent from the position of the blade troller by a conventional RS232 serial port at 38400 with respect to flight direction. At the advancing baud. On the receiver side, a second transceiver mod- blade aerodynamic lift increases while lift at the re- ule receives the data and sends it to a standard PC treating blade decreases. To isolate the rotor shaft RS232 serial port. In the PC, a small computer pro- from the resulting moment, flapping hinges are nec- gram receives the data bytes and saves them directly essary. The VPM-M16 autogyro has one hinge in the to a hard disk for analysis later. The transceiver mod- centre of the rotor (a so-called teetering rotor). The ules allow a half duplex communication between the theory for calculating these moments is more compli- PC and the telemtric system. cated and is not shown here. 3. Experimental determination of the blade loading To compare the theoretical determined blade load- ing with the real loading, the moments acting in a rotor blade during a real flight should be measured. Loading of rotor blades can be measured by strain gauges. During calibration tests relations between measured strain data and the bending moment are de- termined. With this data, actual blade moments can be calculated from in-flight measured strain data. Figure 6: Telemetric system 3.1 Strain measurement system Fig. 6 and 7 show a first prototype of the described Four strains should be measured simultaneously at strain measurement system. In addition to this, a a data rate of at least 200 Hz. The problem in a real small video camera with a 2.4 GHz video signal trans- flight test is to transfer the measured data from the mitter can be seen. The video signal is recorded by a
101.4 each data frame. At a baud rate of 38400 with one start and one stop bit, 3840 bytes/second can be trans- mitted. So, 256 data frames can be recorded per sec- ond. This is more than originally required. When measuring only one channel without supply voltage, a data frame consits of eight bytes, which leads to 480 measurments per second. Figure 9 shows the uncorrected measured strain data. A lot of failures are visible. However, compared to the whole number of data frames (200/s) the abso- lute number of errors is small (less than 1%). Many of these errors can be detected and eliminated. Figure 7: Strain measurement and telemetric system video recorder, also located in the airframe. By means of this camera, the motion of one blade can be ob- served. This supplements the analysis of the strain gauge data. Due to the very simple protocol (serial at 38400 baud) and the wireless data transfer between the ro- tating and the fixed system some loss of data can- not be avoided. The relatively high data rate (more than 200 Hz) allows for some data bytes to be missing from the sequence. However, it is essential to know whether there are bytes missing or not. To accom- plish this besides the strain data some additional bytes are transmitted, synchronisation bytes and one count Figure 9: Uncorrected strain data byte. Figure 8 shows the used protocol for one data frame. Besides missing data frames other types of errors 4 sychronisation bytes: are possible. For example, single wrong data bytes 0AAh 001h 0FFh 0FBh are more difficult to find. Most of them can be de- up to 11 data bytes: tected by comparing successive strain data (low pass Channel Counter filtering). Data which does not fit to neighbouring val- ues are deleted and substituted again by interpolated Ch0 high Ch0 low Ch1 high Ch1 low data. In this way, most data errors can be detected and Ch2 high Ch2 low Ch3 high Ch3 low corrected. The accuracy of this procedure seems to be sufficient for this application. In Fig. 10 and 13 some supply voltage spikes can still be seen. If necessary, these spikes can Figure 8: Transmitted bytes for one data frame be deleted by hand. In the present work, this is not done, the spikes are purely neglected in the interpre- The first three bytes are for synchronisation pur- tation of the data. Figure 10 shows the same data as poses of the RS232 UART at the receiver side, the Fig. 9, but after error analysis. Nearly all errors could fourth byte, 0FBh, defines the beginning of each data be deleted. frame. When this byte is received, up to eleven data 3.2 Instrumented blade bytes following it are recorded. The first data byte Three types of blade loading are to be determined: is a binary representation of the channels to be mea- 1. flapping moments at three radial positions, sured. To achieve a higher rate of measurements per 2. one lead-lag moment and second it is possible to transfer the data of less than 3. one torsional moment. four channels. The counter byte simply counts from 0 The lead-lag and the torsional moment should be to 255. By observing this byte, up to 254 missing data measured at the same radial position as one of the frames can be detected. In a later analysis, missing flapping moments. According to Figure 3 the flapping data may be inserted by interpolating between known moment decreases rapidly from the cantilevered end data. Each strain value is transmitted as a signed 16 in radial direction. Therefore the strain gauge bridges bit binary integer word. The strain gauge data is fol- for the flapping moment are located near this end. A lowed by the voltage of the supplying NiCd-battery. distance of 500 mm between the measurement sta- A maximum of 15 bytes are to be transferred for tions is chosen. Lead-lag and torsional moments are
101.5 2000.0
1500.0
1000.0 Flapping 1 Lead−Lag
500.0 Torsion
0.0
Strain in um/m −500.0
−1000.0
−1500.0 Flapping 2
−2000.0 700 820 940 1060 1180 1300 1420 1540 Time in Seconds Figure 10: Corrected strain data measured at the second flapping measurement point. The radial positions of the strain gauge bridges are Figure 12: A VPM M16 autogyro during take off shown in Fig. 11. By using the calibration test data, moments can be