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Design of a Helicopter Hover Test Stand Design of a Helicopter Hover Test Stand A Major Qualifying Project Report Submitted to the Faculty of the WORCESTER POLYTECHNIC INSTITUTE in Partial Fulfillment of the Requirements for the Degree of Bachelor Science in Aerospace Engineering by Bror Axelsson Jay Fulmer Jonathan Labrie March 6, 2015 Approved by: Professor Maria Chierichetti, Advisor Aerospace Engineering Program Aerospace Engineering Department, WPI Professor Anthony B. Linn, Co-Advisor Aerospace Engineering Program Aerospace Engineering Department, WPI Abstract The development of helicopter test stands allows for the testing and improvement of various components of helicopter rotor head and blade designs. The goal of this project is to design, build, and test a fully articulated helicopter rotor head system for future implementation on a hover test stand. The stand will be used to measure the forces and moments at the blade roots and the strain along the blades. The design of the rotor head is modular, allowing for the type and number of blades to be changed as desired without major disassembly of the test stand. The design is based on a fully articulated, four bladed rotor head with a custom fabricated swashplate and driveshaft. Additionally, a safety system was designed to ensure the safe operation of the hover test stand and protect the users in the case of failure at maximum rotor speed. The recommended data acquisition system for measuring stresses and strains is a light based system that uses fiber optic technology to accurately collect and transmit data from the rotating blades to data analysis equipment in the stationary frame. i Authorship Section Primary Author Abstract Bror Chapter 1: Introduction Bror Chapter 2: Background Jay 2.1 Rotor Test Stands Jon 2.1.1 Principles of Operations Jon 2.1.2 Scaling Jay 2.2 Helicopter Rotor Head Systems Bror 2.2.1 Flybar Rotor Heads Bror 2.2.2 Solid Articulated Rotor Heads Bror 2.2.3 Fully Articulated Rotor Heads Bror 2.2.4 Bearingless Rotor Heads Bror 2.2.5 Hinges and forces Bror 2.3 Motor and Motor Drives Jon 2.3.1 Alternating Current (AC) Motor Jon 2.3.2 Direct Current (DC) Motor Jon Jay 2.4.1 Slip Rings Jay 2.4 Sensors and Data Acquisition 2.4.2 Wireless Sensors Jay 2.4.3 Wireless Data Acquisition Jay 2.4.4 Fiber Optics Jay 2.4.5 Bragg Grating Jay Chapter 3: Methodology Jay 3.1 Hover Test Stand Design Bror 3.1.1Figure Design 2: A Fully Speci Articulatedfications Rotor Head (Lewis & Darbo, Bror 2006)3.1.2 Test Stand Design Jay 3.1.3 Engine Design Jon 2.2.4 Bearingless Rotor Heads 3.1.4 Engine Mount and Belt Tensioner Jay 3.1.5 Power Transfer System Jay Figure 8: An example of a wireless strain gauge. 3.1.6 Driveshaft Design Jon 3.1.72.4.3 DrivesWirelesshaft D Analysisata Acquisition Jon 3.1.8 Support Bearing Design Jay ii 3.1.9 Swashplate Design Jay & Jon 3.1.10 Swashplate Torque Link Design Jay 3.1.11 Pitch Control System Jay 3.1.12 Rotor Head Design Jon & Jay & Bror 3.1.13 Design for Manufacturing Jon 3.1.14 Computer-Aided Design Jay & Bror 3.2 Budgeting Jon 3.3 Manufacturing Jon 3.3.1 Process Documentation Jon 3.3.2 Computer-Aided Machining Jon 3.4 Safety Enclosure Jay 3.5 Assembly Bror & Jay 3.5.1 Feathering Spindle Assembly Jay 3.5.2 Pitch Control Arm Assembly Jay 3.5.3 Rotor Head Assembly Jay 3.5.4 Follower Assembly Jay 3.5.5 Swashplate Assembly Bror 3.5.6 Final Assembly Bror 3.6 Data Acquisition System Bror 3.6.1 Data Acquisition Box Jay 3.6.2 Stress Measurements and Data Transfer Jay 3.6.3 Angular Velocity Measurement Jay 3.7 Test Plan Bror Chapter 4: Conclusions and Recommendations Jay 4.1 Changes in the Project Scope Jay 4.2 Design Compromises Jay 4.3 Recommendations Jay & Jon 4.4 Conclusion Bror iii Table of Contents Abstract ............................................................................................................................................ i Authorship....................................................................................................................................... ii Table of Figures ........................................................................................................................... viii Table of Tables ............................................................................................................................... x Chapter 1: Introduction ................................................................................................................... 1 Chapter 2: Background ................................................................................................................... 3 2.1 Rotor Test Stands .................................................................................................................. 3 2.1.1 Principles of Operations ................................................................................................. 3 2.1.2 Scaling ................................................................................................................................ 5 2.2 Helicopter Rotor Head Systems ............................................................................................ 8 2.2.1 Flybar Rotor Heads ......................................................................................................... 9 2.2.2 Solid Articulated Rotor Heads ........................................................................................ 9 2.2.3 Fully Articulated Rotor Heads ...................................................................................... 10 2.2.4 Bearingless Rotor Heads .............................................................................................. 10 2.2.5 Hinges and forces ......................................................................................................... 11 2.3 Motor and Motor Drives ..................................................................................................... 14 2.3.1 Alternating Current (AC) Motor................................................................................... 14 2.3.2 Direct Current (DC) Motor ........................................................................................... 15 2.4 Sensors and Data Acquisition ............................................................................................. 17 2.4.1 Slip Rings ..................................................................................................................... 17 2.4.2 Wireless Sensors ........................................................................................................... 18 2.4.3 Wireless Data Acquisition ............................................................................................ 19 2.4.4 Fiber Optics .................................................................................................................. 21 2.4.5 Bragg Grating ............................................................................................................... 22 Chapter 3: Methodology ............................................................................................................... 24 3.1 Hover Test Stand Design .................................................................................................... 24 3.1.1 Design Specifications ................................................................................................... 24 3.1.2 Test Stand Design ......................................................................................................... 24 3.1.3 Engine Design............................................................................................................... 25 iv 3.1.4 Engine Mount and Belt Tensioner ................................................................................ 27 3.1.5 Power Transfer System ................................................................................................. 28 3.1.6 Driveshaft Design ......................................................................................................... 28 3.1.7 Driveshaft Analysis ...................................................................................................... 31 3.1.8 Support Bearing Design................................................................................................ 44 3.1.9 Swashplate Design ........................................................................................................ 46 3.1.10 Swashplate Torque Link Design................................................................................. 50 3.1.11 Pitch Control System .................................................................................................. 53 3.1.12 Rotor Head Design ..................................................................................................... 54 3.1.13 Design for Manufacturing .......................................................................................... 62 3.1.14 Computer-Aided Design ............................................................................................. 63 3.2 Budgeting ............................................................................................................................ 65 3.3 Manufacturing ..................................................................................................................... 67 3.3.1 Process Documentation ................................................................................................ 67 3.3.2 Computer-Aided Machining ......................................................................................... 67 3.4 Safety Enclosure .................................................................................................................
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