1928

Item 1928

DESIGN: SynchroLite ~ Power Train (for 2 motors) - Assembly - Layout - Electric Motor - 2 Flytec

Overview:

The electric helicopter idea on this web page consists of simply replacing the single motor and primary pulley reduction assembly, which are shown in the following picture, drawing and link, with a pair of electric motors, as shown in the second drawing.

DESIGN: SynchroLite ~ Power Train (for 1 engine) - Assembly - Layout - Belt & 2 Gear Sets (10)

Drawing of Electric Power-train for SynchroLite Helicopter:

View A displays:-	10 DP gears	Crown & pinion at stock 90º	Twin X-shafts with coupling ⁽¹⁾
View B displays:-	8 DP gears	Crown & pinion at custom 101º	Single X-shaft

Any combination of the above 3 options is available.

Coupling can be constant velocity joint, double universal joint, or pair of bevel gears on X-shafts that are rotated 30º or 45º forward.

Additional information is in envelope in SynchroLite - Power-Train binder.

Electrics- Flytec:

For information on Flytec motors see; Binder Megaflux & Flytec.

For drawing of Flytec see; drawing 1928.dc and 1929.dc

Motor: HPD 13.5 2490 * 2 = 4,980 http://www.flytec.ch/e-drive/hdp13_e.htm, http://www.flytec.ch/e-drive/Download/Motoren/Motordaten%20HPD13.5.pdf

Management: MMS 13.5 1710 * 2 = 3420

Battery: LIPO, - Akku 60 Ah, 4869 * 2 = 9738

Charger: ASC 18-1, 1336 * 1 = 1336

Total 19,472 * 1.5 = $33,000.00 Can funds

Notes:

The gears will be 8 or 10 DP.

For gear calculations see: DESIGN: SynchroLite ~ Power Train - Reduction Secondary - for Assembly 1316 (10)

The current V angle on is 22º with a 25" gap.

Seriously consider going down to a DP of 8 or down to a DP of 10. This will result in a reduced gap of 1" to 2" and may require that the V-angle be increased or that the precone angle be increased. What about absolutely rigid rotors??? See drawing 0472.dc. This will also decrease the lateral dimension between the two motors and put them further behind the seat, which is good. And also decrease the weight. Also it will put the motors and reducer more in the inset of the pilots seat back AND away from the tail boom, which is better for fitting the oil-flinger and trough. However, this may put the masts too close to the pilot's shoulders.

Reference: The assembly is 0472.html & 0472.dc

Reference: Gearbox 0959.dc & 0959.html

The motor drawing is on 1929.dc

Weight and Balance is S_E_WeightAndBalance.html

For improved efficiency see; DESIGN: Electrotor-SloMo ~ Motor - Radial Flux - Overview - 6-phase for Intermeshing (Bilateral)

Potential concern: Will 2 * 13.5 kW = 36.2 hp be enough? The Flettner had 17 lbs per horsepower, which would gives 615.4 lbs of thrust; but .....

Does a total storage of 2 battery packs * 60 Ah / 2 motors @ 230 amps mean 15.6 minutes of flying?

Gears:

FORM: Arrow Spiral Bevel Gear Selection.

	basic Arrow gear 10 PD	basic Arrow gear 8 PD
	10P45L15 & 10P15R45	8P45L15 & 8P15R45
	Item 0226 & 0227	Item 0143 & 0144
OD of gear	4.492	5.627	"
Bore of pinion	0.625	0.75	"
Horsepower:	17.43	17.43	hp
Pinion Speed:	1980	1980	rpm
Pinion Working Torque:	540	555	in-lb
Estimated Rated Pinion Torque:	1110	1110	in-lb
Catalog Rated Pinion Torque:	540	998	in-lb
Catalog Pinion Pitch Diameter:	1.5	1.875	in
Pitch Line Velocity:	778	973	ft/min
Dynamic Factor:	0.8582	0.8452
Allowable Pinion Torque:	463	843	in-lb
Service Factor:	0.835	1.52	:1

FORM: Hamilton Spiral Bevel Gear Selection.

	10 PD	8 PD
	15 / 45 teeth	15 / 45 teeth
	Item 0226 & 0227	Item 0143 & 0144
Pinion Speed	1980	1980	rpm
Catalog Pinion Pitch Dia.	1.5	1.875	in.
Pitch Line Velocity	778	973	ft/min
Diametral Pitch	10	8
Face Width	0.6875	0.8125	in
Allowable Contact Stress	200,000	200,000	Steel Rockwell C55 min.
Allowable Bending Stress	30,000	30,000	Steel Rockwell C55 min.
Elastic Coefficient	Pinion & Gear - Steel	Pinion & Gear - Steel
Load Distribution Factor	One member straddle mounted	One member straddle mounted
Geometry Factor [I]	.119	.119
Geometry Factor [J]	.247	.247
Durability	12.56	23.2	hp.
Strength	18.25	32.0	hp.
Durability Service Factor
Strength Service Factor

The following notes relate to the two columns in the Hamilton calculations above.

If the speed is increased by 7% then the strength and durability go up by approximately 6%.
If both members are straddle mounted then Durability goes up by 12% the Strength goes up by 12%.

The bore diameter for the Arrow 6P15 pinion is xx" diameter. This is fine for xx horsepower but the power for both masts must pass through the Starboard pinion. By increasing the pinion by one tooth (xx) the bore can be xx" diameter and this is good. Note that the stagger must be opened up from xx" to xx" and the gears must be dropped by xx" ~ to the location of the pilot's spine's most forward point.
The angle between the gears is xxº and hopefully this will allow the input shaft to have a diameter slightly greater than the Arrow xx" diameter.

FORM: Hamilton Straight Tooth Gear Selection.

This is the above table with the Geometry Factors changed to straight tooth values.

Geometry Factor [I]	.074	.074	.074
Geometry Factor [J]	.228	.228	.228
Durability	7.8	14.4	23.2	hp.
Strength	16.85	29.5	45.9	hp.
Durability Service Factor
Strength Service Factor

Overrunning Clutch:
Some of the following has been copied over from 1316 and MAY have to be modified

The overrunning clutch is to be located between each motor and its input shaft to the gearbox. The torque is 132 ft-lb Power Train Access Form

?	Consider 2 Warner CSK 35 (Item 0568), Max. torque 207 ft-lb. Sprag. C/w brgs, 0.66 lbs.
?	Consider Warner CSK 40, (Item 0741) Max. torque 384 ft-lb. Sprag. C/w brgs?, 1.10 lbs. This weighs more but it means less material in adjoining items.
	Consider 2 Marland-RINGSPANN R206 (Item 0524), Max. torque 195 ft-lb. No brgs. Keyway
	Consider Marland-RINGSPANN R208 (Item 0141), Max. torque 450 ft-lb. No brgs. Keyway
	http://www.stieber.de/products/gfkgb.html
	Look into the other ones mentioned on the line below

For additional information see: Overrunning Clutch: Overrunning Clutch for SynchroLite with 1 engine Overrunning Clutch for SynchroLite with 2 engines

Housing:

An upper casting will contain the bearings for the mast and the attachment lug to the fuselage. The lower portion may consist of two halves, which might be identical except LH & RH, The left hand one has a plug where the input shaft is on the right hand one and this allows for a future PTO.

Lubrication:

Splash from bottom center by oil flinger.

Mounting:

The gearbox will have a single central mounting point to the fuselage. It will be in the same casting that contains the mast bearings. This is because the bearing at the top of each mast makes up the triangle and the mast and its bearings must be strong.

The gearbox will contain mounting 4 points to pick up the engines 4 mounting points. There will probably be an adapter/spacer between the two.

Initially displayed: July 14, 2010 ~ Posted to Rotary Wing: July 14, 2010 ~ Last Revised: September 12, 2011

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.