Basics of Helicopter

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE
A project supported by the European Commission, the European Aerospace Industry, the Ministry of Civil Aviation of the Republic of India, HAL and SIATI
Introduction
Familiarisation with
Composite Blade
Manufacturing
Helicopter Basic Informations
Familiarisation with Composite Blade Manufacturing
3. - 5. June 2003 - Bangalore

PRODUCTION MANAGEMENT - PM24
Familiarisation with composite blade manufacturing
Page: 1

Newspapers and televison very often report about

spectacular rescue missions with helicopters
Where a helicopter appears, it is admired by the people

but behind this enthusiasm many problems had to be solved in the past
Page: 2

Principle of helicopter
is many 100 years old
Dream of
Leonardo da Vinci:
Aircraft which is able to

start and land vertical,
can hover in the air and
is controllable in all
directions
Leonardo da Vinci sketched
1493 the helicopter concept
The word HELICOPTER is coming from two Greek words:
HELIX meaning spiral and PTERON meaning wing

Page: 3

Realization Phase of Helicopter Concept

Until the dream of Leonardo da Vinci becomes truth many problems had to be solved
Development of a practical helicopter

occupied the first half of the 20th century
Following the important development steps and events

for the evolution of the helicopter will be presented

Page: 4


Louis Breguet: First helicopter flight 24.08.1907 with a pilot
No control system so at each corner 4 men were guiding the aircraft
Piston engine 45 PS, Take off weight 620 kg, 32 rotor blades
1,5 m height, 1 minute flight time

Page: 5


Paul Cornu: First helicopter free flight 13.11.1907 with a pilot
Piston engine 24 PS, Take off weight 260 kg, 2 rotors with 2 blades, Diameter 6,0 m
2,0 m height, 30 minutes flight time

Page: 6


Etienne Oehmichen: Several flights from 1922 onwards
180 PS, Take off weight about 300 kg, 4 rotors, each with 2 blades
First world rekord May 1924 for distance: 1000m in 50 ft, flighttime 14 minutes

Page: 7

Realization Phase of Helicopters

Juan de la Cierva: 1923
Autogyro, 4 bladed main rotor
Problems at forward flight occur (rolling of helicopter)
Inventor of flapping hinges

Page: 8

Activities of Henrich Focke on helicopters started 1930 with a licence agreement

for the production of Autogiros from de la Cierva
First ideas for the development of a true helicopter in 1931:
Safe landing possibility after loss of engine power
Good handling performance and stability also at gusty weather
Sufficient safety in operation
Easy handling equivalent to fix-wing aircraft
Acceptable flight performance
Easy maintenance

Page: 9


Configuration lay-out:
Start of activities 1932
Decision to choose side-by-side configuration
Elimination of torque
No interference between the rotors
Free airflow (only obstructed by the support frame)
Good static and dynamic stability along the roll axis
1936: 26th June,

First flight:
28 sec
Fourth flight:16 min

Page: 10

MTOW
1024 kg
Empty Weight
818 kg
Payload
80 kg
Max. Speed
145 km/h
Max. Climb
3,6 m/sec
Max. Ceiling
3427 m
Rotor Dia.
7m
Engine Power
(Take off)
110 kw

Page: 11


Established Records:
Date of Flight
Record Performance
Previous Record
25.6.1937
Endurance
1 h 20 min 49 s
1 h 02 min 50 s
25.6.1937
Ceiling
2439 m
158 m
(Brguet-Dorand)
26.6.1937
Average Speed
over 20 km
122,5 km/h
44,6 km/h
(Brguet-Dorand)
26.6.1937
Range
80,6 km
44,6 km (BrguetDorand)
25.10.1937
Range
108,9 km
20.6.1938
Range
230,2 km
29.1.1939
Ceiling
3427 m
10.5.1939
First autorotation
Page: 12

Development of a practical helicopter occupied the first half of the 20th century
Page: 13

Optimization Phase for Helicopters

After the first half of the 20th century the dream of all helicopter scientists becomes truth
Aircraft which is able to start and land vertical, can
hover in the air and is controllable in all directions
Helicopter applications most for military customer and operations
In the fiftees Optimization Phase for Helicopters

Helicopters has been started
The civil market discovered helicopters for its needs
Helicopter developments are now driven by the requirements of the market
Continuous improvements of the operational capabilities
with increase of the flight safety and comfort
and reduction of manufacturing and operating costs
Page: 14

Applications and Helicopter Operations
Emergency Medical Service, Search and Rescue

Utility, cargo transportation, offshore oil exploration
Public transport, business flying, sightseeing
Agriculture, forestry, fire fighting
Power and pipeline patrols
Parapublic applications, police, law enforcement
Military applications

Page: 15

Requirements for Civil Helicopter

Applications
3 Improved Performance
4 All Weather Capability
Heliradar, Deicing
Higher Cruising Speed, Increased Range
5 Noise Reduction
External Noise
2 Comfort
6 Safety
Dam. Tol. Design, Hums,
Later Remove of TCIs
Vibrations, Interior Noise,

Travel like in cars
1 Economical Improvements
Manufacturing Costs, Weight, DOC

Priority for Helicopter Manufacturer
Main objective is to sell more helicopter, second comfort, third acceptance of environment
These objectives particularly necessary for future developments of helicopter systems and especial for dynamic systems
Page: 16

Economical Aspects
Direct operating costs generally fall into five categories
Maintenance, Fuel, Insurance, Crew and Depreciation.
Direct Operating Costs acc. to Olson
(Reducing Helicopter Operating Cost, Vertiflite, Jan/Feb 1993)
Fix Costs
Depreciation
Rents
Insurance
Crew
Training
Documentation
Stockkeeping
Overhead
Credits
Variable
Costs
Quelle: SIP 4 Studie Betriebskosten des Hubschraubers BO108/EC135; 1993

Page: 17

Economical Aspects
Maintenance
24%
Crew
6%
Insurance
29%
Others
15%
Fuel
5%
Depreciation
36%
Rotor
4%
Variable Costs
Values
of BO105
Fuel
35%
Gear Boxes
9%
Engines
27%
Maintenance Hours
10%
Variable costs of helicopters are mainly influenced by dynamic components

This is one reason why you will find most of the developments
and research activities in the field of dynamic components
Page: 18

Dynamic Components of Helicopters

Rotor Blades
Rotor Hub
Rotor Mast
Tail Rotor
Hydraulic System
Shafts
Power Plants
Gearbox
Controls
Page: 19


The heart of a helicopter is the rotor which is
responsible for the lift and the control
The rotor needs a drive
Power Plants
Technical data (EC135) :

RPM out about 6.000
Power per engine 560 kW (750 shp)
Fuel capacity 580 kg
RPM too high => Gearbox for lower RPM necessary

Page: 20


Gearbox connects power plants with rotor
and reduce RPM suitable for rotor
Gear Box
Technical datas:
Weight 190 kg (EC135)
RPM input about 6.000
RPM out (rotor mast) about 400

Page: 21


Gearbox of EC135

Page: 22

Tiger Drive System

Page: 23

Rotor
The rotor produces the necessary lift and is
the means for the control of the helicopter
Main Rotor Head
Pitch Lever
Vibration Absorber
Driving Link
Swash Plate
Rotating Pitch Link

EC145 Main Rotor System
Page: 24

Rotor Blade
The rotor blades are the rotary wings and
generate the total lift of the helicopter
RPM about 400 U/min

(for diameter 10,0 m)
Blade tip speed about 220 m/s
Acceleration at blade tip 900 g

Centrifugal force at attachment about 150kN
(15 to for MTOW 3 to)

Page: 25

Rotor Wakes
Blattwirbelzopf
The rotor in forward flight generates

a very complex vortex system
Mach Number Effects
Blade Vortex
Wave Collisions
Longitudinal Flow
Reverse Flow
Stall due to High
Angles of Attack

Page: 26

Aerodynamic of Rotor Systems
Situation in Hover
Rotational velocity

Velocity distribution
versus blade span for
hover manoeuvre
Page: 27

Forward Flight

Lo
re w e r
tre v
at elo
in c
g ity
bl
ad at
e
Asymetrical velocity distribution leads to different lift

on the advancing and the retreating side of the blade
Rotation speed
Hi
g
ad he
va r v
nc elo
i n ci
g
bl ty a
ad t
e
Situation in Forward Flight
Page: 28


Consequence of asymetrical lift
distribution is rolling of helicopter
Flapping Hinge
Cierva invented in1920

the Flapping Hinge
Flapping of rotor blades induces movements in

rotor plane; additional hinge is necessary
=> Lead Lag Hinge
Page: 29

Damping and Lead-Lag Damper
In flapping direction
the damping resulting
from aerodynamic
forces is sufficient
In Lead-Lag direction
the damping resulting
from aerodynamic
forces is only marginal
and not sufficient
For the lead-lag movements of

the blades additional damping
devices are necessary
Lead-Lag
Damper
Flapping
Hinge
Lead-Lag
Hinge
Necessity of damper
in lead-lag direction
Page: 30

Principle of Articulated Rotor
Lead Lag Hinge

Blade Feathering
Flapping Hinge

Page: 31

Collectiv Control of Helicopters

Page: 32

Cyclic Control of Helicopters

Page: 33

Influence of Main Rotor Torque
Tail Rotor Thrust against

Helicopter Torque
Rotor-Rotation counter-clockwise
generates a
Helicopter-Rotation clockwise
Page: 34

Yaw Control of Helicopters

Page: 35

Control System for Helicopters
Stick for
Longitudinal
and Lateral Control
Pitch for
Collektiv Control
Pedals for
Yaw Control
BK117 C-1 Cockpit
Control Levers
Pitch, Stick, Pedals
Page: 36

Flexball
Control Levers
Page: 37

System II
Hydraulic System
Flexball
Servo Actuators
(System I und II)
System I
Control Levers
Page: 38

Swash
Plate
Upper Control
Hydraulic System
Flexball
Collective
Control
Control Levers
Cyclic
Control
Page: 39


Tasks of Swash Plates
Transfer of movements from the non
rotating system in the rotating system
Rotating System
to Rotor Blade
Swash Plate
Upper Control
Hydraulic System
Flexball
Control Levers
Non rotating system

Input from
Hydraulic System
Page: 40

Pitch Link
Swash Plate
Upper Control
Hydraulic System
Pitch Link
Flexball
Connection of rotating part of the

swash plate with rotor blade
Control Levers
Page: 41

We have seen ...............

........ how a helicopter is able to start
and land vertical, can hover in the
air and is controllable in all
directions.
The heart of a helicopter
is the rotor blade
Helicopter blades are one of

the most sophisticated parts
in the world of composites
Page: 42

Fields of Influences on Rotor Blades

Strength
Market Need
Safety
Helicopter Class
Erosion
Lightning
Main Dimensions
Corrosion
Aerodynamic
Weight
Performance
Manufacturing
Noise
Quality Aspects
Rotor Concept
Manufacturing Costs
Flight Missions
Certification
Loads
Maintenance Costs
Materials
Maintenability
Blade Layout
Dynamic
Vibrations
All this subjects will be content of our work shop
Continuation with Basics of Rotors and Blades
Page: 43

Basics of Helicopter

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EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Familiarisation with Composite Blade Manufacturing

3. - 5. June 2003 - Bangalore

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Newspapers and televison very often report about

Where a helicopter appears, it is admired by the people

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Aircraft which is able to

3. - 5. June 2003 - Bangalore

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Realization Phase of Helicopter Concept

Development of a practical helicopter

Following the important development steps and events

3. - 5. June 2003 - Bangalore

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Realization Phase of Helicopter Concept

3. - 5. June 2003 - Bangalore

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Realization Phase of Helicopter Concept

3. - 5. June 2003 - Bangalore

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Realization Phase of Helicopter Concept

3. - 5. June 2003 - Bangalore

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Realization Phase of Helicopters

3. - 5. June 2003 - Bangalore

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Realization Phase of Helicopters

Activities of Henrich Focke on helicopters started 1930 with a licence agreement

3. - 5. June 2003 - Bangalore

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Realization Phase of Helicopters

1936: 26th June,

Fourth flight:16 min

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Realization Phase of Helicopters

3. - 5. June 2003 - Bangalore

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Realization Phase of Helicopters

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Realization Phase of Helicopters

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Optimization Phase for Helicopters

In the fiftees Optimization Phase for Helicopters

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Applications and Helicopter Operations

Emergency Medical Service, Search and Rescue

3. - 5. June 2003 - Bangalore

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Requirements for Civil Helicopter

Higher Cruising Speed, Increased Range

Vibrations, Interior Noise,

Manufacturing Costs, Weight, DOC

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Quelle: SIP 4 Studie Betriebskosten des Hubschraubers BO108/EC135; 1993

3. - 5. June 2003 - Bangalore

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Variable costs of helicopters are mainly influenced by dynamic components

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Dynamic Components of Helicopters

EU-INDIA CIVIL AVIATION PROJECT - IMPLEMENTATION PHASE

Dynamic Components of Helicopters

The rotor needs a drive

Technical data (EC135) :