GEARBOX TEST RIG FOR SKYSPOTTER 150 HELICOPTER

7 ACC JOURNAL 2022, Volume 28, Issue 1 DOI: 10.15240/ ul/004/2022-1-001 GEARBOX TEST RIG FOR SKYSPOTTER 150 HELICOPTER Jan Bělík VÚTS, a.s., Measu emen Depa men , S á o ská 619, 460 01, Libe ec XI – Růžodol I, Czech Republic e-mail: [email p o ec ed] Abs ac SkySpo e 150 is an unmanned helicop e in oduced ecen ly by Modelá na LIAZ. The gea box es ig de eloped o his helicop e has an inno a i e design. The d i e is combined wi h a dynamome e and an axial o ce mechanism, which simula es he load om he main o o on he gea box ou pu sha . I leads o a special solu ion. The measu emen me hodology was de eloped including all senso s and design o he ig wi h a non- adi ionally o ien ed dynamome e . The design has sa e y ea u es ha p o ec he es ig componen s and ope a o . The es ig is used o many es s du ing he de elopmen and imp o emen o he new helicop e gene a ion. I also se es o e i ying he gea box pa ame e s du ing i s li e ime; i means es s o new gea boxes as well as echnical diagnos ic du ing pe iodical inspec ions. Keywo ds Angula gea box; Tes ig; Vib a ions; Measu emen . In oduc ion Sou ce: [1] and i s gea box Fig. 1: SkySpo e 150 The company VÚTS coope a es wi h Modelá na LIAZ on he de elopmen o he es s a ion o angula gea boxes. The gea box is moun ed in he helicop e ame in he ho izon al posi ion, as shown in Fig. 1. The d ones ha e weigh limi a ions; he e o e, he gea box mus be ligh , bu also su icien ly igid and sa e. The gea box mus ha e a maximum a io be ween 8 weigh and powe . This canno be achie ed wi hou ex ensi e gea box es ing. D ones ha e g ea usage in he wo ld nowadays. SkySpo e 150 should ha e wide usabili y in he mili a y se ice (sea ching, moni o ing, equipmen anspo and mo e) bu also in he ci il sec o . The applica ion can be ound in i e igh e uni s, geological explo a ion, escue wo ks and elsewhe e. I s bigges ad an age is he possibili y o ly unde di icul condi ions o a long ime. 1 Tes Rig Design The schema ic diag am o he es ig is shown in Fig. 2. The scheme p esen s all main componen s used in he design and hei loca ions. The main pa s a e a d i e, wo dynamome e s and an axial o ce mechanism. The s ain gauge lange senso s by Kis le a e used o o que measu emen . Sou ce: Own Fig. 2: Schema ic diag am o he es ig The basis o he es ig consis s o a welded ame shown in Fig. 3. All main pa s a e connec ed o he ame. The ame design allows bigge dynamome e moun ing in he e ical o ho izon al posi ion, which means i is possible o es o he gea box ypes wi h di e en axis o ien a ion o o he helicop e componen s ( o example an engine). 9 Sou ce: Own Fig. 3: The es ig du ing assembling 1.1 D i e and Dynamome e The d i e and he dynamome e we e supplied by TES Vse ín. The d i e is a s anda d p oduc o his company. I is an asynch onous mo o wi h a maximal powe o 50 kW and an ex e nal ai -cooling. The bigge dynamome e is Siemens asynch onous se omo o wo king as an elec ic b ake (load). This pa has a maximal b aking powe o 40 kW and i wo ks in he e ical o ien a ion. The dynamome e can wo k in his posi ion due o a o que measu emen ealized by an ex e nal senso and he usage o special bea ings. The smalle dynamome e is also Siemens asynch onous se omo o , bu i s maximal powe is only 4.5 kW. 10 1.2 Sha and Bea ings The bea ings a e moun ed h ough clamping slee es o di ec ly p essed o pa s o he design o he p oposed de ice. The sha o he d i e and he gea box connec ion a e designed as wo pa s shown in Fig. 4. The s ain gauge lange o o que measu emen is moun ed be ween hese wo pa s. A bea ing 6406 is p essed on each pa o he sha . Bea ings a e moun ed in clamping slee es KTR 100 – 90 x 13. Sou ce: Own Fig. 4: Sha connec ing d i e and gea box The same solu ion was used o he sha connec ing he gea box and he smalle dynamome e shown in Fig. 5. The only di e ence is in he usage o wo bea ings on he gea box side sha pa . Two bea ings a e used because o he anspo a ion possibili y o he independen smalle dynamome e pla o m. Sou ce: Own Fig. 5: Sha connec ing gea box and smalle dynamome e The las sha assembly o connec ing he gea box wi h he axial o ce mechanism and he bigge dynamome e in he e ical posi ion is shown in Fig. 6. The sha be ween he gea box and he axial mechanism mus enable i s axial displacemen . I is ensu ed by wo bea ings NK 32/20 TN, which a e needle bea ings wi hou an inne ing. The sha has a g ound su ace a he bea ing loca ion allowing he axial displacemen . These bea ings a e p essed in pa s o he ame. The axial o ce is ans e ed ia axial bea ings 53 310. The sha be ween he axial o ce mechanism and he bigge dynamome e uses he same moun ing as he d i e sha . The only di e ence is he applica ion o la ge bea ings 6407 and clamping KTR 100 – 100 x 174. Sou ce: Own Fig. 6: Sha connec ing axial o ce mechanism and bigge dynamome e 11 1.3 Clu ches The gea box is connec ed o he es s a ion sha s by he same clu ch as in he helicop e . Each sha has a sa e y clu ch (be ween he d i e o he dynamome e s and he o que senso s) ensu ing he es s a ion p o ec ion agains o e loading. The sa e y clu ch disconnec s he o que when an unexpec ed condi ion occu s. Sou ce: Own Fig. 7: Gea clu ch [2] An aluminum clamp clu ch ans e s he axial o ce om he axial o ce mechanism o he gea box ou pu sha . This ma e ial was chosen o he eason he gea box sha is undamaging. The clu ch be ween he axial o ce mechanism and he bigge dynamome e o que senso does no ans e he axial o ce because i could damage he o que senso . The e o e, he gea clu ch is used as shown in Fig. 7. Each clu ch was dimensioned o he maximal load o he d i e and he dynamome e . The assembly was made by a conical clamping on a smoo h sha . 1.4 Axial Fo ce Mechanism Sou ce: Own Fig. 8: Ve sion wi h se omo o The i s d a o he ealiza ion o he axial o ce loading mechanism was p oposed o he use o he se omo o . The schema ic diag am o his solu ion is shown in Fig 8. A mo ing sc ew d i en by he se omo o p oduces he axial o ce ac ing in he axis o he ou pu sha . 12 The nu on he mo ing sc ew ans e s he o ce o a dis ibu ion pla e. App op ia e sp ings should be placed be ween he nu and he dis ibu ion pla e because he mo ing sc ew angula mo emen wi hou he sp ings is close o ze o. The disad an age o his solu ion is i s highe p ice and complica ed design. Sou ce: Own Fig. 9: Ve sion wi h ai sp ings A new solu ion wi h ai sp ings was designed as a cheape and simple solu ion, as i is shown in Fig 9. The ai sp ings di ec ly p oduce he axial o ce. All pa s o he mechanism mus ha e su icien s i ness o high o ce p ecision and epea abili y. An ai p essu e senso is connec ed o supply he ci cui o each pai o he ai sp ings. The axial o ce can be con olled and egula ed by a p opo ional al e; he measu ed ai p essu e se es as he eedback signal. The dis ibu ion pla e posi ion is con olled ia a displacemen capaci i e senso . A linea guidance is no necessa y o use because wo pai s o he ai sp ings lead he dis ibu ion pla e. The mechanism has a mechanical ends op de ining dead poin s o he dis ibu ion pla e displacemen o egimes wi hou he comp essed ai and/o oo big p essu e. Conclusion De elopmen and design o he es s a ion o angula gea boxes wi h axial o ce and o que load is p esen ed. This solu ion is p ima ily ocused on es ing o gea boxes used in unmanned helicop e de eloped by Modelá na LIAZ company. The es s a ion can load he gea box by de ined o que and axial o ce on he ou pu sha and simul aneously measu es ac ual alues o o que, angula speed, axial o ce, ib a ions, empe a u e and noise. Acknowledgemen s This wo k was suppo ed by he Czech Minis y o Indus y and T ade in he amewo k o he TRIO p og am. Li e a u e [1] LIAZ: SkySpo e 150 UAV sys em. [online]. A ailable om WWW: h ps://www.liaz- ua .com [2] LENZE SELECTION: Zubo é spojky – mechanické. [online]. [accessed 2022-02-25]. A ailable om WWW: h ps://www.lenze-selec ion.com/cs-cz/ y obky/spojky- h idelo e-p i ubo e-spojky/zubo e-spojky/ Ing. Jan Bělík 13 TESTOVACÍ ZAŘÍZENÍ PRO PŘEVODOVKY VRTULNÍKU SKYSPOTTER 150 Bezpilo ní ulník SkySpo e 150 je y inu i mou Modelá na LIAZ. Tes o ací zařízení p o pře odo ky ulníku nejsou s anda ní p aco iš ě. Je zde pohon p o ázaný s dynamome em a axiálním za ěžo acím mechanismem simulujícím za ížení od o o u na ýs upním hřídeli pře odo ky. P o o je po řeba speciálního p aco iš ě. Byl na žen měřící ře ězec če ně jedno li ých snímačů a kons ukce se speciální o ien ací dynamome u. Kons ukce má bezpečnos ní p ky, k e é ch ání es o ací zařízení a její obsluhu. Tes o ací p aco iš ě je yuži o k ý oji no ých gene ací ulníku. Dále slouží k o ěřo ání pa ame ů no ých pře odo ek, ale i k echnické diagnos ice pře odo ek při opako aných kon olách. TESTANLAGE FÜR DIE GETRIEBE DES HUBSCHRAUBERS SKYSPOTTER 150 SkySpo e is ein unbemann e Hubsch aube und wu de on de Fi ma Modelá na LIAZ en wickel . Bei de Tes anlage ü die Ge iebe des Hubsch aube s handel es sich um keinen S anda da bei spla z. Hie wi d de An ieb mi einem Dynamome e und einem Belas ungsmechanismus e bunden, wobei de Belas ungsmechanismus eine Belas ung om Ro o au die Ausgangswelle des Ge iebes simulie . Dahe beda es eines speziellen A bei sbe eichs. Es wu den eine Messke e inklusi e einzelne Ab as e sowie eine Kons uk ion mi einem speziellen O ien ie ungsdynamome e en wo en. Die Kons uk ion e üg übe Siche hei selemen e, welche die Tes anlage und de en Bedienung schü z . Die Tes anlage wi d zu En wicklung neue Helikop e gene a ionen genu z . Wei e dien sie zu Übe p ü ung de Pa ame e neue Ge iebe, abe auch zu echnischen Diagnos ik de Ge iebe bei wiede hol en Kon ollen. STANOWISKO BADAWCZE PRZEKŁADNI ŚMIGŁOWCA SKYSPOTTER 150 SkySpo e 150 o bezzałogowy śmigłowiec op acowany p zez i mę Modelá na LIAZ. S anowiska badawcze p zekładni śmigłowca nie mają s anda dowej kons ukcji. Napęd jes połączony z dynamome em i mechanizmem obciążenia osiowego, k ó y symuluje obciążenie głównego wi nika na wale wyjściowym p zekładni. Z ego powodu po zebne jes zas osowanie specjalnego s anowiska. Op acowano o pomia owy obejmujący poszczególne czujniki o az kons ukcję ze specjalnie ukie unkowanym dynamome em. Kons ukcja posiada elemen y bezpieczeńs wa, k ó e ch onią s anowisko badawcze i jego obsługę. S anowisko badawcze jes wyko zys ywane do p ojek owania śmigłowców nowej gene acji. Ponad o służy ono ównież do we y ikacji pa ame ów nowych p zekładni, a akże diagnos yki echnicznej p zekładni podczas p zeglądów ok esowych.