MAIN ROTOR HUB
TECHNOLOGY
By Philippe LEGENDRE
1
ENSEMBLES MECANIQUES DU SUPER-PUMA
Rotor principal
Rotor arrire
Transmission arrire
B.T.A
B.T.I
Moteur 1
Moteur 2
B.T.P
2
HISTOIRE DE L HELICOPTERE
1. LES PIONNIERS
Paul CORNU (1907)
ELLEHAMMER (1912)
BREGUET et RICHET (1907)
3
HISTOIRE DE L HELICOPTERE
2. LES PRECURSEURS
Etienne OEHMICHEN (1924)
(1 km en circuit ferm)
R.P. PESCARRA (1924)
(Commandes de pas cyclique et collectif)
HISTOIRE DE L HELICOPTERE
3. L AGE D OR DE L AUTOGYRE
CIERVA C30
(1re voilure tournante construite en srie)
CIERVA C 8L
(1re traverse de la Manche par
une voilure tournante en 1928)
HISTOIRE DE L HELICOPTERE
4. VERS LA MATURITE
BREGUET-DORANDGyroplane Laboratoire(1935)
FOCKE ACHGELIS FA 61 (1936)
SIKORSKY VS300 (1939)
6
LES DIFFERENTS GIRAVIONS
FN
FN
rotor
Rotor
FA
TF
TH
TF
Aile
mg
mg
L HELICOPTERE
LE COMBINE
TH
FN
FN
TH
rotor
Rotor basculant
FA
mg
TF
Aile
FA
TF
TH
TF
mg
mg
L AUTOGYRE
mg
LE CONVERTIBLE
7
LES AUTOGYRES
CIERVA C30
(Observation du champs de bataille
vers la fin des annes 1930)
Autogyre WALLIS WA116
(Utilisation sports aeriens)
8
LES COMBINES
PROPULSION PAR REACTEUR
LOCKHEED XH 51
PROPULSION PAR HELICE
LOCKHEED AH 56 Cheyenne
LES DEUX TYPES DE CONVERTIBLES:
RYAN XC 142
LE TILT-ROTOR
(Concept sur base hlicoptre)
LE TILT-WING
(Concept sur base avion)
BELL-BOEING V22 Osprey
10
ROTOR ENTRAINE PAR REACTION
1. jection de gaz comprim en bout de pales
Air pur (Hautepression)
Gaz chauds (Basse pression)
SNCASO SO 1221 Djinn
11
ROTOR ENTRAINE PAR REACTION
2. Moteur raction install en bout de pales
HILLER Hornet
Fuses
Stato-racteurs
Pulso-racteurs
Turbo-racteurs
HILLER YH18
12
ROTOR ENTRAINE PAR REACTION
3. Combustion en bout de pales
HUGHES XH17 Flying Crane
(Le plus grand rotor jamais construit : ~40m)
Systme mixte-(Haute pression)
13
HELICOPTERES
Bi-rotors en tandem ( VERTOL H21)
Bi-rotors latraux (MIL V12)
BI-ROTORS
Bi-rotors co-axiaux ( KAMOV Ka25)
Bi-rotors engrenants (KAMAN
h43)
14
HELICOPTERES
MULTI-ROTORS
BENSEN Flying carpet
3 ROTORS...
CIERVA W11 Airhorse
4 ROTORS...
CURTISS-WRIGHT WZ 7
10 ROTORS !!!
15
COMBIEN DE PALES AU ROTOR PRINCIPAL?
MIL Mi 26
BOLKOW BO103
8 pales
BELL 206 Jetranger
2 pales
1 pale!!.
16
HUB TECHNOLOGY
1) TWO-BLADE HUBS
2) MULTI-BLADE HUBS
Trend towards greater simplicity:
By the use of new concepts and new materials
By enhanced integration of functions and
components
Articulated hubs on bearding
Spheriflex-type hubs
bearingless main rotors (BMR)
Coupled with efforts:
To reduce weight and costs
To decrease the maintenance
requirements
17
Rotors Technologies
World Firsts
1955
- Gas-turbine helicopter, jointly with Turbomeca
1967
- Rigid rotor hub, composite main rotor blades
1968
- "Fenestron" tail rotor
1974
- Composite "Starflex" hub
1984
- DGAC / FAA certification for limitation-free
flight in icing conditions
1988
- Bearingless Main Rotor (BMR)
1989
- Spheriflex Main and Tail Rotors
1991
- FEL Rigid main Rotor - Spheriflex tail Rotor
1997
- Spheriblex Main and Tail Rotors
2001
- Significant noise level reduction
18
THE MAIN ROTOR HUB
MAIN FUNCTIONS
To support the blades when spinning and not spinning
To provide the blades with the required degrees of freedom in:
Flapping / Lead lag / pitch
To provide the pitch or angle of attack variations:
Collective pitch variation / Cyclic pitch variation
To transmit the MGB power to the rotor
RELATED FUNCTIONS
To fix the blade frequencies (especially lead lag)
To provide lead lag damping
To provide blade coning stop and droop restrainer
To fold the blades (manual or automatic)
To de-ice the blades
19
TWO--BLADED ROTORS
TWO
THE FIRST TWO-BLADE ROTORS
BELL
gimbaled to decrease the lead lag moment
liable to weaving
gyroscopic stabilizer
HILLER
same type of rotor
gyroscopic stabilizer operated by aerodynamic flaps
BOTH TYPES
very soft suspension with long,braced rotor mast
DEVELOPMENTS IN TWO-BLADE DESIGN
Elimination of the gimbal and gyroscopic stabilizer (Jet ranger)
Introduction of coning flexibility (B.212)
Problems with large rotors = lead lag stiffness
Vibration problems: introduction of resonance reduction concepts (nodamagic)
DEVELOPMENTS IN TWO-BLADE DESIGN
DISCONTINUATION OF THE TWO-BLADE DESIGN: On new BELL helicopters
Though this concept is still in use ultra light helicopters (Robinson)
20
TWO--BLADED ROTOR
TWO
21
22
INTRODUCTION
Designing new rotor concepts with a view to reduce
weight, cost and maintenance burden, while improving
safety and reliability has always been one of the major
objectives of Eurocopter.
Different rotor heads have been developped: starflex,
spheriflex, bearingless, bmr, fenestron, btr
EC135 BMR
This stems from a long evolution on the last 40 years
through the main significant steps:
A feasibility phase,
A safety improvement phase,
A cost reduction phase.
EC120 FENESTRON
23
MAIN ROTOR HUB TECHNOLOGY
ARTICULATED HUBS
HINGED ROTOR HUBS ON BEARINGS:
TECHNOLOGIES USED
- Pitch change hinge on battery of ball bearings.
- Flapping-lead lag hinges : needle bearing, tapper roller bearing.
THE PROBLEMS
Lubrification
Oil
Grease
Leakages
Flaking
Maintenance
Potential
False brinell effed
Frequently lubrificated
Ceramic balls
24
ALOUETTE MAIN ROTOR HUB
25
GAZELLE MAIN ROTOR HUB
26
BK 117
MAIN ROTOR HUB
Main rotor System
Assembly
27
BK 117
MAIN ROTOR HUB
Assembly of Inner Sleeve
and Control Lever
28
BK 117
MAIN ROTOR HUB
Rotor Head witrh Innr
Sleeve Installed
29
332 MK I MAIN ROTOR HUB
30
332 MK I MAIN ROTOR HUB
31
MRP AH 64
32
MAIN ROTOR HUB TECHNOLOGY
HINGE ON ELASTOMERIC BEARINGS:
TECHNOLOGY USED
Spherical thrust-bearing: retaking of the centrifugal force and
pitch charge, flapping and lead lag hinges ensured by a single
component.
33
STARFLEX: THE FIRST STEP IN
THE COST REDUCTION PHASE
The famous STARFLEX fully composite
rotor hub marked the first step in cost
reduction compared to the previous
technology:
Reduction by 3 of the number of
parts,
AS350 STARFLEX MAIN ROTOR
Reduction of 65% of the production
cost,
Fail safe design for safety
improvement.
This semi-rigid hub equips cureuil and
dauphin families.
AS365 STARFLEX MAIN ROTOR
34
ECUREUIL STARFLEX MAIN ROTOR HUB
M.R.P. COMPONENTS
350/355
35
MRP AGUSTA
AG 129
36
MRP BELL 406
37
BELL 406
38
UH 60 A - BLACK HAWWK
Main rotor hub
39
MAIN ROTOR HUB TECHNOLOGY
Spherical thrust-bearing + flat bearing: pitch change hinge ensured
by the flat bearing, flapping and lead lag hinges realised by the spherical trust
bearing.
40
S 76
41
MAIN ROTOR HUB TECHNOLOGY
Tapered bearing + cylindrical bearing: suppression of the lead lag
hinge wich is ensured by the blade cuff flexibility.
42
TIGRE
43
TIGRE
44
MAIN ROTOR HUB TECHNOLOGY
HINGE ON ELASTOMERIC BEARINGS (following):
THE ADVANTAGES / BEARINGS
On condition maintenance: no moreTBO = suppresion of heavy maintenance
practises.
The elastomeric components are removed to the reach of remoral criterion.
ETABLISHMENT OF THE REMORIAL CRITERON
Fatigue test at bench, under the flight loads (2 to 4parts).
First phase: estimation of the MTBR (reliability) and etablishment of the removal
criterion.
Second phase: justification of the inspection interval.
45
MAIN ROTOR HUB TECHNOLOGY
HINGE ON ELASTOMERIC BEARINGS (following):
PROBLEMS PRESENTED BY THE ELASTOMERS
LOW TEMPERATURES (-40 C / -45 C):
Starting:
Oligocyclic fatigue on level of the adherisation.
In flight:
State deformations / contraints different of qualification test one (+ 15 C).
Increase of propagation speed.
HIGHT TEMPERATURES (+50 C):
State deformation/contraints different of qualification test one (+ 15 C).
Increase of propagation speed.
Behaviour of adherisation under the effect of the heating induced by the thermal
discipation (damping).
46
MAIN ROTOR HUB TECHNOLOGY
HINGE ON ELASTOMERIC BEARINGS (following):
PROBLEMS PRESENTED BY THE ELASTOMERS (following):
LOW TEMPERATURES (-40 C / -45 C):
Starting procedure ==> Reduction of stiffness according to the functioning time.
HIGHT TEMPERATURES (+50 C):
Fatigue tests on samples or on actual parts to determinate the propagation
speed.
AGEING (BLACK RUBBER):
Fatigue tests on samples for determination of the evolution of the fatigue
strength: law time / temperature.
OZONE ATTACK
TEST ON SAMPLES AFTER EXPOSITION IN OZONE CHAMBER
47
MAIN ROTOR HUB TECHNOLOGY
HINGE ON ELASTOMERIC BEARINGS (following):
PROBLEMS PRESENTED BY THE ELASTOMERS (following)
AGEING (BLACK RUBBER):
Reduction of the fatigue strength ==> Increasing of the crack growth speed.
Increasing of stiffness = => Constraints in the armatures and surrounding parts.
OZONE EFFECT:
Multiple surface crack favoured by static constraints state.
48
49
What is a spheriflex?
FLAPPING STOP
HUB CUP
The spheriflex is a development of the
famous starflex, on which the arms were
removed.
FAIRIN
G
The
spheriflex
follows
the
general
guidelines of simplicity and reduction of
operational costs.
FLAPPING
STOP
SLEEVE
SLEEV
E
DROOP
RESTRAINER
DROOP RESTRAINER
HUB
DAMPER
AXE PA LE JAU NE
FR
AN
CE
UR
OC
OP
T ER
HUB
PITCH HORN
TI
ON
OT
EN
DAMPER
SPHERICAL THRUST BEARING
PITCH HORN
50
332 MK II MAIN ROTOR HUB
51
SPHERIFLEX MRH
332 MK II
CONVENTIONAL HUB
359 PARTS
SPHERIFLEX HUB
122 PARTS
No bearing,
No lurification,
Fail-Safe hub plate (Kevlar Strip)
52
332 MK II
53
DAMPER
TAIL ROTOR
On SPHERIFLEX tail rotor hub the
design is simplified: the blade is
directly attached on the spherical
thrust bearing
TIGER SPHERIFLEX TAIL ROTOR
54
SHORT DEVELOPMENT SCHEDULE
NH90
04/1993
09/1995
EC120
01/1993
06/1995
03/1997
EC155
MAIDEN FLIGHT CERTIFICATION
12/1996
06/1997
12/1998
EC225
T0
11/1998
11/2000
09/2002
SPHERIFLEX rotor hub is easy to finalyze, because it is possible to modify different
parameters independantly: stiffness, damping, loads...
55
IMPROVEMENT OF THE SPHERIFLEX
The development of the SPHERIFLEX is driven by cost efficiency.
This cost effectiveness is the result of intensive efforts made to
reduce manufacturing and maintenance costs as well as weight,
while maintaining safety at the highest level.
These goals where achieved thanks to:
- Innovative layout,
- Family concept,
- New materials.
56
INNOVATIVE LAYOUT
3 main steps in terms of design simplification can be identified:
Interblade damper for main rotor,
Tilted blade pins for main rotor,
Twin plate hub for tail rotor.
57
INTERBLADE DAMPER
The advantages of this layout are:
Increased lever arm, inducing lower stiffness
requirement
==> simplified damper design,
Easier installation due to more room availability,
EC155 SPHERIFLEX MAIN ROTOR
Simplified hub design: no need for
damper
attachement
==> reduced flapping hinge offset,
Improved cooling, and low static load
==> improved reliability,
Simplified installation of blade locking actuators for
automatic blade folding.
NH90 NFH SPHERIFLEX MAIN ROTOR
58
MANUAL BLADE FOLDING
Manual blade folding is one of the major
design constraints.
Generally to avoid any interference between
the front blades and the rear blades, special
setting of flight controls is necessary, in
addition to the removal of at least one pitch
link.
A rearward tilting of the blade pins ensures
blade folding without any maintenance action
on flight control system.
59
TILTED BLADE PIN
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
VERTICAL BLADE PIN
TILTED BLADE PIN
0
0
20
40
60
80
100
120
140
160
180
Blade pin tilting ensures a progressive and
continuous displacement of the blade.
-0,5
-1
200
TILTED BLADE
PIN
Blade folding duration is shortened and
can be performed with a reduced
maintenance team as demonstrated on
Nh90 and EC225.
-1,5
-2
VERTICAL
BLADE PIN
-2,5
BLADE TIP DESCENT
60
TWINPLATE HUB
Simplification of the design of the blade
root.
Reduced size of the hub:
15% saving on production and
maintenace costs,
12% saving on weight.
61
MATERIAL TREND
Since the seventies the metallic materials have made significant
progress in terms of fatigue behavior:
- Stainless steel,
- New titanium alloys,
- metal matrix composite.
These new matallic alloys allow a second step in the cost reduction
effort: it is possible to produce simple hub with quasi-infinite life.
62
NEW MATERIALS STAINLESS
STEEL AND TITANIUM
Conventional steel is now replaced favorably by stainless steel or
titanium .
This ensures a decisive advantage in terms of damage tolerance.
Cancelation of cadimium plating compensates the slightly higher
blank cost and participates toward a cleaner environment.
Fatigue behavior is equal or greater than that of conventional steel:
35 NCD16
MARVAL
X12
15 5 PH
Ti 10 2 3
TA6V
540 Mpa
570 Mpa
568 Mpa
590 Mpa
400 Mpa
63
NEW MATERIALS
STAINLESS STEEL AND TITANIUM
The Choice Between Stainless Steel and Titanium Is Motivated by the Best
Weight/cost Compromise :
EC225 SPHERIFLEX MAIN
ROTOR:
EC120 SPHERIFLEX MAIN ROTOR
Ti 10 2 3 HUB
INTEGRATED 15 5 PH
HUB/MAST
15 5 PH MAST
MMC SLEEVES
EC155 SPHERIFLEX MAIN
ROTOR:
INTEGRATED 15 5 PH
HUB/MAST
MMC SLEEVES
15 5 PH SLEEVES
64
65
4BW Rotor System
4BW Inflight
66
BEARINGLESS ROTOR HEAD OF BELL 680
67
BEARINGLESS ROTOR HEAD OF HUGES HARP
68
MD900 EXPLORER
Rotor Exploded View
69
EC 135
70
EC 135
71
Modularity of the Design
Flexbean
Pitch Case
Blade
Modular Blade Assembly
72
SPHERIFLEX
BMR
Easy adjustment (dynamic)
Concept very tolerant on utilisation
Production cost
ADVANTAGES
Development cost
Blade folding
Large experience
Number of parts
DRAWBACKS
Control power decrease for military
aircraft (combat)
DMC
Control power (=> maneuverability)
Decrease of the number of parts
DMC (to be confirmed with experience
return)
Delicate adjustment
Flexbeam stiffness + adapter stiffness =>
weight on extremty of blade for
Sophisticated suspension system
Number of blades elevated for decrease
exitation level
Not adaped for high speed (aircraft
attitude) (CxS ou )
Production cost
Development cost
Blade folding
Little experience
Weight global (reinforcement,
suspension)
73
FEASIBILITY LIMITS
SPHERIFLEX
BMR
CABRI
<1t
- EC 135
2,5 t
ECUREUIL / A109 /
2 t 2,5 t
- BELL 430 2,5 t
DAUPHIN / S76 / B412
4/5t
- MD 900
2,7 t
SUPER PUMA / NH90 / UH60 / S92
8 / 10 t
- COMMANCHE
4,2 t
MI 38 / E101 ~ 15 t
No limit of employment for EUROCOPTER range
LOW LIMIT ~ 2 t
Suspension
BMR =>
Sas
=> Cost expensive
and complexity
HIGHT LIMIT ~ 5 6 t
Material limit
74
MAIN ROTOR HUB TECHNOLOGY
TILT ROTOR
75
HUB OVERALL ARCHITECTURE
76
77
COMMANDES DE VOL DE L HELICOPTERE
78
LA CHAINE DE COMMANDES DE VOL
La chaine de commandes
Plateau tournant
Plateau non tournant
Rotule
Parties en rotation
Parties mobiles (sans rotation)
B.T.P
Les Plateaux cycliques
79
THE MAIN ROTOR CONTROL COMPONENTS
Pitch control by swashplate
Vertical slide to vary the collective pitch
Tilting to vary the cyclic pitch
Mixed controls
Indepedent controls
COLLECTIVE
and
CYCLIC
ECUREUIL
swashplate
PUMA
swashplate
COLLECTIVE
and
CYCLIC
BELL 47
Pitch control by SPIDER
Spider fitted above the rotor (DJINN)
Spider fitted in the rotor mast (LYNX)
Control link connecting the stick and swashplate
With collective/cyclic pitch mixer
80
SWASHPLATE
Functional diagram
Main rotor shaft
Blade lever
Drive
scissor
Fixed part
Turning
part
Flight
controls
81
SWASHPLATE
Example of construction
Link
Trunnion
Scissor
driver
Rotating
star
Spherical ball
joint
Scissor
Stationary
star
Scissor
82
GUIMBAL SWASH PLATE
83
Pitch control by SPIDER
Collective pitch contol
Cyclic pitch control
84
Laraigne , une variante du systme des
plateaux cycliques
WESTLAND WG13 Lynx
85
COMMANDE DU ROTOR PAR
MOBILES DE PALES
VOLETS
KAMAN SH2 Seasprite
86
COMMANDES DE VOL:
DEPLACEMENT DU CENTRE DE GRAVITE !!!
Solution SEIBEL YH24:
Dplacement du cockpit
Solution HILLER:
La plate-forme
volante
87
