Industrial Turbine

[cbergen]

We received a Purchase order for an Industrial Turbine from a well known Aerospace Manufacturer, so I thought we would do a build here on HF to show what all is involved with this large machine. I have invited the purchaser to take a look here as we go, and hopefully introduce themselves....:)

It will be a couple of weeks 'til we get the engine but we can put together the sub assemblies in the meantime.

[rkeith2]

Now this has my total attention

[v22chap]

Oh ,,,boy ,, me too

[snappa]

me too

[bcook01]

Great!

[piwko4]

Couple of fans, some bearings, and a little fuel. Seems simple to me....

Subscribed!!

[rkeith2]

Couple of gears, couple of fuel cells, couple of balls to fly it

[cbergen]

I got quite a bit done this week on the pair of Industrial Turbines, started with the heads.

The head on the Industrial Turbine is no different than what is included on our Gassers, Observers, Tazers, etc. Even swinging 850mm blades, this aluminum head has proven plenty strong to carry up to 50 Lbs total flying weight.

[cbergen]

While waiting on the second Turbine, I temporarily assembled the Lower Frames. These are made from 1/8th" G10 for tremendous strength and rigidity.

The aluminum Heat sinks are where the Wren Turbine is directly attached to the lower frames, and are utilized to dissipate the heat preventing damage to the G10 framework. After running the helicopter, DO NOT touch these heatsinks!! :)

Dual landing gear struts are installed on our Industrial Birds, as they are designed to carry heavier payloads.

[cbergen]

Some of the drive train and control items are next. The main gear is doubled up for strength, ensuring the drivetain can handle the power of the Turbine and the torque required to lift payloads. This is, again, the same autohub from all of our other models, with dual one way bearings and a solid thick walled hub to transfer the power and torque from the dirve train to the main shaft.

The clutch and clutch bell are also doubled up, doubling the contact surface in this critical part of the drivetrain, to again handle the power and torque required for heavier payloads. Since the Turbine engine spins at a higher RPM, we have adjusted the engagement RPM of the clutch, and use a double length 10 tooth pinion for the proper gear ratio at this RPM.

[cbergen]

The main shaft is 10mm, is fully hardened, hollow, and one of the strongest on the market. Able to handle the power and weight carrying capabilities of the Industrial Birds, and the same shaft that you get with Gassers, Observers, and Tazers.

In the Industrial Birds, it is supported by 3 aluminum bearing blocks, with a total of 4 radial bearings and 1 thrust bearing.

The tail rotor drive transmission assembly is also shown here, with the shaft supported by bearings front and rear, and with gear mesh adjustment ability. The aluminum Torque Tube tail drive shaft plugs into the delrin coupler for easy removal and installation of the complete tail boom assembly.

WIth all these assemblies complete, we can start putting the upper frames together.

[cbergen]

Here is where the two birds wil be slighty different, one will have Futaba gear, the other opted for JR gear.

The Futaba 9255 servos are going into the first one for plenty of power carrying an underslung mount with large camera. A Futaba 611 gyro and 9256 servo will control the tail, while Duralite battery packs regulated ot 5.3 keeps everything powered properly.

The other bird will have JR 8717 servos and the new Spartan DS760 gyro and JR8900 servos for tail control. This will be my first Spartan Gyro setup, it should handle the big tail pretty well. It will also have Duralite packs, but with a 6V regulator and step down for the tail servo.

I've assembled one side of the upper frames to better show the relationship of how it all goes together.

You can see the main shaft bearing blocks, one on each side of the main gear,and the dual bearing block at the top for tremendous support. The bearing block below the main gear has the one radial bearing and the trust bearing.

[cbergen]

Had a busy week, but made some progress on the twin Industrial Turbines.

With the drive train and servos installed, the two upper frame halves are assembled.

The gyro has it's own specified mount, and yes, we even use Zeal Tape on the Turbine heli's. Not necessarily for vibration dampening, but because it is a good reliable way to attach the gyro!!

[HFG]

Don't be a heli tease Cbergen :)

[cbergen]

We also install flame retardant and anti-chafing braiding on the servo wires. We get this from B&B Hobbies (Bob and Becky, terrific people to get to know and work with, visit with them at your favorite funflies!).

We have also added extensions onto the servo wires and shrink wrapped the connections (forgot to get a pic.....) as a safety to prevent the connections from coming apart.

The Spartan gyro looks dwarfed on the front of that heli!!

[cbergen]

Swash, washout, heads installed, linkages are in place.

We can now power it all up and center the servos to start cyclic and collective mechanical setup.

Both birds are getting Duralite Battery systems for power, the one with 8717's is going to have the HC setup at 6 volts with step down to 5.3v for the 8900g tail servo.

[cbergen]

One recent addition,

One of these birds will be carrying an underslung camera mount with a RED Camera. For a camera of this size and weight, a strong camera mount has to be utilized, and the customer already had a mount from Copterworks. The mount itself weighs 6.5 Lbs, with the RED camera coming in at 12 Lbs estimated.

I asked Jody from Helicam Solutions if he could add some landing gear to the mount to turn it into an underslung system capable of having the Industrial Turbine sitting on top of it.

I think he succeeded!! (yes my feet are off the floor!) Since I only weigh 110 Lbs :), it should be able to handle the heli.....

This is a rotating system (no retracts) with a clear view for the camera. I was very impressed with Brent Murrays version of a Copterwork underslung with his own retracts adaptation, the video was incredible!

[HFG]

Saweet, any photos of you beside the complete heli (size reference) ?

[cbergen]

Welllll, They're not complete yet.....:)

They will both be swinging 850mm blades so the rotor span will be over 6 ft!

[lperagallo]

Now you tell me there is flame retardant, anti chafe braiding. Could have used it a couple of weeks ago

Lou

[cbergen]

It's flame retardant in that it won't support combustion. It will melt (it's still plastic) but it will not continue to burn.

Sure stinks when you try it though......

We use it more for the anti chafing purposes, the flame retardant nature is a bonus. It also looks a lot better than the multi-color servo wires.

[cbergen]

These are the cameras going on one of the Industrial Turbines, along with 2 ea 5.8 Ghz downlink systems. They are available from http://wirelessvideocameras.com/ .

[cbergen]

The fuel tanks are 1.5 liters (50 oz) each, and are located on CG, at least for the first Industrial Turbine. They are aluminum, and are available in different colors.

[cbergen]

The second Industrial Turbine is goign to have a slightly different exhaust setup, requiring the fuel tanks to be more to the rear, but still close to CG to keep the CG shift to a minimum as fuel is used up.

[cbergen]

Tail booms and tails are completed as well. My table is running out of room!!