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Author Topic: Geared E power NOT best for CLPA  (Read 723 times)

Offline Rudy Taube

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Geared E power NOT best for CLPA
« on: January 24, 2010, 05:22:18 PM »
This was originally my response to a question on the "indoor" thread. I thought others in the E CLPA group might be interested in the topic of geared systems.

IMHO: The annoying whine of a geared setup is reason enough not to use one. There are other reasons too.    (BYW: my wife says I do not have any HO, I do not know what she means by that?  n~)

I can see why some would consider a geared system. ..... Geared elec. systems are more efficient, they allow larger, slow turning props and fast turning motors (where both items are happy). They are tempting, but they have problems.


In the beginning of ERC (many yrs. ago) we all used geared setups in our RC fomies (1/2A size planes) and powered gliders. We also tried geared setups in our 40 pound IMAC scale aerobatic planes, and all sizes in between. In the 1980s we tried geared wet systems in pattern (I had a beautiful OS Max geared .60, for a short time ;-) and we hooked up two piped .90s on a geared system in IMAC/TOC.  We loved the power that the very large props delivered! .... BUT:

PROBLEMS:

1. Like others have said, annoying whine, NOT quiet. (defeating one of the important advantages of E power)
2. In the small indoor size, the gear system is very fragile. In the std. CLPA size it is still fragile. You would spend more time on maintenance than you would on flying.
3. Our large models needed constant lube for the gears but still had high wear. Belt systems have problems in models, but they are used in full scale electric planes with their strong metal mounts.
4. One more item for "Murphy" 
5. One more added expense
5. Motors got hot, needed cooling collar.
6. NOT reliable enough for CLPA.

When outrunners became available, we all converted and are very happy campers! 

If CL ever has an elec. "MAX LIFT" event, then a geared system would be perfect. 

Here is what is now used in our IMAC planes today:

             http://www.aero-model.com/Hacker-Brushless-A200-8.aspx

This would make one awesome indoor/outdoor CL motor. Let's see, a 130" WS Nobler on 100' lines, COOL! ..... This demo plane might get the spectator crowds attention at a contest! ..... Dennis, do you have the Ph# for the Pontiac Dome? 

Regards,  H^^
Rudy
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Alan Hahn

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Re: Geared E power NOT best for CLPA
« Reply #1 on: January 24, 2010, 05:33:07 PM »
Rudy,
I think I agree with you. The Outrunner motor really seems to offer the needed torque at a reasonable efficiency to fly CL stunt "as is". We are now putting together electric systems that rival the weights of IC systems, + a full fuel tank.

So at this point, we have the flexibility to choose our rpm range and match the power to weight of any IC setup ( something the glow guys don't have).

Now I can't say that at some future point, someone will come up with a new plane with a geared electric system that beats anything. Also a geared motor isn't that much more irritating than a piped glow sound, so the judges can't complain that much!

But at this point of time, there really isn't a need to get to the 90% efficiency level in electric to be competitive with any glow setup. Of course for most of us the hand/eye coordination is never going to be there! HB~>

Offline Dennis Adamisin

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Re: Geared E power NOT best for CLPA
« Reply #2 on: January 24, 2010, 07:24:59 PM »
To summarize, I tried, I flied, and I got my butt kicked!  10 flights to destroy what LOOKED to be a very tough gear box...

Denny Adamisin
Fort Wayne, IN

As I've grown older, I've learned that pleasing everyone is impossible, but pissing everyone off is a piece of cake!

Offline Arch Adamisin

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Re: Geared E power NOT best for CLPA
« Reply #3 on: January 25, 2010, 08:44:20 AM »
Personally, I thought the geared unit that Denny used was superior to the outrunners . It ran quietly, it ran cool and it ran perfectly, right up until it failed. We'd used them in RC many times without incident. But then, we were not using a Governor so we were only using one side of the gear teeth. I feel that the governor required us to use both sides of the gear teeth and as such work hardened them and caused the failure. I, personally haven't given up on the idea but with the success we've had using the outrunners, it's not on the top of the priority list right now. Maybe later this fall I'll have time to revisit this idea.

     Arch

Offline Dean Pappas

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Re: Geared E power NOT best for CLPA
« Reply #4 on: January 25, 2010, 11:11:39 AM »
You're baiting me ... right, Rudy?
Sure enough, the gearboxes we have readily available are reliability nightmares for Stunt. The biggest reason is the short distance between the output bearings, which allows wiggling and eventual (okay, rapid!) destruction of the gears. The Pattern guys are solving this as we speak, and the latest generation of gearboxes from both Hacker and Neu are way better than they used to be, as well as somewhat heavier!  HB~>

Soft mounts that do not allow any prop shaft wiggle at all, but that are quite soft in rotation, do wonders for both gear wear-life and noise! Even the outrunner guys are finding this out, but wobble is tough to eliminate in those setups, and the consequences usually involve the motor and prop exiting the airplane!

In return, both braking and efficiency will be substantially better. Weight will be a wash, at best. Very big prop diameters are probably not a good idea for us, so we may just end up using gearboxes to add blades and improve brakes.

Belts are no good above maybe 20K RPM, and the benefit will come from using motors with Kv's of maybe 3000, at 40K or 50K RPM, so we are stuck for now.

How about a separate prop-shaft mount and a soft coupler to a hard mounted motor/gearbox?

later, Dean P.
Dean Pappas

Offline Rudy Taube

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Re: Geared E power NOT best for CLPA
« Reply #5 on: January 25, 2010, 11:02:40 PM »
Hi Dean,

"..... You're baiting me ... right, Rudy? ....."

Yes! (insert picture of me with Rod and Reel here)  LL~

I know that you engineers just can't resist "geared systems". They are a great way to help too dissimilar things get along better. Without the 28 speeds on my bike I would have to move to Kansas, without the beautiful auto transmissions in our cars we would be even more dependent on the crazy middle east, etc.

But, gears are not always the answer.

I started flying when I was 16. All my life I have had a great deal of confidence in the planes power system, both piston and jet. There was ONE exception, the Cessna 421 twin I flew during college. Their GEARED engines were notorious for having problems. I never trusted that plane and it was one of the very few planes I did not enjoy flying. Like I said in my post, the power is great but it comes at too high of a price (reliability) for me.

I do understand, and admire the wonderful attitude you engineers have that drives you in your pursuit of perfection. If our little corner of the hobby had a mission that required more power than our present rules allowed, then I could see (maybe?) giving up some reliability, adding noise, working harder, etc. just to get a little more power out of a legal system.

The rules on our power systems in CLPA are such that the mission in CLPA is met with power systems that are well below the max. size/power allowed. Unless the mission changes (longer than 67' lines allowed, different power hungry maneuvers, much larger planes, etc.) then I see no reason to trade reliability for some gain in a smaller than legal motor. It is just too easy for us to add more "reliable" Volts. We seem to be at a more than satisfactory place using only 1/2 of our allotted Volts under the rules (18.5V). Even the Wet guys are still way below their rule size limits, and they still have a VERY POWERFULL YS supercharged .91 on a pipe in reserve if needed! ;-)

I can see why geared systems are attractive in RC pattern. The weight limit on a relatively large 2M plane does not leave much room for a very large power system, it needs all the power per oz. it can get. Plus the power mission is much more challenging in RC pattern, with power draining maneuvers on a looong vertical up line.

For years we tried the geared systems in IMAC. Now, with the availability of LARGE non-geared outrunners and LOTS of volts, we never looked at gearing again and the manufactures have stopped making them.

But ..... Please keep the candles burning late into the night in your reseach lab at the Bob&Dean "Skunk Works". We all benefit from your hard work and talented brain cells!  y1

PS: I like your last idea. The full size aircraft using electric power are using belt drives but they don't seem to scale down to our size very well?

Warm Regards,  H^^
Rudy
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Alan Hahn

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Re: Geared E power NOT best for CLPA
« Reply #6 on: January 26, 2010, 08:02:01 AM »
Like I said in my original comment and as Rudy says too---we don't seem to need the extra complexity.

I don't know of anyone who needs the potential extra braking power that a geared system is offering. This would show up as a surge in rpm in the down lines (and zero amp draw for the motor), and at least for my setups I don't see it. It is possible that with a big and heavy plane, and a 3 or 4 blade prop that you might see this, but again no one has mention that they are seeing this  (is anyone??) in PA.

Maybe that really is an issue for RC Pattern. If it is I wonder why they haven't contacted guys at CC to see if they can get some regenerative braking (basically shorting out the motor leads and letting the motor act as a generator. I note that I don't think we have that on our ESC's now (could be wrong).


Offline Dean Pappas

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Re: Geared E power NOT best for CLPA
« Reply #7 on: January 26, 2010, 09:58:03 PM »
Hi Guys,
We do have the brake with the CC and many other brand ESCs, that's how we stop the prop for landing.
We use the regenerative braking in Pattern, and the restarts are sometimes problematic.
It sure helps: as a matter of fact, it is vital in some places in the F3A schedule.
I don't see CC modifying the governor mode to use it, though. The loop stability problems are ugly!
Cogged belts don't like more than about 20 K RPM. The NEU ORK series with Kvs in the 1000 to 1400 range would belt nicely, and the rubber band will help attenuate the cogging/commutation vibration that makes prop and airframe noise. Someday ...

Dean
Dean Pappas

Offline Dennis Adamisin

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Re: Geared E power NOT best for CLPA
« Reply #8 on: January 27, 2010, 07:35:41 AM »
(clipped)
The NEU ORK series with Kvs in the 1000 to 1400 range would belt nicely, and the rubber band will help attenuate the cogging/commutation vibration that makes prop and airframe noise. Someday ...

Dean


Dean
Can you elaborate on that some?  I was thinking that the Hybrids inrunner-outrunner (like the ORKs) would be the Next Big Thing after outrunners - are the hybrids  prone to being noisy?  Is it as simple as soft mounting?  The much smaller/lighter props we use in CLPA would also have a much different harmonic signature - maybe no worries alt all?

Denny Adamisin
Fort Wayne, IN

As I've grown older, I've learned that pleasing everyone is impossible, but pissing everyone off is a piece of cake!


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