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Author Topic: 4" Bellcranks.  (Read 15795 times)

Offline John Desrosiers

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Re: 4" Bellcranks.
« Reply #50 on: December 07, 2010, 04:41:58 PM »
OOOOOhhhhhh boy here we go again.

Offline RandySmith

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Re: 4" Bellcranks.
« Reply #51 on: December 07, 2010, 06:21:00 PM »
Why wouldn't it work to just bend the pushrod to go vertically up to the horn height and then horizontal to the horn?  Brace the 90 degree bends to avoid flex.  Or do I not understand the problem?   

                        ___________________________
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2 words ...  heavier and  flex  ....  both are not really what ya want

Randy

Offline proparc

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Re: 4" Bellcranks.
« Reply #52 on: December 09, 2010, 04:44:51 PM »
Kim-

 (It 'only' takes 38o to get 30o flap deflection with those dimensions.).

SK

Serge, is this an Excel spreadsheet and if so, can you send it to me with working explanations?
Milton "Proparc" Graham

Offline Serge_Krauss

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Re: 4" Bellcranks.
« Reply #53 on: December 10, 2010, 10:07:42 AM »
Serge, is this an Excel spreadsheet and if so, can you send it to me with working explanations?

Yes, it's a spreadsheet by a correspondent of a friend. I'm not sure whether I'm free to give it away. I'll try to check with my source. Meanwhile why not take this off forum via an e-mail, and I'll see what I can do.

SK 

Offline Howard Rush

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Re: 4" Bellcranks.
« Reply #54 on: December 10, 2010, 04:05:42 PM »
I decided to make my own spreadsheet, having come up with a method not requiring me to be smart.  I started a new post in Sparky's "Engineering" category
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Offline Dennis Moritz

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Re: 4" Bellcranks.
« Reply #55 on: December 10, 2010, 04:21:35 PM »
Can a push/pull arrangement solve the geometric inconsistencies of a pushrod system?

Offline John Miller

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Re: 4" Bellcranks.
« Reply #56 on: December 10, 2010, 04:36:12 PM »
Can a push/pull arrangement solve the geometric inconsistencies of a pushrod system?

Only if the flaps horns are circular, then the push pull cables will automatically align with the tangent points, which is what corrects the geometry. H^^
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Offline Dennis Moritz

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Re: 4" Bellcranks.
« Reply #57 on: December 10, 2010, 06:28:35 PM »
Would this be more or less Rube Golberg than the other suggestions?

Offline Dennis Moritz

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Re: 4" Bellcranks.
« Reply #58 on: December 10, 2010, 06:40:53 PM »
Wait a minute. We didn't consider how the change of incidence in the control surfaces may differ in effect as it is moved through the angle shifts in control. For instance will 17 degrees of flap incidence exert half the lift augmentation of 34 degrees incidence. But I guess the aim is to deflect the flap/elevator up/down in equal proportion to handle movement in order to equalize feel at the handle as it relates to the airplane's turn inside and out. Is there an algorithm programed into fly by wire systems that make a non one to one relationship between stick moves and control deflection? What about grand prix cars. How have the racers worked out the ratio of steering wheel to the front wheels. Is it a constant ratio or does it change in relationship to the angle of input. Slop in the elevator. Haven't some folks advocated a dead zone near neutral.

Offline John Miller

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Re: 4" Bellcranks.
« Reply #59 on: December 11, 2010, 05:18:07 PM »
Wait a minute. We didn't consider how the change of incidence in the control surfaces may differ in effect as it is moved through the angle shifts in control. For instance will 17 degrees of flap incidence exert half the lift augmentation of 34 degrees incidence. But I guess the aim is to deflect the flap/elevator up/down in equal proportion to handle movement in order to equalize feel at the handle as it relates to the airplane's turn inside and out. Is there an algorithm programed into fly by wire systems that make a non one to one relationship between stick moves and control deflection? What about grand prix cars. How have the racers worked out the ratio of steering wheel to the front wheels. Is it a constant ratio or does it change in relationship to the angle of input. Slop in the elevator. Haven't some folks advocated a dead zone near neutral.

I spent an hour typing out a great reply Dennis, but it disappeared into the great maw of the internet.

I'll try to remember what I said, and re type it.

Dennis, I don't believe we've met in person, so though I'm inclined to consider your post as legitimate, a small part of me feels like you may be jabbing a few of us with a stick though. For the sake of this discussion, I'll try to answer your questions as I understand the answer to be. H^^

"Wait a minute. We didn't consider how the change of incidence in the control surfaces may differ in effect as it is moved through the angle shifts in control. For instance will 17 degrees of flap incidence exert half the lift augmentation of 34 degrees incidence. But I guess the aim is to deflect the flap/elevator up/down in equal proportion to handle movement in order to equalize feel at the handle as it relates to the airplane's turn inside and out."

What follows is a lot of verbage to say yes, that is the aim.


I'm going to assume that you mean angular rotation, rather than incidence in your question. It's easy to get the two mixed up, but they really are two different things.


Though the change of rotation with the control surfaces, and it's affect on the planes turn quality is important,  it's not really the total issue we are trying to correct with our "Corrected Geometry'.What is more important, is the ratios between the bellcrank,flaps, and elevators. These ratios work best when they remain as nearly constant as we can get them throughout the rotation. a moving variable within the constraints of one of these points in our control system will cause asymmetry with in the system. Eliminating such variables will result in an easier, and more repeatable turn regardless of the amount of input needed.

Over the years, after being involved in literally hundreds of drawings, or redraws, of OT, Classic, and Modern stunt designs, I've seen tremendous differences in asymmetry, if you please, in control systems. One of the worse, involved a well known Classic Stunt design, a Nat's winner for the designer pilot, but not always so well behaved for the average pilot/builder in todays time. After checking the controls, I found that if built as shown on the plans, the controls had asymmetry problems, as well as ratio problems, with a difference of about 7 degrees between up and down, as well as 3-4 degrees difference between the flap and elevator, up and down.

In the classic era, we simply learned how to fly them this way, but today we'd find it difficult to switch to different planes, like flying Classic, and PAMPA classes on the same day at a meet.


"Is there an algorithm programed into fly by wire systems that make a non one to one relationship between stick moves and control deflection? What about grand prix cars. How have the racers worked out the ratio of steering wheel to the front wheels. Is it a constant ratio or does it change in relationship to the angle of input."

The simple answer is yes. The problem, and the solution, is related to your question about Grand Prix cars and the steering arrangements. I'm sure you and others are aware of the fact that when turning, the inside wheel of a 4 wheel vehicle must turn and trace a smaller diameter, than the outside wheel. It also has to do this regardless of the radii of the circle, or whether or not the radii remains constant through out the turn.

The same thing happens in our bellcrank to flap link, and like the solution for a turning car, we attach our push rod at the 90 degree point, relative to the pushrod.This is "Corrected Geometry" in it's simplest form. As shown by Lou, and others, there are other items we can factor in to reduce additional small errors, but, the 90 degree attachment of the bellcrank to flap horn pushrod is the major contributor to getting rid of asymmetry in the control system. The smaller errors are basically lost in the noise of most systems.

Further more, with modern control systems that use a elevator mounted above the flap chord line, leads to simpler layouts for the flap/elevator link.

It's possible to layout this link to dispose of nearly all errors produced, but I believe it's more of an exercise for those of us who enjoy figuring this type of solution. Larry Cunningham published an article in Stunt News some years ago, describing "Magic Geometry" He discovered an angular relationship between the flap elevator pushrod, at neutral, and the extremes. When this relationship fell with in certain variables, the ratio between the flaps and elevator would even out, "magically", corrected.

Since the greatest amount of asymmetry comes from the bellcrank/flap link, I've come to believe that once that is corrected, there's little to be gained, realistically, by finding the solution to possible flap/elevator asymmetries. Modern designs, when checked, usually fall with in a 1 to 1.5 degree error, and is usually within the noise. The solution in my case, often has the elevator pushrod attaching to the flap horn 90 degrees relative to the wing chord, and the same 90 degrees relative to the stab chord at the other end.

Modern practise advocates the use of Ball Links through out the control system. This gives us a very tight, not sloppy, and accurate control system. It will react linearly, and instantly to control inputs. It's now much more important to use the right incidences, and get alignments correct to make a plane into a 'point and shoot" competition machine.

So, your last question takes on new meaning when it comes to modern stunt designs and thinking.

"Slop in the elevator. Haven't some folks advocated a dead zone near neutral."

My own personal experiences, from back in the day, through even today, is that some people suggest slop in the elevator as a solution for hunting in level flight, upright, and inverted. Back in the day we noticed that our planes seemed to fly better as they aged. Maybe we also were getting used to them, but our older planes did not seem to hunt as much as brand new fresh ones.

When one of these older planes went in, we usually found, post mortem, that the hole for the elevator end of the pushrod, had worn and had slop. when we purposely made the holes sloppy, those modified planes also hunted less. Not wondering why, we were only kids anyway, we simply knew that it worked.

Fast forward to today. Modern stunter design has progressed, along with our collective education. We've learned why things happen, and how to design in the corrections needed to help prevent problems in the first place. Because of this, many of us relegate building slop into the elevator to sport planes, or perhaps to planes that we wouldn't consider placing high in competition with. It works, but it also adds just a slight sluggishness around neutral, a hesitation at intersections, that can present a lack of crispness, or authority, a pilot needs to compete at the higher levels.

Now, the design solutions have been discussed on these various forums for years. I will mention them, basically in order of importance as I perceive it to be.

First three elements to consider are design, power, and practise. Design and power could be interchangeable.

Power must be appropriate for the job. If you're serious, you need to save up and get a serious power plant. If you're fighting the engine, or motor, you cannot make the best of your practise.

Speaking of practise, if you're serious, use a coach, if at all possible . I know many who have practised their mistakes and now perform them perfectly.

I saved design for last, even though it should be either first, or second.

If you're serious, the design you select to fly should have the capability to perform with the best out there. It should have the right "numbers". further more, If you use modern, tight, not sloppy controls, then you need to use the proper geometry with in that control system. When you do so, other aspects of the planes design will come into play. How do you keep the plane from hunting? You should search out the threads and discussions on using downthrust, out thrust, positive incidence in the stab. flap elevator ratios become important and vary with weight and flight speed.

Learn to build light, straight, and only strong enough. Over building only adds weight.

There's more, but your a smart person, you'll find it. Last but not least, don't be afraid to ask questions. Listen carefully to the answers you get. Some may not apply to your goals.  H^^
Getting a line on life. AMA 1601

Offline Dennis Moritz

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Re: 4" Bellcranks.
« Reply #60 on: December 11, 2010, 06:39:21 PM »
Very clear. Thank you. Yeah. I jab a little, but I'm also sincere and got into this geometry issue, since it's about getting planes to turn inside/outside with a similar feel and response. A critical performance parameter. My flying skill has gotten to a place where I can tell how critical this is. Took a while. I found your explanation very informative. My math skills ceiling(ed) at 6th grade. Spread sheets are cuneiform to me. (Cuneiform: earliest known form of writing, Sumerian, incised on clay tablets. Lots of numbers to keep track of sales.)   :o

Offline Howard Rush

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Re: 4" Bellcranks.
« Reply #61 on: December 11, 2010, 09:36:15 PM »
Dennis jabs professionally.  It is to his credit that not much jabbing spills over into these discussions. 
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Offline Bill Little

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Re: 4" Bellcranks.
« Reply #62 on: December 11, 2010, 11:24:28 PM »
Quote
The simple answer is yes. The problem, and the solution, is related to your question about Grand Prix cars and the steering arrangements. I'm sure you and others are aware of the fact that when turning, the inside wheel of a 4 wheel vehicle must turn and trace a smaller diameter, than the outside wheel. It also has to do this regardless of the radii of the circle, or whether or not the radii remains constant through out the turn.

There is something that might add a mess to whatever y'all are talking about.  When a four wheeled vehicle with two wheels steerable, front wheels we'll say, and vehicle is traveling "under control"  (not in a skid), the tire paths will always have the front wheel describing a path that is "inside" the rear wheel.  When the car begins a slide, skid, or "drift", the rear wheel's path will be "inside" the front wheel's path on the side to which it is turning.  This visible when the tires leave marks on the pavement. 

Will this in any way translate to the control system geometry being discussed? ???

Big Bear
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Offline Serge_Krauss

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Re: 4" Bellcranks.
« Reply #63 on: December 12, 2010, 08:42:05 AM »
There is something that might add a mess to whatever y'all are talking about.  When a four wheeled vehicle with two wheels steerable, front wheels we'll say, and vehicle is traveling "under control"  (not in a skid), the tire paths will always have the front wheel describing a path that is "inside" the rear wheel.  When the car begins a slide, skid, or "drift", the rear wheel's path will be "inside" the front wheel's path on the side to which it is turning.  This visible when the tires leave marks on the pavement. 

Will this in any way translate to the control system geometry being discussed? ???

I'd have to disagree a bit. For hard cornering, a front drive car will behave as you describe, but in a drift or slide initiated with throttle on a rear wheel drive car, the car will usually oversteer, with the rear tires following a larger radius (rear tracks outside front tracks). Some understeering pigs have been built, and of course manufacturers have tried their best to produce understeering cars for public use, in the belief that less-skilled drivers will be more likely to maintain control.

But as you hint, this is not related to bellcrank size, but rather to c.g. placement and flap size/deflection. Flapless planes "oversteer", while excessive flaps cause "understeer" (fuselage pointed out of turn). The 4" bellcrank question has been answered a couple times already: it reduces line tension necessary to overcome hinge moments, may reduce asymmetry in control surface motion, and can be used to create less sensitive controls. Howard is currently addressing the first consequence in his computations on the engineering board.

SK

Offline Bill Little

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Re: 4" Bellcranks.
« Reply #64 on: December 12, 2010, 09:45:36 AM »
Hi Serge,

If I was using a diagram, I would have been more clear.  Example: The path of the front tires will be to the left (inside) of the rear on a left hand drift.  Does that make more sense?

Yep, I have seen the stop action pictures of a model "skidding" through a square corner.  The control input has to be done at a height several feet about where the pull out is anticipated.
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Offline sleepy gomez

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Re: 4" Bellcranks.
« Reply #65 on: December 12, 2010, 10:43:21 AM »
Don't forget about the squeegee effect where a wheel may be steered into a turn at a given degree but the surface of the tire is still rolling pointing at a lesser degree due to tire flex.  It would seem that since model aircraft operate with much less traction in their environment than a tire on pavement that the squeegee effect would be more prominent. 

Offline Bill Little

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Re: 4" Bellcranks.
« Reply #66 on: December 12, 2010, 11:59:05 AM »
Don't forget about the squeegee effect where a wheel may be steered into a turn at a given degree but the surface of the tire is still rolling pointing at a lesser degree due to tire flex.  It would seem that since model aircraft operate with much less traction in their environment than a tire on pavement that the squeegee effect would be more prominent. 

Especially if the tires are radial construction versus bias ply.
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Offline John Miller

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Re: 4" Bellcranks.
« Reply #67 on: December 12, 2010, 12:17:45 PM »
Kingfish, I do believe der's a whole lotta jabin' goin' on. #^
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Offline Serge_Krauss

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Re: 4" Bellcranks.
« Reply #68 on: December 13, 2010, 06:05:56 AM »
If I was using a diagram, I would have been more clear.  Example: The path of the front tires will be to the left (inside) of the rear on a left hand drift.  Does that make more sense?

Bill-

Yes , I agree.

SK

Offline Russell Shaffer

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Re: 4" Bellcranks.
« Reply #69 on: December 13, 2010, 05:08:50 PM »
Circular flap horn, no bellcrank, no problem?  Has anyone tried this on a flapped model?  I know there have been control lines run directly to elevator horns in the past, but this seems pretty smooth on this extremely crude mock-up. I'm thinking it might be necessary to use very close handle spacing which could lead to worse problems. I'm a mechanic, not an engineer, as you can see.
Russell Shaffer
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Just North of the California border

Offline Bill Little

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Re: 4" Bellcranks.
« Reply #70 on: December 13, 2010, 05:12:10 PM »
I do have a pertinent question pertaining to 4" BCs.  I have a circular one made by Golden State Models.  it is what Ted was using in the Imitation and Excitation (possibly others?) .

What effect does the circular BC have in relation to linkage geometry, loads, etc??

Bill
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Offline John Miller

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Re: 4" Bellcranks.
« Reply #71 on: December 13, 2010, 05:50:59 PM »

What effect does the circular BC have in relation to linkage geometry, loads, etc??

Bill

It only affects the geometry specific to the Bellcrank itself. It maintains the 4" moment arm, at all angles of rotation. It also solves the problem Howard was solving for with his off angled arms. with the one in his illustration.

These are small possible error points, that I tend to consider to be in the noise. The greatest error comes from the flap pushrod being mounted at 90 degrees to the wing chord. Solve that big error, and most of the small ones really do fall into the "noise".

Using a round flap horn will correct the error, but I'm not sure about illiminating the bellcrank. I know it's been done in times past, but there's a reason it didn't really catch on.

It's possible that the entire flight load ends up at the flap horn, and the two pulley wheels where the wires make the turn. Stress applied at those wheels could overly stress the leadout wire. Another possible problem seems to be maintaining the loeadouts in the pulley wheel.
 H^^
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Offline Russell Shaffer

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Re: 4" Bellcranks.
« Reply #72 on: December 13, 2010, 07:26:25 PM »
A guard will keep the cables on the pulleys (the horn needs one also).  Yes, the pulleys and the horn will take the full flight loads, I don't have the skills to determine how the loads would be divided, but it won't be on a single bellcrank pivot.  Someone here can surely determine the force vectors, but I would just mount the whole contraption on a plywood plate and secure it to the wing center section. I have a biplane with exposed controls, I should build an experimental installation.  If it doesn't work out I can put it back to a standard system, assuming that it survives the test flight. Unless it has been tried and proven to be a poor idea, of course. 
Russell Shaffer
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Offline John Miller

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Re: 4" Bellcranks.
« Reply #73 on: December 13, 2010, 07:55:31 PM »
Go for it Russell, If nothing else, the project may answer a few questions. Let us know how it all works out for you.
Getting a line on life. AMA 1601

Offline Russell Shaffer

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Re: 4" Bellcranks.
« Reply #74 on: December 13, 2010, 08:10:41 PM »
If I do it, I'll take before and after pictures.  The biplane doesn't have flaps so it would just be a circular bell crank rotated 90 degrees.  Now that I think a little more about it, there would be no reason to do the pulleys on a non flapped airplane.  Just added complexity.  With flaps, it does away with the bell crank and the flap pushrod by adding 2 pulleys - about a break even.  The only possible advantage would be to eliminate the pushrod angularity but I don't think I'm a good enough flyer to tell the difference.  Those who have seen me fly will agree. 
Russell Shaffer
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Offline Howard Rush

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Re: 4" Bellcranks.
« Reply #75 on: December 13, 2010, 10:05:07 PM »
You could have a separate wheel on the bellcrank for driving the control surfaces.  Then the whole load wouldn't be on them. This sounds like a cool project.  Keep us informed.
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Offline Russell Shaffer

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Re: 4" Bellcranks.
« Reply #76 on: December 13, 2010, 10:34:31 PM »
Please correct if I'm wrong on this thought - the longer the bell crank to flap pushrod, the less the angular effect?  It really isn't much of a factor on a non-flapped airplane.  A circular bell crank on a non-flapped plane would dispose of most of the angular difference if I see the problem correctly.  If the reasoning is right so far, then on a flapped plane, run a pushrod from a circular crank to the elevator and drive the flaps from the elevator horn.  An extra few inches of flap pushrod would have a negligible weight penalty and no extra parts. Am I crazy?  Don't ask Dan.
Russell Shaffer
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Offline Bill Little

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Re: 4" Bellcranks.
« Reply #77 on: December 14, 2010, 08:31:52 AM »
OK,  The circular bell crank maintains its (4") leverage through out its range of motion.

I have seen many "triangular shaped" horns on the flap connector wire.  The pushrod from the BC connecting to the front edge of the horn, the elevator push rod connecting to the rear edge of same horn.  This allows some correction for the push rod angularity in the vertical axis.  The Tom Morris arms are "kinked" to afford much of the same corrections.   The vertical arm from the elevator connector is also "tilted forward" in the vertical axis for the same reason. 

So, what actual differences would be "felt" by substituting a circular BC in place of a "standard" BC while applying either method of angular correction to the vertical control horns?
Big Bear <><

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Offline John Miller

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Re: 4" Bellcranks.
« Reply #78 on: December 14, 2010, 09:27:20 AM »
A good question Bear. Personally my opinion would be little to no difference that could be felt at the handle. I suppose that Ted is the one to answer this question since he flew several ships set up with the circular bellcrank.

You will notice the difference with the bellcranl to flap horn link corrected. It's subtle, and the plane seems to fly and track easier.  H^^
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Offline Bill Little

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Re: 4" Bellcranks.
« Reply #79 on: December 14, 2010, 09:47:33 AM »
Thanks, John.  The curing of the angles between the pushrods and horns has become a no brainer, even if I cannot do the exact math! LL~  the old "TLAR" is not bad in that case. 

With any means of trying to correct that problem, the effects are noticeable.  I simply try to shoot for a 90* angle, at neutral, between the horn and pushrod.  Using ball joints at the BC and a stand off is a step in the right direction, I think.  I also try to line up the pushrod, at neutral, to be inline with the each connecting end when viewed from the top.  This means offsetting the BC mounting pivot slightly inboard or outboard.  Make sense?
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Offline Howard Rush

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Re: 4" Bellcranks.
« Reply #80 on: December 14, 2010, 02:57:01 PM »
How about some graphs, guys?
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Offline Chris Wilson

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Re: 4" Bellcranks.
« Reply #81 on: December 14, 2010, 03:29:30 PM »
Circular flap horn, no bellcrank, no problem?  

I can see problems arising with this system.

Losing line tension, guard or no guard could result in the line either coming out of its travel or simply binding up. The whole internal section of the lines should be kept under pre-load to avoid this happening and how do you design that in?

The lack of adjustability, now has does one change the rates of this system when its in place? Perhaps stepped pulleys like that used on lathes?

And the difficulty of manufacture -
1. Two small guide wheels and their attendant ball races, posts, guides and fixing points,
2. Larger wheel, again probably with ball races, axial loads and so on.

Its going to cost 10 fold what a normal bell-crank/ flap horn setup would be and exclude 99% of home builders to boot.
Maintenance must be considered also as it has moving and flexing parts.

And the all up weight and smoothness of travel (would this system allow the controls to fall under its own weight)?
MAAA AUS 73427

You have enemies? Good. That means you've stood up for something, sometime in your life.
 Nothing in life is so exhilarating as to be shot at without result.  It's not enough that we do our best; sometimes we have to do what's required

Offline Russell Shaffer

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Re: 4" Bellcranks.
« Reply #82 on: December 14, 2010, 04:48:12 PM »
"I can see problems arising with this system.

Losing line tension, guard or no guard could result in the line either coming out of its travel or simply binding up. The whole internal section of the lines should be kept under pre-load to avoid this happening and how do you design that in?"

I think the line could be kept in place if the assorted pulleys were shielded well.

"The lack of adjustability, now has does one change the rates of this system when its in place? Perhaps stepped pulleys like that used on lathes?"

I don't see any good way to change rates other than at the handle. A stepped pulley would work but it would get really heavy. 


"And the difficulty of manufacture -
1. Two small guide wheels and their attendant ball races, posts, guides and fixing points,
2. Larger wheel, again probably with ball races, axial loads and so on."

The small pulleys can be bought in one form or another, these ones are door hardware.  The large one is certainly more difficult.  I think you would have to fabricate it.

"Its going to cost 10 fold what a normal bell-crank/ flap horn setup would be and exclude 99% of home builders to boot."

I bet it would cost 20 times more than a standard setup with a 4 inch nylon bellcrank unless you did all the work yourself. The 10 fold cost estimate is probably very conservative.


"Maintenance must be considered also as it has moving and flexing parts.

And the all up weight and smoothness of travel (would this system allow the controls to fall under its own weight)?"

I don't think maintenance would be a problem, but weight sure would be.  The large horn pulley would be the main offender. 

This is starting to look like a bright idea that isn't so bright after all.  How many years have we been doing just fine with a simple bellcrank and horn system after all?  I think I should go out to my shop and do some more work on my new build, the one with the standard control setup. 
Russell Shaffer
Klamath Falls, Oregon
Just North of the California border

Offline Bill Little

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Re: 4" Bellcranks.
« Reply #83 on: December 14, 2010, 06:17:51 PM »
How about some graphs, guys?

X_______l________Y
               l
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Offline Bill Little

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Re: 4" Bellcranks.
« Reply #84 on: December 14, 2010, 06:19:02 PM »
Sorry, best I can do..........
Big Bear <><

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Offline L0U CRANE

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Re: 4" Bellcranks.
« Reply #85 on: December 15, 2010, 11:22:39 AM »
Chris to your post #81, and Russell to your #82... (I think those were the numbers...)

Circular bellcranks have been used in CL racing models at least since the 60's and 70's. They allow the leadouts to run in a very small holes or slots in the thin wings - no need for clearance fore and aft as the bellcrank "arms" rotate... These bellcranks are very flat pulleys - a  smaller diameter disk sandwiched between two slightly larger disks of, say, 1/16" aluminum. To keep the leadouts in the bellcrank's groove diameter, the lines were bound on with fine wire, in several places beyond the needed rotation angles. The leadout also went through a bend like the neutral adjust on a HotRock handle, to keep it from slipping away from the set 'neutral.'

Pushrod hole was in the cheeks of the bellcrank, so it acted exactly like current bellcranks... Not like another pulley system...

So, much of this HAS been done, for special uses, at least. Ted Fancher did try a circular bellcrank a while back. Wish I remembered more of what he said about it.

Russell -

Actually, you could lay your larger pulley down "flat", and do away with the 90° turn-around pulleys... So, upright or flat, your 'simple breadboard' of a system may need only one addition: Mount a second pulley on the leadouts-pulley to operate only the control surface 'cable runs.' The flying lines can be secured as in racing models, and won't slip or fall off.
 
Cables can stretch a bit. They'll need some tension pre-load to absorb that. It will affect only the control-surface-system pulley set-up. Even adjustability might be possible: Say the cabling wraps twice around each driving or finally-driven pulley, AND has some form of lock to secure your neutral... Easing the pre-load tension and the position-lock on whichever surface needs adjustment could let you 'slip' that pulley and control surface as needed...

That might take a bit more access to the interior of the model than the small "inspection panel covers" some of us use to adjust ball-link position on a control surface's horn...

As far as response profile -it will be linear, according to the ratios of the driving and driven pulleys. If the interior pulleys' bearings run free under the cable pre-load, there's no reason that control surfaces wouldn't drop from their weight alone. The hinges between wing&flaps and stab&elev may still be a limit on that.

\BEST\LOU

Offline L0U CRANE

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Re: 4" Bellcranks.
« Reply #86 on: December 15, 2010, 11:39:20 AM »
Going all the way back to replies #65, #66 and #67...

Sleepy, I learned what you called the squeegee effect is actually called the 'slip angle' between the tire and its path on the road. Bias-ply tires - anyone else old enough to remember them? - flexed to much greater 'slip angles' than steel belted radials. Any "loss" in cornering may be due to the lower slip angles radials tolerate. The rubber compounds and other factors make that question less important these days...

And, I think, we went through that whole section of this topic with little or no use of the terms oversteer and understeer.

Classic definition: When an understeering car 'loses it' and goes off the road, it goes front-end first; an oversteering car goes off rear-end first.

The original GM Corvair did not oversteer IF THE TIRE PRESSURES WERE CORRECT. But nobody wanted to run 12-14 psi fronts and 26-28 psi rears... The original VW Beetles oversteered lots, and there wasn't tire pressure guidance to correct it. Buyers just understood that they oversteered, and learned to love it...
\BEST\LOU

Offline Howard Rush

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Re: 4" Bellcranks.
« Reply #87 on: December 15, 2010, 01:12:20 PM »
I think I've decided that you don't need a circular bellcrank for stunt.  If you have one, though, you'd probably want to have round control horns ("quadrants"), too, as Russell plans.  I plotted up the geometry I had CADed for my new plane using pretty much the method John described.  John's method works nicely.  I only had to clock the bellcrank output arm around a tad to even up the control response between up and down.  From the picture, you can see that the relationship between leadout movement and flap movement is pretty linear, whereas the bellcrank movement is right curvy.  A round bellcrank would have cost you mechanical advantage at the control extremes, where you need it most.  I can imagine some inaccurate corners.  

It's not clear on the drawing because the caption moved, but the X axis is the length of forward leadout between the wingtip and the bellcrank.
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Offline Russell Shaffer

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Re: 4" Bellcranks.
« Reply #88 on: December 15, 2010, 01:17:49 PM »
Leverage is a good point - the farther the deflection the more effort required?  At the same speed anyhow.  A standard bell crank is also far simpler.  Just buy the parts and install them carefully. 
Russell Shaffer
Klamath Falls, Oregon
Just North of the California border

Offline Chris Wilson

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Re: 4" Bellcranks.
« Reply #89 on: December 15, 2010, 05:18:09 PM »
If the interior pulleys' bearings run free under the cable pre-load, there's no reason that control surfaces wouldn't drop from their weight alone.
I would have to disagree mate, the reason that a tensioned cable system is not likely to drop under its own weight is due to the force needed to flex the cable every time it rounds a pulley as compared to simply hinging around a point in a normal system. Any cable will have resistance to deformation.

Its much like comparing a belt drive to a roller chain drive, except here there is only one roller's friction to over come.

And honestly, beyond a nice theoretical exercise I can't see the point since the human wrist that provides the input motion in not linear anyway and the further your wrist moves away from its natural center the harder it becomes angle it further ( just ask anyone who does JuJitsu to confirm this one for you) but perhaps a circular system inserted at some point could limit angular error instead of compounding it further.

Cheers mate.
MAAA AUS 73427

You have enemies? Good. That means you've stood up for something, sometime in your life.
 Nothing in life is so exhilarating as to be shot at without result.  It's not enough that we do our best; sometimes we have to do what's required

Offline Russell Shaffer

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Re: 4" Bellcranks.
« Reply #90 on: December 15, 2010, 05:35:09 PM »
I'm going to go with Howard's theory of loosing mechanical advantage at the ends of the control travel, just when it is most needed.  No circular cranks for me in the near future, at least.  I made another low inverted pull out this afternoon so it would seem that bell crank choices are the least of my problems. 
Russell Shaffer
Klamath Falls, Oregon
Just North of the California border

Offline Mark Scarborough

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Re: 4" Bellcranks.
« Reply #91 on: December 16, 2010, 12:04:24 AM »
Russell,,
them thar' low pullouts do tend to change priorities dont they! ~^
The other factor to consider in this whole exchange,, none of the minutia is relevent if you dont build a straight airplane, with a free, smooth control system.
accurcy in construction as well as ease of achieving that accurecy can sometimes be more relevant than ultimate perfect geometry,,
For years the rat race had me going around in circles, Now I do it for fun!
EXILED IN PULLMAN WA
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Offline Russell Shaffer

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Re: 4" Bellcranks.
« Reply #92 on: December 16, 2010, 08:59:52 AM »
All good points, Mark.  All I did was break a prop so I was fortunate this time.  High tec control systems won't compensate for pilot error when I try to fly in the lower half of the sphere.
Russell Shaffer
Klamath Falls, Oregon
Just North of the California border

Offline Chris Wilson

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Re: 4" Bellcranks.
« Reply #93 on: December 16, 2010, 07:24:18 PM »
I'm going to go with Howard's theory of loosing mechanical advantage at the ends of the control travel, just when it is most needed.  No circular cranks for me in the near future, at least.  I made another low inverted pull out this afternoon so it would seem that bell crank choices are the least of my problems. 
Wouldn't having a fast rate at the end of flap or elevator movement encourage a stall at the very time when you don't need one?

I would like a slow rate for the first and last few degrees of movement with the middle section fairly fast by comparison - but how do you achieve that?
MAAA AUS 73427

You have enemies? Good. That means you've stood up for something, sometime in your life.
 Nothing in life is so exhilarating as to be shot at without result.  It's not enough that we do our best; sometimes we have to do what's required

Offline Howard Rush

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Re: 4" Bellcranks.
« Reply #94 on: December 16, 2010, 08:13:55 PM »
That sounds interesting.  I'll send you something, but it might not help.
The Jive Combat Team
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Offline Ted Fancher

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Re: 4" Bellcranks.
« Reply #95 on: December 19, 2010, 01:22:56 PM »
I would say the amount of non-linearity for the small amount of control travel we use is insignificant. And of course the controlling entity is also non-linear, plus it possesses a tremendous ability to compensate for such anomalies.
Don

Shucks, Don.  All we need are circular bellcranks driving circular horns with push/pull cables combined with a circular/axis pivoted handle driven by a pilot who drives that handle's axle with a bolt surgically attached to the pivot point of his wrist and everything will be linear and then everyone would take turns winning the Walker Cup...or not.

Also, it seems to me the whole thing is being discussed "in reverse".  Shouldn't we first determine how much airload is on the movable surfaces and then build our system backwards from there?  That's the only significant work being done by the whole magilla.

Ted
« Last Edit: December 19, 2010, 05:12:19 PM by Ted Fancher »

Offline L0U CRANE

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Re: 4" Bellcranks.
« Reply #96 on: December 19, 2010, 02:58:14 PM »
Ted, your point is excellent, but so is Don's, no?

We can accept that the airloads on the control surfaces increase as they move away from neutral?

Wth the 'traditional' bellcrank and horn parts, we get a strange combination - The leadout arms and the flap pushrod radii do not change, so their mechanical advantage stays the same. BUT... their effective radii, relative to the directions of the loads applied to them, get smaller as they rotate away from neutral.

Example: 4" bellcrank with 1" radius to flap pushrod. At neutral and at 45° rotation. At neutral, the leadouts are 2" away from bellcrank pivot. Pull is at right angles to the line between leadout holes. Flap pushrod radius is 1" and the force it passes through from the bellcrank is at ~right angles to that bellcrank 'horn.'

Good so far?

At 45° bellcrank rotation, pull forces haven't changed direction, but the leadout arms radius to those forces has foreshortened by the Cosine of 45°: 0.717.. So, the 2" arms appear to the pull force to have reduced to 1.41..." each. The flap pushrod hole radius is also foreshortened by the same proportion (the bellcrank is one solid piece, right?)

So at 45° either way, the bellcrank can only pass about 70% as much force as at neutral into the pushrod system. (The flap driven radius also foreshortens - THAT ratio doesn't change.) To meet the same, or increasing control surface airloads, we need to put more force into the system - from the handle. (Netzeband's Wall, anyone?)

A circular bellcrank is a bit different. Presuming the flap is pushrod-driven from a hole in the bellcrank 'face,' THAT pushrod hole radius foreshortens just as in the 'traditional' setup, BUT the "leadouts" radius does not. There IS an increase in mech adv... (If the flaps/elevators are driven from spools on the bellcrank, the same -full- pull force is not affected by the trig numbers.

Neither of these examples means anything about the control forces we meet at the surfaces. These describe ONLY the relationships of forces input and output at the bellcrank. Maybe Igor B has some numbers, or approaches for specific models to find numbers for the force increases? These would have to be carefullly tailored to each idividual model, wouldn't they...

But, since we expect airload feedback force DOES increase as the surfaces move away from neutral, and the further from neutral, the greater forces passed to the pushrods, and on back to the bellcrank. This is a separate thing from just the internal relationships of input and output at the bellcrank.

And, Don is spot-on that the initiating factor for control surfaces movement is still that trainable, very adaptable, flexible, loose nut at the back of the handle...

IMHO...
\BEST\LOU

Offline Howard Rush

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Re: 4" Bellcranks.
« Reply #97 on: December 19, 2010, 11:51:13 PM »
I would say the amount of non-linearity for the small amount of control travel we use is insignificant.

That's about what I concluded after calculating the effect of following John's recommendations, particularly if you look at flap and elevator response to leadout travel.
The Jive Combat Team
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Offline Howard Rush

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Re: 4" Bellcranks.
« Reply #98 on: December 20, 2010, 12:02:56 AM »
Also, it seems to me the whole thing is being discussed "in reverse".  Shouldn't we first determine how much airload is on the movable surfaces and then build our system backwards from there? 

I think so.  Given a scheme to manipulate hinge moment and a tool that actually tells you the rate of change of control surface position with leadout travel, you'd think a guy could make a pretty good stunt plane control system (Yes, PW, if he ever gets a stunt plane built).
The Jive Combat Team
Making combat and stunt great again


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