Design, development and testing of a mini solid state adaptive rotorcraft

The design principles, analytical models, construction methods and test results for a new type of solid state adaptive rotor (SSAR) are presented. A pair of directionally attached piezoelectric (DAP) torque-plates were fabricated and attached to the root of a 23.5 '' diameter helicopter rotor assembly. The DAP torque-plate tips were joined to a pair of graphite-epoxy servopaddles which were moved in pitch by the action of the torque-plates. The torque-plates were constructed from a single aluminum substrate and PZT-SH DAP elements mounted symmetrically at 45 degrees. Electrical signals were carried to the DAP torque-plates via a shielded brush and rotating contact assembly. A series of non-rotating static tests were conducted on the rotor, demonstrating servopaddle pitch deflections up to +/- 5.8 degrees and good correlation with classical laminated plate theory. Non rotating dynamic testing showed a system natural frequency in excess of 2.5/rev and good correlation with inertial models. Because the servopaddles were aeroelastically tailored to balance out propeller moments, deflection degradation with increasing rotor speed was barely noticeable up to +/- 1 degrees pitch levels. However, as rotor speed increased, total servopaddle deflections in the rotating frame at 1600 RPM (full speed) were degraded, but still operated up to +/- 2.7 degrees in pitch. To conclude the study, the rotor was attached to a converted Kyosho Hyperfly electric helicopter. Flight tests demonstrated fundamental controllability. A system-level comparison showed that the SSAR Hyperfly experienced a 40% drop in flight control system weight, an 8% cut in total gross weight a 26% decrease in parasite drag and a part count reduction from 94 components to 5.