Why hasn't helicopter control methods improved?

Princhester: You’ve caught me before coffee, but I’ll try to explain. The engine is connected to the rotor via a transmission and a Sprague clutch or “free wheeling unit”. (The purpose of the clutch is to allow the blades to continue turning in the event of a power failure.) The tachometer on a helicopter has two needles. In a Robinson R-22 they are opposing and cross, while in a 300CB they overlap like clock hands. RPM is measured in percentage of allowable RPM.

Since the RPMs should remain fairly constant, the tachometer cannot be used to measure the amount of power being used. That’s done with the manifold pressure (MP) gauge.

If you increase the pitch of the rotor blades you get more lift, but you also get more drag and RPM are reduced and you have to add throttle. You do this with the twist-grip throttle, or the correlation device (“governor”) does it for you. The governor does a good job in most phases of flight, but I’ve found it’s not good enough in hovering flight to maintain proper RPM. I mentioned “milking the throttle” earlier. Sometimes you still have to do that even with the correlation device on.

Here are some examples of RPM/MP mismatches:
[ul][li]Low RPM/Low MP: If you increase the throttle, the RPM and MP will be increased simultaneously.[/li][li]Low RPM/High MP: Lowering the collective increases the RPM and reduces the MP because the pitch angle will decrease resulting in less drag.[/li][li]High RPM/High MP: Reduce the throttle to reduce RPM and MP at the same time.[/li][li]High RPM/Low MP: Raise the collective. This causes more drag, which lowers the RPM and increases the MP.[/ul][/li]
Now, why is MP important? On the MP gauge there is a yellow “caution” range and a red “never exceed” line. When operating at or above the red line, the manifold pressure gauge is telling you that in the event of a power failure the helicopter may not be able to execute a safe autorotation landing. This is because at a high angle of attack (AOA) the rotor RPM will decrease rapidly due to drag. How rapidly depends on the inertia stored in the rotor system. An R-22 has a low-inertia rotor system. A Huey, for example, has a high inertia rotor system.

NASA = National Aeronautics and Space Administration. It started out as the National Advisory Committee for Aeronautics (NACA) - perhaps you’ve heard of the NACA cowling? Aircraft research is still an important part of NASA’s work:

http://www.dfrc.nasa.gov/Research/index.html

It’s been a movie staple that persons with no apparent training can hop into a helicopter and take off with it. Is it pretty safe to say that even someone with pretty good mechanical aptitude would have no chance whatsoever to even start the engine? How about commercial airline pilots? Is helicopter flying so unlike airplane flying that even one of them be totally lost in a helicopter?

No, you can’t just jump into a helicopter and fly it. (Starting the engine is basically the same as starting an airplane engine, though.) I saw a news report back in the '80s (Man, I wish I could find that footage!) where a guy was getting ready to take off on a training flight. The instructor had gone back to the office, and the guy decided to lift the collective just a little. The helicopter was destroyed. It’s not uncommon for an instructor to leave a student, but they expect the student to behave appropriately. For example, a student might be instructed to stay with the aircraft and not do anything. The guy in the video didn’t have common sense.

In Biggles, Billggles jumped into a JetRanger and his present-day counterpart asked if he knew how to fly one. Biggles replied, “If you can fly a Sopwith Camel, you can fly anything!” The Camel was indeed a handfull; but it in no way would have prepared Biggles to fly a helicopter.

Even a commercial airline pilot with 10,000 hours would not be able to fly a helicopter without proper training. Some control inputs in an airplane are exactly wrong in a helicopter. For example: Let’s say you’re in an airplane and your nose is very high. You push down. In a helicopter with a semi-rigid rotor system (like a Robinson R-22 or a Bell JetRanger) this would unload the rotor disc creating a negative-G situation. This could cause “mast bumping” that might cause the rotor system to depart the aircraft. It could also result in a “boom chop” that severs the tail boom.

I got my fixed-wing rating before I took up helicopters. My patterns were fine. My approaches were perfect. But I always bollixed the last bit. My instructor ws mystified. I “wasted” hours of flight time because I wasn’t pushing the nose down after the flare. It finally occurred to me that I was trying to land the Robbo like a Skyhawk. In a Skyhawk I would keep pulling back on the yoke until the wings stopped flying. In the Robbo I kept pulling back on the stick instead of levelling the skids. When I finally realised what I was doing, I did it right the next time. The instructor was astonished and asked me how I did it. I explained to him that I was landing as if I were still in a Cessna.

Helicopters fly differently from airplanes. I’m often asked if it’s harder to fly a helicopter. It’s not. It’s just different.

They’d probably get that far.

Yes. From my very limited experience. If you try to fly a helicopter with no previous experience you might just wreck the machine and injure yourself. If you manage to get it into the air to any altitude you’ll crash and burn.

Previewed and J.L.A beat me too it. I was gonna mention Biggles too :slight_smile:

IIRC they did at least have him wobble all over the sky before he got to grips with it.

My qualifications are meager (a private pilot who hasn’t flown in years and whose helicopeter lessons were one hilarious and embarrassing story after another; a lifetime electronics and gadget hacker, who used to teach “practical electronics design”) However, I think that I can put some of the key problems into layman’s terms that might help.

Crudely: instability increases responsiveness and flexibility. It also increases, well, instability, which can be a deadly problem if your don’t have the power (or can’t rapidly and precisely increase the power) and rate of change (via control surfaces) that you need to get out of trouble.

An airplane has four primary degrees of freedom: three axes of orientation (aka “atttitude”: pitch, roll and yaw) and one of thrust. However, especially in the early days, when engines were less powerful and control surfaces were less capable, the three secondary axes (“slip” – moving one direction while pointed in another) were more important in critical maneuvers. The air craft were limited in their ability to "do as they were told, because of the limited strength of the available structural materials, available engines, and the need to devote [relatively] more of the available power to generating sufficient lift. Even today, a simple maneuver like maintaining a heading despite a crosswind, or climbing while level, requires use of “slip” relative to orientation, and it’s a basic pilot skill.

Airplanes were also designed for stability - the ability to self-correct to stable straight and level flight, predictably maintain a specific heading and orientation, etc. Now of course, in a dogfight, the ability to change orientation (heading) rapidly and unpredictably (unpredictable to your opponent anyway) can be very valuable. Also, let’s not forget the role of a jet’s high momentum in defining allowable maneuvers – it has a signifcant mass and high forward speed, but only air to “grab” to change its motion.

Today, after a century of experimentation and refinement of tactics, our best fighters are inherently unstable – that extra edge is now necessary, and we’ve developed fly-by-wire computers that turn the pilots control commands into predictable responses by implementing often counterintuitive actions of the control surfaces (like ailerons, tail flaps, extension flaps, elevons, etc.) A pilot couldn’t make all the necessary calculations, and certainly couldn’t make the necessary fine corrections many times a second. Such planes can’t be flown at all without the computer – they’d fall out of the air in seconds or minutes. (Though there has been discussion of making the control surfaces default to a relatively unresponsive and stable configuration in the event of emergency computer failure, I don’t know if that has ever been implemented, since computer damage would likely result from combat damage – a bad time to become a predictable brick)

Helicopters, however, rely strongly on SEVEN degrees of freedom for their design functions. The four primary degrees of freedom are obviously as important in directed flight or combat as they are for a fixed wing craft, but the three additional degrees of slip (motion independent of orientation) are also crucial. Helicopter take-off, for example, is pure slip – movement “up” while pointed “forward”, and key combat tactics include the need to hover behind a building or hill and “pop up” or “pop out” to deploy weapons (and then hide again). The ability to station-keep at a key location in a combat zone while changing orientation to track an object moving on he ground or in the air is also quite useful.

While I’ve simplified the helicopter’s controls to seven primary degrees of freedom (almost twice the simplified degrees of freedom of an airplane) the control surfacesand control [parameters of a helicopter are far more interelated. The speed and pitch of the rotors affects the counter-rotation torque (as the helo spins the rotors, the rotors try to spin the helo in the other direction: there’s nothing to “hold on to” in midair). The effects of adding power are more complex. The leading rotor (the one moving in the direction of the craft’s motion at a giving instant) is moving much faster than the craft itself, while the trailing rotor is moving much slower – each rotor is a separate wing flying in very different (and constantly changing) conditions, and they switch roles hundreds of times a second. This has required a much more sophisticated mechanical system to control all the factors in a predictable way. In a sense, a helicopter is already made manageable by a mechanical analog computer – and that very same mechanical “computer” that makes it flyable also limits its abilities

Crudely, you can consider each degree of freedom to add a “power” of complexity. if the problem iof maneuvering an airplane is X[sup]4[/sup], the problem of maneuvering a helo is X[sup]7[/sup] or X[sup]8[/sup] – probably more, because the mission of a combat helo routine demands it to change its motion (flight regime) rapidly (e.g. from hover to slip), within the limitations of the helo’s hardware abilities (e.g. rotor tips that can’t exceed Mach 1, engines that can’t instantly double their power with afterburners, turbines whose exhaust velocity adds signficant forward thrust when called upon to generate more lift power. etc)

I absolutely expect that helicopters will incorporate more fly-by-wire in coming decades, but I hope this grotesque simplification helps explain why it is a much more complex problem than the “sexier” (in the eyes of many) jet fighter.

Could someone explain degree of freedom to me? I’m having a hard time understanding how helicopters can have seven. It just seems to me you have three axes in space (x,y,z) and you can have translation about any axis and rotation about any axis. 3 translations plus 3 rotations = 6 .

Seahawk pilot checking in. (Seahawk is the Navy variant of the blackhawk).

The various 'hawks do not use fly by wire in the exact sense. There are direct mechanical linkages between all flight controls and their respective control surfaces. The sort-of exception is the stabilator (the horizontal wing like structure on the back of the tail.), which helps control nose attitude. It is controlled automatically and based on the helicopter’s airspeed, collective position (power), lateral accelleration, and pitch rate. The flight control computer sends electrical signals to the actuators in the tail that control its position. The computer can be bypassed, but it’s still fly-by-wire as there is no direct mechanical linkage to the stabilator from the cockpit.

The 'hawks also have a variety of control mixing (e.g. automatically feeding in some left pedal with increased collective) to reduce pilot workload. Some of these are mechanical and some electrical. There is also an autopilot system which uses digital and analog components to generate electrical signals which can manipulate the flight control linkages.

To answer the OP, helicopter controls are pretty intuitive, and automatic flight control systems are as advanced in helos as in fixed wing aircraft. I think one of the reasons helicopter controls are different is that they have to be intuitive and functional in both hover and forward flight. I’ve read some interesting articles on the V-22 program and back-and-forth on whether to make their controls more helicopter-like or airplane-like.

Finally, on the throttle control comments – most military helicopters (and most commerical civilian helos) use gas turbine engines these days. This reduces pilot workload over a R-22 or other non-gas turbine aircraft because the engine’s internal systems take care of controlling the amount of power the engine generates. Basically you spool the engine up, put it in the “fly” position and don’t worry about it until it’s time to shut it down (or it malfunctions).

NASA = National Aeronautics and Space Administration

While the “Space” part gets all the attention, they still do an awful lot on “Aeronautics.”

Here’s a link to some of their aeronautics activities.

To make up for my rambling discourse above, here’s a link to a clip similar to the one Johnny LA etc. referred to: First and last flight #1

WNBC (NYC Channel 4) had a harrowing crash in May that brought back (to me, anyway) memories of what it was like to recover after “losing it” for even a few seconds. This was an experienced pilot, who flew that particular helicopter daily (Amazingly, there were no fatalities!)

in 3-space, a rigid body can never have more than 6 dof. **KP/b] seems to be treating acceleration as a seperate dof to velocity which is not the standard way of defining it.

:smack:

just

:smack:

Yes, I was using it in a nonstandard sense, for the purpose of simplified explanation. I don’t blame anyone for being confused, since I (deliberately) didn’t specify the DoF exactly. I also misspoke, somewhat deliberately, to paint a cartoon picture. I apologize.

The control software can have far more than 6 independently controlled parameters, and that is arguably the relevant parametrization space for the issue of “why isn’t this a solved problem in helos”. I din’t want to go there --and since I haven’t tried building one, I’m sure I wouldn’t do a good job of seaprating or enumerating them.

There are also several other basic physical parameters that I didn’t enumerate which are very relevant to flight. Altitude, for example: it makes a big difference if you’re at 100 ft or 10K (actually, as you approach the ground, it becomes a very major influence on the craft; the same can apply to buildings, geographic features, etc) Some of these factors are much more significant (or are significant at far lower magnitude) for helos than common fixed wign military craft – wind, for example. (I’m sore some hotshot helo pilot will come along to call me a wuss, and tell me that wind ‘taint nuthin’ at all. I’ll take that well-deserved bitchslap gladly, if it means I don’t have to land a helo in a mild-moderate crosswind ever again.

Just the memories of some of those lessons make me sweat.

Dunno about the ‘hotshot’ part, but this is one military military pilot who NEVER takes wind for granted. It is a huge factor in making helicopter fly, and particularly when it’s hot and you’re heavy, can make the difference between getting off the ground or not – or surviving a single engine failure or not.

sorry for the hijack, but isn’t reducing weight one of the main benefits of fly-by-wire? flight?

NASA does a lot of stuff. This will get you the 2004 work of NASA’s Office of Biological and Physical Research. The title of this one jumped out at me: “The Synergism of Electrorheological Response, Dielectrophoresis, and Shear-Induced Diffusion in Flowing Suspensions.” (To be sure, most of these will mention microgravity tests or some such, but often that part is just to get the NASA funding…)

Re: swashplates

Whatever happened to rigid rotors? I read a review of one of the early test rigid rotor copters by a fixed-wing maven. He claimed to have lifted off, flown slowly over the tarmac and settled gently with no more instruction than the kind words of the test pilot in the next seat. (I’m sure that some of my 30+ year old memory of the article is bad, but I distinctly remember that the writer had no or minimal rotating experience and that he described moving forward and laterally.)

I believe it depends upon the case. I have heard it referred to as reducing weight, but my guess is that it depends on how it is implemented. You remove a lot of mechanical linkages and gears, which is good, but you include a lot more electronics and actuators, which is bad. My guess is that you would have a net weight loss overall. Just an educated guess though.

Complexity, expense, and safety are the biggest reasons you do not see more fly-by-wire. Direct mechanical controls are considered a lot safer, they sure as hell cost less, and are easier (generally) to maintain.

By the way, I do most of my testing in this wind tunnel.

As to rigid rotors, I am not familiar with the specific vehicle you describe, but the stresses generated in the blades of such a craft would require incredible stong (and therefore heavy blades) and and incredibly strong (and therefore heavy) hub shaft. You try and alleviate most of the moment generated by the blades with flap and lag hinges. A rigid rotor wouls transmit everything. You think a current helicopter shakes you up a bit? That thing would be like riding around with one of those old-fashioned machines for jiggling away fat strapped to your stomach.

My guess was uneducated. Since I’ve never flown a turbine, I can only go by R-22s and 300CBs. I’d guess that the flight control system and hydraulic system with actuators would weigh more than the existing linkages. Of course, neither of those helicopters have hydraulic systems. Larger ones do.

There are basically three types of rotor systems: Fully articulated, semi-articulated, and rigid.

A fully articulated rotor system has three or more blades. There are “flapping hinges” that allows the blade to flap up and down, “feathering hinges” that allows the blade to change AOA, and “lead-lag” hinges that allow the blade to move fore and aft in relation to the other blades.

A semi-rigid rotor system, or “teetering” rotor system is a two-bladed rotor system that has a “teeter hinge” in the middle allowing the blades to flap as a unit. There is no “lead-lag” hinge. It also has “coning hinges” to allow the blades to cone.

A rigid rotor system does away with all but the feathering hinges. Flapping, coning and lead-lag (since most are multi-blade systems) are accomplished by the flexibility of the rotor blades themselves.

Semi-rigid main rotor system
Helicopter Rotor Systems