ABC Rotor Blades: Design, Manufacturing and Testing

Abstract

ABC is the acronym for "Active Blade Concept" and represents a 38% Mach scaled model rotor of the Advanced Technology Rotor (ATR) of Eurocopter Germany (ECD, [4]). In contrast to the ATR the model rotor is fully articulated. Specifically, it is equipped with a flap at the trailing edge of each blade, which is driven by a piezo-electric actuator. The ABC project is a cooperation between the French ONERA and the German DLR within the research concept "The Active Rotor". This rotor will be used for investigations of the effect of different flap positions on noise, vibrations and performance. ONERA was responsible for the structural design of the blade and the manufacturing of a prototype blade. DLR’s responsibilities covered manufacturing of carbon fibre moulds and the five series blades (including one spare blade) using the experiences of the prototype blade manufacturing. Additionally, all instrumentation with Kulite pressure sensors, strain gages, hall sensors and accelerometers was part of DLR’s contribution. In 2005 a wind tunnel test in S1MA is scheduled under the lead of ONERA with validation of the flap efficiency for vibration reduction and performance enhancement. Following this, a second test under the lead of DLR is planned in the large low-speed facility of DNW with emphasis on flap effectiveness to reduce noise radiation. This paper deals with the particularities of the mould, the build up of the blades including the mechanism to drive the flaps, the test of the flap units in laboratory and in the S3MA wind tunnel, the manufacturing of the prototype blade and its testing and the series blades manufacturing and laboratory test of these.