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155 lines
8.1 KiB
Markdown
155 lines
8.1 KiB
Markdown
# ThunderFly Auto-G2 Autogyro
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The _ThunderFly Auto-G2_ is an autopilot-controlled autogyro based on the [
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Durafly™ Auto-G2 Gyrocopter](https://hobbyking.com/en_us/duraflytm-auto-g2-gyrocopter-w-auto-start-system-821mm-pnf.html) RC model, with several parts of the original model substituted for 3D printable ones.
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::: info
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Auto-G2 autogyro’s airframe was originally developed by [ThunderFly](https://www.thunderfly.cz/) and has since evolved into the updated [TF-G2 platform](https://docs.thunderfly.cz/instruments/TF-G2).
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Check out our site for more information on the current [TF-G2 commercial airframe](https://www.thunderfly.cz/tf-g2.html).
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:::
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All the added parts are available on [GitHub](https://github.com/ThunderFly-aerospace/Auto-G2) as an open-source project.
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Printed parts are designed in [OpenSCAD](https://openscad.org/).
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## Modifications
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Durafly Auto-G2, in its original design, has a three-blade rotor with 400 mm long blades with a CLARK-Y profile.
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Rotor head allows tilting in the ROLL axis only.
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Autogyro is controlled by a rudder and an elevator.
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Durafly Auto-G2 autogyro box contains the autogyro polystyrene body, ESC, motor (probably 800kV), 4 servos, tail airfoils, 3 blades with rotor center parts, wire chassis and a prerotator.
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Modification of the Durafly model are as follows:
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- Addition of an autopilot
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- Rotor head with two axes of freedom (pitch, roll)
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- Two-blade rotor with safely breakable rotor plate
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- Larger landing gears
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### Autopilot
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The aircraft with all of the modifications is already quite heavy.
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Therefore a low-weight flight controller is recommended (e.g. [Holybro pix32](../flight_controller/holybro_pix32.md) or [CUAV nano](../flight_controller/cuav_v5_nano.md)).
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The autopilot should be mounted on the bottom side of the autogyro on a 3D-printed damping pad.
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We have used the damping platform found on [thingiverse](https://www.thingiverse.com/thing:160655)
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### Rotor-head
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The rotor head is (compared to the original autogyro) modified so that it allows a motion in both roll and pitch axes.
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Thanks to this, the rotor can control turning as well climbing of the autogyro.
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Directional control of an autogyro by the rotor is possible even in the case of low airspeed compared to the original rudder and elevator control.
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The printed rotor head consists of three parts.
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The bottom part is screwed using an M2.5 screw to the original plywood pylon.
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An M3x35 screw found between the first and the second part creates the pitch axis freedom and the connection between the second and the third part the roll axis freedom.
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The latter axis is made of an M3x30 screw with a screwed self-locking nut.
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From the rotor side, the screw head has a large area washer.
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Rotor axis, made of M3x50 high tensile strength screw, goes through the third part.
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Bearings used are 623 2Z C3 SKF.
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At the end of this part, there are ball rods attached via M2.5 screws to servos positioned in the bottom part of the pylon.
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It is preferable to exchange these original servos for better quality ones as they are weak and in the original construction, they help each other.
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### Two-blade rotor
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The original Durafly Auto-G2 autogyro has a three-blade rotor, which has been modified in this build to use a two-blade rotor.
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The reasons are reduced vibration and easier construction.
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Printed central parts are designed to be used both with Chinese Durafly blades or 3D printed blades.
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The rotor's central part consists of several components, which have the following roles:
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- They enable blade flapping.
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- They have deformation zones that break upon impact with the ground.
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Thanks to this, the rotor can usually be repaired quickly by replacing only one component.
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- Easy setup of blades' angle-of-attack.
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#### HobbyKing rotor blades
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It is possible to use a printed central part of the rotor with the original blades.
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The blades used were "Durafly™ Auto-G2 Gyrocopter 821mm - Replacement Main Blade" (Discontinued)
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Hobbyking blades differ in the position of the center of gravity, and it is therefore necessary to balance them properly.
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#### 3D printed rotor blades
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It is also possible to print rotor blades.
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The printed rotor blades are still under development, but preliminary tests show they are of better quality, mostly thanks to their precise shape and absence of longitudinal grooves.
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However, some of the production processes still need to be tuned.
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#### Balancing
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Proper blade balance is very important to minimize vibrations.
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Blades have to be balanced in such a way, that the center of gravity is located in the middle of the rotor axis.
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Printed blades are balanced in the production process, and there is no need to further balance them.
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### Release device
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If you want to launch an autogyro using a winch or if you want to launch it by towing, you need to print a release device.
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It is a small box equipped with a servo that pulls out the pin and releases the rope.
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The whole part is glued, using a hot-melt adhesive, under the engine on the bottom part of an autogyro’s body.
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If an autogyro is towed by a rope its engine must not be turned on.
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It can be handled, for example, by nulling the engine’s output in the transmitter if the release device switch is closed.
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## Parts List
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### Electronic
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- Autopilot ([Holybro pix32](../flight_controller/holybro_pix32.md), [CUAV nano](../flight_controller/cuav_v5_nano.md))
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- GPS (GPS Module NEO-6M, with patch antenna)
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- Airspeed sensor ([SDP3x series](https://sensirion.com/products/catalog?categories=differential-pressure&series=SDP3x&page=1&page_size=12))
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- Stronger servos as a substitution for the original ones (optional), ([BlueBird BMS-125WV](https://www.blue-bird-model.com/products_detail/411.htm))
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- Additional servo for release device (optional)
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### Mechanical parts
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- Rotor head Bearing (623 2Z C3)
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- Propeller ([APC 10x7](https://www.apcprop.com/product/10x7e/))
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- [Prop adapter](https://mpjet.com/shop/gb/prop-adapters/184-collet-prop-adapter-19-mm-4-mm-shaft-m629-standard.html)
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### Printable parts
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- Rotor head:
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- [Pylon end](https://github.com/ThunderFly-aerospace/Auto-G2/blob/master/CAD/stl/111_1001.stl)
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- [Pitch part](https://github.com/ThunderFly-aerospace/Auto-G2/blob/master/CAD/stl/111_1002.stl)
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- [Roll part](https://github.com/ThunderFly-aerospace/Auto-G2/blob/master/CAD/stl/111_1003.stl)
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- Rotor:
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- [center part washer top](https://github.com/ThunderFly-aerospace/Auto-G2/blob/master/CAD/stl/111_1008.stl)
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- [center part washer bottom](https://github.com/ThunderFly-aerospace/Auto-G2/blob/master/CAD/stl/111_1004.stl)
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- [center plate with deformation zones](https://github.com/ThunderFly-aerospace/Auto-G2/blob/master/CAD/stl/888_1001.stl)
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- [washers for setting AoA of blades](https://github.com/ThunderFly-aerospace/Auto-G2/blob/master/CAD/stl/111_1005.stl)
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- [Rotor nut](https://github.com/ThunderFly-aerospace/Auto-G2/blob/master/CAD/stl/888_1002.stl)
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- Rotor blades (optional)
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- Autopilot holder
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- [Release device](https://github.com/ThunderFly-aerospace/Auto-G2/blob/master/CAD/stl/888_1010.stl)
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- [Front wheels](https://github.com/ThunderFly-aerospace/Auto-G2/blob/master/CAD/stl/888_1011.stl)
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### Recommended spare parts
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- Servos with improved quality (recommended [BlueBird BMS-125WV](https://www.blue-bird-model.com/products_detail/411.htm), original servos are not very durable))
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- Propeller ([APC 10x7](https://www.apcprop.com/product/10x7e/))
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- Rotor centre plate with deformation zones (3D printed)
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- Rotor blades ("Durafly™ Auto-G2 Gyrocopter 821mm" (Discontinued on HobbyKing), similar blades, or 3D printed)
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## Video
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<lite-youtube videoid="YhXXSWz5wWs" title="[ThunderFly] 3D printed autogyro rotor"/>
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## Photo gallery of changes
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