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Volume 37 No 1 Feb-Mar 1986.pdf - Lakes Gliding Club

Volume 37 No 1 Feb-Mar 1986.pdf - Lakes Gliding Club

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JUUAN ROSS<br />

Ware all familiar with tug aeroplanes and<br />

accept that they land trailing their tow cables,<br />

not questioning Ille hazards 01' inconvenience<br />

this causes. 'If it were possible to rewind the<br />

tow cable fully into the tug, four important<br />

benefits would ,be realised.<br />

,Hsl, operations wourld t!e safer - persons<br />

and objects wou'ld not be struck.<br />

Secondly, the cost 01 replacing broken cables<br />

and repairing, damage caused by cable strikes<br />

would be saved.<br />

Thrclly, tug utilisation would be improved by<br />

as much as '20% ona typical launch cycle - the<br />

absence 01 a cable lraiing below the tug allows<br />

a 'lower 'approach, hence a touchllown closer to<br />

the boundary fence, and less time is spent taxying<br />

back; also for reconnection, the cable has<br />

only to be pulled out from the tug's tail.<br />

Finally, cables longer than the current norm<br />

may 'be titted, being rewound for landing.<br />

longer cables would reduce the danger resulting<br />

from the glider rising too high on tow.<br />

I discussed the potential for a cable rewinding<br />

system during 1'984 at laSham and Southdown<br />

GCs. Tne Opinions and comments received<br />

were most encouraging and I decided to design<br />

and evaluate an aerotow cable rewind system<br />

for the third year project section of my degree<br />

course,<br />

An elementary rewind system had recently<br />

been tried at the Booker GC. It was unsatisfactory<br />

for a number of reasons. Rewind took<br />

9O-120sec and was only completed when the<br />

lug was very close to the ground. lihe control<br />

system waS too simple-, the pilot being expected<br />

to switch off the rewind motor whefl all the cable<br />

was wound in. The jettison system severed the<br />

cable; apparently quite a few cables were accidentally<br />

broken in this way and, once spliced,<br />

the.y would not fit into the small bore conduits<br />

used. Perhaps most significantly, no indication<br />

was given to the pilot when full cable rewind had<br />

been achieved. The pilot was forced to use a<br />

crude mirror system to view the cable periodically,<br />

seriously adding to his already high workroad<br />

close to the ground.<br />

Based on the results of discussions and the<br />

Booker experience a brief specification was<br />

drawn up.<br />

1. Rewind time: to be 45sec for a 200ft cable.<br />

2. Cable type: to tle up to 300ft of conventional<br />

7mm diameter cable fitted with Ottfur or T0St<br />

rings.<br />

3. Operation: a single command from the pilot<br />

should Initiate rewind, lihe pilot must be<br />

informed by Indicator lamp of full rewind. After<br />

landing the cable must be unwindable without<br />

pilot Intervention: nevertheless U must not wind!<br />

out under air or taxying toads. Whenever fully'<br />

unwound the cable mus.t be jettisonable.<br />

4. PUot workload: this must not be increased<br />

by the system.<br />

5. Tug performance, weight and balance must<br />

nOf be significantly altered.<br />

A system layout was developed and is illustrated<br />

in, Fig 1. The system is electrically powered,<br />

using the tug's 12v DC circuit. An electric<br />

clutch is used in conjunction with an Irreversibly<br />

geared motor: it the clutch is kept energised<br />

then the cable will not drag out. A tail mounted<br />

microswitch, pressed by the- launch point i'lelper<br />

who will pull out the cable, releases the clutch.<br />

AEROTOW CABLE<br />

REWIND SYSTEM<br />

This is a summary of the work Julian did for his final year project of<br />

his BSc course in aeronautics and astronautics at Southampton<br />

University and which was supported by the BGA via the 1984<br />

Churchill Award.<br />

Fig 1. The system layout.<br />

,1,'.1,'"<br />

tug structure<br />

'''-../<br />

I' i', ,. "\<br />

""~--_:_..:;,..~<br />

conduit<br />

winch<br />

interface structure<br />

emergency rel'ease cable<br />

A switch in the cockpit. starts both clutch and<br />

molar, rewinding the cable. A stop piece Is<br />

attached to the cab'le, very ,close to the glider<br />

end: this activates 'a second microswitch at the<br />

tail, stopping the molor, but allowing: Ihe clutch<br />

tQ stay energised.<br />

Direct tension forces are reacted a\ the winch<br />

itself, through the interface structure to the tug<br />

airframe. Sidetoads are reacted at the tail.<br />

Fig 2. The system fitted to a tug.<br />

stop mechanism<br />

also supporting<br />

tailwheel<br />

Light alloy is used for much 01 the system,<br />

giving low weight combined with good strength.<br />

The Aotable exception is the 300mm diameter<br />

cable drum, which is of GRP.<br />

A modular approach is applied to the desigrl:<br />

this permits simple maintenance, rearrangement<br />

for different tug types and easy 'upgrading<br />

or modification of individual modules. Fig 2 illustrates<br />

the system fitted to a tug.<br />

Winch unit dimensions are: max height<br />

300mm; max length 300mm; max width 420mm.<br />

Weight is approximately 5kg without cable.<br />

A prototype system was constructed.<br />

Static load testing showed the prototype<br />

winch to nave a :safe margin of strength. Strain<br />

gauge resUlts showed fhat no stresses were sufficiently<br />

high tQ give anxiety regarding fatigue,<br />

Bench running demonstrated correct functioning<br />

of the winch and control system. A drum<br />

rotation speed Of around, 240rpm was found to<br />

be 'necessary to obtain the specified rewind<br />

time. .<br />

One interesting result showed that the quality<br />

of cable winding on to the storage drum is very<br />

much dependent on the distance between the<br />

coiled cab'le sUrface and the point of feed.<br />

Unless this dimension Is kepf above a critical<br />

value, chaotic coiling occurs, taking excess volume<br />

and leading to tangling on unwinding,<br />

A production system is estimated to have Cl<br />

unit material and parts cost of £100, with unit<br />

construction time of between four and six man<br />

days. This shOUld lead 10 a basic cost of<br />

£200-250, fo which must be added fitting costs,<br />

22 SAILPLANE & GLIDING

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