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MAIN ROTOR DRIVE SYSTEM

5.1 FUNCTIONS OF MAIN ROTOR DRIVE SYSTEM

5.2 MAIN GEARBOX SUSPENSION

5.2.1 GENERAL
5.2.2 MGB SUSPENSlON COMPONENTS

5.3 ENGINE/MGB COUPLING

5.3.1 ENGINE/MGB COUPLING COMPONENTS

5.4 MAIN GEARBOX (MGB)

5.4.1 MGB DRIVE TRAIN
5.4.2 MGB MODULES
5.4.3 MGB COMPONENTS
5.4.4 MGB LUBRICATION SYSTEM
5.4.5 MGB LUBRICATION SYSTEM COMPONENTS

5.5 ROTOR BRAKE

5.5.1 ROTOR BRAKE PRINCIPLE
5.5.2 ROTOR BRAKE CHARACTERISTICS
5.5.3 ROTOR BRAKE COMPONENTS

FOR INSTRUCTION ONLY

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List of effective pages

Page 01.................................................................Iss. 41-2006 Page 08............................................................... Rev. 24-2008

Page 02............................................................... Rev. 27-2008 Page 09.................................................................Iss. 41-2006

Page 03.................................................................Iss. 41-2006 Page 10............................................................... Rev. 03-2008

Page 04.................................................................Iss. 41-2006 Page 11............................................................... Rev. 27-2008

Page 05.................................................................Iss. 41-2006 Page 12.................................................................Iss. 41-2006

Page 06.................................................................Iss. 41-2006 Page 13.................................................................Iss. 41-2006

Page 07.................................................................Iss. 41-2006 Page 14.................................................................Iss. 41-2006

FOR INSTRUCTION ONLY

Ce document est la propriété d' ETS ; il ne peut être communiqué à des tiers et/ou reproduit sans l'autorisation préalable écrite d' ETS Rev.
5.2 et son contenu ne peut être divulgué. This document is the property of ETS ; no part of it shall be reproduced or transmitted without
the express prior written authorization of ETS and its contents shall not be disclosed. © Eurocopter Training Services 05-2006 27-2008
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5.1 FUNCTIONS OF MAIN ROTOR DRIVE SYSTEM

The main rotor drive system transmits engine power to
the main rotor and to the tail rotor drive shaft.

The main rotor drive train consists of:

- the engine/MGB coupling
- the main gearbox (MGB)
- the MGB suspension

As the engine is a free turbine type, there is no clutch.

The free wheel is integrated in the engine.

5.2 MAIN GEARBOX SUSPENSION

5.2.1 GENERAL

The MGB supports the rotor mast casing in which the rotor airframe at 2 points:
shaft is mounted. The rotor shaft transmits cyclic periodi- - at the rotor mast by 4 rigid bars that transmit the lift to the
cal vertical and horizontal loads to the MGB (normal rotor airframe.
vibrations at nω where ω is the rotor angular velocity). If - on the MGB by a flexible suspension between the gear-
the MGB was rigidly attached to the transmission deck, box bottom and the airframe. The suspension absorbs
this vibration would be transmitted to the airframe. The so- the forces Fx, Fy, the moments Mx, My and the main rotor
lution consists of inserting a flexible suspension between counter torque CR.
the MGB and airframe to absorb most of the vibrations.
Such systems are said to filter out the vibrations.
The main rotor/MGB assembly is thus secured to the Gearbox bottom
Y
Changes in direction of lift vector

FY
X FX X'

CR
Cr
MX Y' Y'
MY

ENGINE

Suspension bar
(4 bars) Articulated
coupling
BTP
MGB

Flexible suspension
Freewheel
FOR INSTRUCTION ONLY

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41-2006
et son contenu ne peut être divulgué. This document is the property of ETS ; no part of it shall be reproduced or transmitted without
the express prior written authorization of ETS and its contents shall not be disclosed. © Eurocopter Training Services 05-2006
5.3
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5.2 MAIN GEARBOX SUSPENSION (Cont'd)

The MGB is suspended like a pendulum and oscillates The basic element of the flexible suspension is a lami-
about the point O (where the 4 suspension bars inter- nated cylindrical pad consisting of a bonded stack of thin
sect). rubber and light alloy disks.
o
Light alloy Rubber
Suspension bar

One end of each of the 4 laminated pads is fixed to the

MGB and the other to the airframe.

MGB
Flexible suspension
AIRFRAME
The vibrations are absorbed radially by the pads which
deform in shear.
The main rotor counter-torque (CR) is transmitted through
the pads by compression.
MGB
MGB

CR

The laminated pads are flexible in shear The laminated pads are stiff in compression

ARRANGEMENT OF LAMINATED PADS

TOP VIEW
R
I2
I2
MGB bottom Lateral axis
FWD

L2
L2
L1
FWD
T T
Longitudinal
I1 axis

- Two laminated pads (L1, L2) react shearwise the loads L1

Fx, My along the longitudinal axis.
-Two other pads (I1, I2) react shearwise the loads Fy, Mx Resistive torque
acting along the lateral axis. (tail rotor)
The 4 laminated pads react the main rotor counter torque
(CR) in compression. The 2 pairs of laminated pads are I1
linked by a cross member (T), which closes the load path R CR
and is loaded almost entirely in tension.
This type of suspension is called "bidirectional" as it acts
along the longitudinal and lateral axes.
FOR INSTRUCTION ONLY
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5.4 et son contenu ne peut être divulgué. This document is the property of ETS ; no part of it shall be reproduced or transmitted without
41-2006
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5.2.2 MGB SUSPENSION COMPONENTS

1 2 3 4 5

I2

L2

To transmit the autorotation torque which changes direc-

tion, each laminated pad is paired with a second pad
that is only compressed when the torque changes sign.
If a laminated pad is destroyed, the assembly is held in
position by a block (3) and continues to transmit the rotor
torque in compression. FWD

1-- Cross member

2-- Structure fitting
3-- Laminated pad support
4-- Laminated pads
5-- Attachment bolt L1

N.B. The longitudinal pads (L) and the lateral pads (l) I1
have different thicknesses.
TOP VIEW

FOR INSTRUCTION ONLY

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41-2006
et son contenu ne peut être divulgué. This document is the property of ETS ; no part of it shall be reproduced or transmitted without
the express prior written authorization of ETS and its contents shall not be disclosed. © Eurocopter Training Services 05-2006
5.5
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5.3 ENGINE/MGB COUPLING

The engine/MGB coupling comprises:
- a casing (1) secured to the MGB and a flanged con-
necting coupling (3) secured to the engine.
- a gimbal ring (2) joining the casing and flanged cou-
pling.
- the drive shaft (4) transmitting the engine torque to the
MGB via the input pinion.

ENGINE

1 3

MGB

NEED FOR AN ARTICULATED COUPLING

The MGB is mounted on a flexible suspension and subject - to absorb the engine overturning torque.
to low amplitude oscillations in flight. In these conditions, the drive shaft only transmits the
The purpose of the gimbal/flanged coupling connection engine torque.
is:
- to maintain the MGB/engine distance constant
- to align the drive shaft with the input pinion

( 1 ) Drive shaft flexible couplings

The flexible couplings ("flector" type) deform to absorb clic fatigue stresses and they must therefore be regularly
the small misalignments between the engine drive shaft checked (as per the Master Servicing Recommendations).
and the MGB power takeoff. Nonetheless they are designed to be fail-safe and to
The flex couplings are subject to high loads as they must deteriorate very gradually.
not only transmit the engine torque but also deform in
case of misalignment. As this deformation is repeated
every shaft revolution, the couplings are subjected to cy-

0.2-0.3 mm
thick α

Stainless steel in a stack ...are mounted between 2 The flexible coupling de-
disks... ... triangular coupling flanges forms to absorb the small
integral with the shafts shaft misalignments

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5.6 et son contenu ne peut être divulgué. This document is the property of ETS ; no part of it shall be reproduced or transmitted without 41-2006
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5.3.1 ENGINE/MGB COUPLING COMPONENTS

Fit washers with Engine

convex side towards shaft flange
flex disks

Flex coupling ENGINE

Flex disks
(See MET) Drive shaft

Coupling tube
Engine
shaft flange
Gimbal pin

Safety pins
Connecting casing
(for gimbal pins)
Flex
coupling

Bushing

Gimbal ring
MGB Nitrided steel Tyrap
gimbal pin

MGB input pinion

pulley flange

Hydraulic
pump

FOR INSTRUCTION ONLY

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41-2006 et son contenu ne peut être divulgué. This document is the property of ETS ; no part of it shall be reproduced or transmitted without
the express prior written authorization of ETS and its contents shall not be disclosed. © Eurocopter Training Services 05-2006
5.7
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5.4 MAIN GEARBOX (MGB)

5.4.1 MGB DRIVE TRAIN

Rotor shaft
390 rpm 100 teeth

Stationary
ring gear

30 teeth
Planet carrier
(5 planet gears)
Epicyclic 390 tr/mn
reduction gear

Sun gear
1690 rpm

The sun gear drives the planet gears, which

Bevel gear rotate in the stationary ring gear and drive the
planet carrier and hence the rotor shaft
Ring gear
61 61 teeth 30 + 100
= 3.59 Speed ratio = = 4.33
17 30
6064 rpm Pinion
17 teeth Lubricating pump

5.4.2 MGB MODULES

The MGB comprises 3 interchangeable modules.

MODULE 1

MODULE 2

MODULE 3

FOR INSTRUCTION ONLY

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5.8 et son contenu ne peut être divulgué. This document is the property of ETS ; no part of it shall be reproduced or transmitted without
24-2008
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5.4.3 MGB COMPONENTS

1 2 3 4 5
Air vent Adjusting shim

24 7

8
23

22
Friction
ring
21

20

19

9
18

17 11 10

12

16 14 13
15

1-- Stationary ring gear (case-hardened steel) 13-- Drain plug with self-sealing valve and electrical
2-- Planet gear (case-hardened steel) "chip detector"
3-- Planet gear spherical bearing 14-- Oil pump
4-- Thrust washer for securing planet gear carrier 15-- Tapered roller bearing
to rotor shaft (chapter 4) 16-- Lower casing (magnesium alloy)
5-- Electric chip detector (chapter 4) 17-- Lubrication system pressure relief valve
6-- Sun gear (nitrided steel) 18-- Ribbed, two-wall main casing (magnesium alloy)
7-- Oil jets 19-- Bevel ring gear (case-hardened steel)
8-- Power takeoff inlet casing 20-- Vertical shaft
9-- Bevel pinion - case hardened steel 21-- Oil pump drive pinion
10-- Tapered roller thrust bearing 22-- Oil filler plug
11-- Cylindrical roller bearing 23-- Tapered roller bearing
12-- Oil level sight glass 24-- Oil recovering cup

The bevel pinion shaft (9) is mounted on a tapered roller The planet gear carrier is flexible so that the planet gears
bearing with a thrust ring designed to temporarily absorb a can oscillate around their spherical bearing; this guaran-
reverse axial thrust (in autorotation and rotor braking). tees proper seating of their teeth in all conditions (load
evenly distributed between the 5 planet gears).
FOR INSTRUCTION ONLY
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41-2006 et son contenu ne peut être divulgué. This document is the property of ETS ; no part of it shall be reproduced or transmitted without
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5.4.4 MGB LUBRICATION SYSTEM

Pressurized oil lubricates and cools the MGB gears and
bearings, and the rotor mast bearings (see § 4.2.2.).

P< 1 bar
PP5
MGB
P

PP5 1
MGB
CHIP

2
13

11

12
25 µ

Engine lubricating oil 5

7 6

3
10 MGB
+ TEMP

4
8
T°>115°C

CORRECT LUBRICATION OF THE MGB IS VITAL, OTHERWISE THE GEARBOX WILL

COMPLETELY FAIL AFTER A CERTAIN OPERATING TIME (55 min.)

The gear pump draws oil from the bottom of the main
gearbox and delivers it to the heat exchanger (cooler).
The cooled oil flows through the filter and into the oil
FUNCTION OF COMPONENTS
1 - Low pressure switch : the "MGB. PRESS" warning
light comes on when the pressure drops below 1 bar.
2 - Electric "chip detector" which monitors the condi-
tion of the rotor mast bearings.
3 - Drain plug fitted with an electric "chip detector."
4 - Thermal switch, which illuminates the "MGB.T" warn-
ing light when the oil temperature exceeds 115°C
slingers to lubricate all the MGB bearings and pinions
and the MAST bearings.
The oil then drains by gravity into the bottom of the
gearbox.
weather start-ups when the oil pressure reaches 6.5 bar.
This reduces the oil flow through the cooler to increase
the temperature quickly.
8 - Engine oil temperature switch, which energizes
the motor-driven fan (9) when the engine lubricating oil
reaches 77°C to blow air through the 2 cooler modules
(10) and (11).
12 - Metal mesh filter with 25µ rating.

5 - Intake strainer 13 - Oil filter bypass, which lubricates the MGB with
non-filtered oil in case of filter clogging.
6 - Gear pump

7 - Pressure relief valve, which opens during cold

FOR INSTRUCTION ONLY
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5.10 et son contenu ne peut être divulgué. This document is the property of ETS ; no part of it shall be reproduced or transmitted without
03-2008
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5.4.5 MGB LUBRICATION SYSTEM COMPONENTS

OIL F I LT E R

Bypass

Shock mounts

Engine
cooler

Filter element

OIL LEVEL SIGHT GLASS

MGB Oil level
cooler sight ball

Drain plug with

electrical chip detector

Low pressure
switch

from rotor
mast

Temperature switch

LUBRICATING PUMP

FAILURE WARNING PANEL :

PITOT MGB ENG ENG ENG FUEL GENE PITOT MGB ENG ENG ENG
FUEL GENE P FIRE
TEMP TEMP CHIP P FIRE TEMP CHIP

FUEL MGP MGB BATT FUEL BATT HORN DOOR MGP HYD MGB BATT
BATT HORN DOOR
P CHIP P TEMP P CHIP P TEMP

FUEL TWT. TGB FUEL INV EMERG GOV TGB GOV TWT
GOV. GOV HYD FILT * XMIT* CHIP
FILT GRIP CHIP GRIP

B3 ARRIEL 2B B3 ARRIEL 2B1

FOR INSTRUCTION ONLY

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27-2008
et son contenu ne peut être divulgué. This document is the property of ETS ; no part of it shall be reproduced or transmitted without
the express prior written authorization of ETS and its contents shall not be disclosed. © Eurocopter Training Services 05-2006
5.11
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5.5 ROTOR BRAKE

Friction pad
Brake disk
The rotor brake is designed :
- To quickly stopping the rotor spinning after engine shut- MGB
down.
N.B. Without a brake, the rotor's kinetic energy would ENGINE
keep it spinning.
- To prevent, on ground, turning the rotor in the open

LEG_00479_00
air.

BRAKING PRINCIPLE: The rotor's kinetic energy is

absorbed by Ferodo friction pads rubbing against a disk
driven by the MGB/tail rotor shaft coupling. Since the
resulting friction transforms the kinetic energy into heat,
there is an rpm limit above which rotor braking is not au-
thorized (too much heat would be dissipated with a risk
of damage to the disk and brake).

5.5.1 ROTOR BRAKE PRINCIPLE

A slotted cage (2) secured to the MGB housing (1) sup-

ports the rotor brake assembly. A mobile slotted cage
(4) carrying the brake pads fits inside the first cage. The
mobile cage cannot rotate but can move axially to force
the pads against the brake disk.
Spring (3) rests on the fixed cage and returns the mobile
ring to its "brake off" position when the brake lever is 2 3 4
released.

CONTROL ACTION: Actuated by fork end control (7),

ring (8) slides on the fixed cage to push back the mobile
cage via diaphragm (5): this forces the brake pads against
the disk.

6 8
6 7 8 5

O Function of diaphragm (5)

When the fork is activated in the "braking" direction, roller Once the required braking force is generated, the dia-
(6) moves through an arc of a circle with center O and, phragm deforms under constant load and hence:
supported by the fixed cage, pushes back ring (8), which
results in BRAKING. THE BRAKING TORQUE IS CONSTANT.
FOR INSTRUCTION ONLY
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5.5.2 ROTOR BRAKE CHARACTERISTICS

Weight .......................................................... 2.100 kg Compulsory time between 2 brake applications .5 min.

Braking torque .............................................8,2 m.daN Pad/disk gap . ................................................... 0.5 mm
Max. braking speed ........................................ 170 rpm Brake force on pilot's control ............................≤15 daN

5.5.3 ROTOR BRAKE COMPONENTS

FLEXIBLE BALL TYPE CONTROL
Moving part of control.
Flexible stainless steel strip slides
between 2 series of balls.

1 2 3 e gap

N0TE -The brake is shown above:

- released in the upper half
- applied in the lower half

Rotor brake
start inhibition switch

Rotor brake
locking device

Rotor brake
LEG_00487_00

control lever
11 10 9 8 7 6

1-- MGB input flange

2-- Diaphragm (Steel spring)
3-- Mobile slotted cage
4-- Brake pad support (Ferodo sintered iron
brake pads, useful thickness = 2 mm)
5-- Brake disk
6-- Control ring
7-- Lever swivel pin
8-- Control lever (fork end)
9-- Control roller
10-- Stationary slotted cage
11-- Laminated shim for adjusting gap
FOR INSTRUCTION ONLY
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41-2006 et son contenu ne peut être divulgué. This document is the property of ETS ; no part of it shall be reproduced or transmitted without
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5.13
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blank

intentionally

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5.14 et son contenu ne peut être divulgué. This document is the property of ETS ; no part of it shall be reproduced or transmitted without 41-2006
the express prior written authorization of ETS and its contents shall not be disclosed. © Eurocopter Training Services 05-2006