AW139 Heli-Collective
This page is split into three main sections:
Parts Guide
Print Guide
Build Guide
The ultimate printer I can recommend is the Bambu Labs X1 carbon with AMS or P1P if you have deep pockets. ($1200). It's a massive leap forward in 3D printing, with excellent quality and impressive speeds. It's pretty much press print and go as the software and hardware do the calibration before each print.
This has to be one of my favourite designs to date. After working on helicopters for over 28 years, I often wondered how to reproduce the controls to make them realistic. The hardest part that any Helipilot has tried is to replicate the magnetic clutch.
I have used a stepper motor (standard Nema 17) as the mag brake, Parallel actuator, Beep trim and later on the autopilot drive unit (series Actuator).
This is NOT a force-feedback unit because helicopters do not operate like that. The control rods/cables are typically connected to servos. Due to the astronomical forces required to move the controls (between 3-20 tonnes), there are no feedback forces through the servos/controls. This is usually done by linear force feel units (springs) acting on a parallel actuator which can reset the datum point at any position. This is the purpose of the Stepper motor in this case. Most modern twin-engined rotorcraft are uncontrollable if full hydraulic servo power is lost.
This system replicates the Bell 212 cyclic forces with force trim in. Most pilots I know on the 212 like to hover, take off and land with force trim off. This makes the cyclic go completely floppy and makes controlling the aircraft easier for more extended periods of time, such as winching.
To increase the force of the cyclic, stronger springs can be added to the force feel units for those preferring a more robust resistance feel. The forces this particular cyclic replicates is that of the Bell 212HP.
This unit comes with the following:
1) A trim release switch beep trim top hat.
2) A cargo release button (not used yet but is connected).
3) An ICS/Transmit dual point trigger (not connected)
4) AFCS release button (Connected but not used yet)
At the moment, The cyclic can be repositioned in any neutral position using the trim release. Once the button is released, the cyclic will hold that position and force feel is enabled. Fine-tuning the cyclic position electrically can be used by trimming the Beep switch top hat in the direction required.
I have included a highly detailed Bell 212 cyclic grip. If you have a resin printer, I recommend using this for a smooth finish. For those that do not have access to a resin printer, I might be able to produce them for you at a cost, but this will be a limited quantity due to the time they take.
Please note: I have made the cyclic fitting 25mm so it will fit most aircraft grips, both rotary and fixed-wing. So if you have another type, it should be interchangeable.
There is no complicated software involved, just Mobiflight, and I soon hope to issue the exact file, so you do not have to programme anything. This unit replicates a standard PC joystick, using a Leo Bodnar card to keep things simple. This means it can be used on XP, DCS, P3D and MSFS!
I hope this puts a smile on your face like it did so many at the EXPO in Lelystad, including real-life pilots!
Pre-release right now while I construct the Build/Print and parts guide, which will be added here (if you want to start printing:
The build guide and components list can be found here:
https://www.737diysim.com/build-guides-1/bell-212-heli-cyclic
General Information:
Build Guide
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STEP:
1
Place FF2 into FF1
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STEP:
2
Secure the parts with QTY 5, M4 x 14mm Countersunk screws
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STEP:
2.1
Insert QTY 2, M4 x 10mm Countersunk screws into the back of the pivot points of FF2.
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STEP:
3
Place the centre support (FF2) onto the assembly
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STEP:
4
Secure it with Qty 4, M4 x 10mm screws
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STEP:
5
Turn the unit over and insert an M4 x 14mm screw into the orice below the text only.
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STEP:
6
Insert an 6203 bearing
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STEP:
7
Insert Qty 2, 608 bearings into Tongs FF4
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STEP:
8
(Repeapt and create Qty 2 tongs)
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STEP:
9
Place the tongs onto the assembly
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STEP:
10
Place the cover (FF6) onto the unit and secure with QTY 5, M4 x 14mm screws.
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STEP:
11
Insert a 6203 bearing
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STEP:
12
Place QTY 2 M4 x 35mm screws into the tongs with M4 nuts to help secure the load springs.
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STEP:
13
Install the fan onto the shroud, and secure it with QTY 4, M3 x 15mmm Screws.
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STEP:
14
Place the fan shroud (L3) on the LHS Frame
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STEP:
15
Secure the shroud with QTY 3, M4 x 20mm screws
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STEP:
16
Insert the reduction stepper motor
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STEP:
17
Place the stepper mountover the parts and secure it to the plate with M3 x 10mm screws
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STEP:
18
Place the stepper mount onto the LHS and secure it with QTY 4, M4 x 16mm screws.
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STEP:
19
Place the LHS support (L2) into L1
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STEP:
20
Secure with Qty2, M4 x 20mm screws.
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STEP:
21
Inser the spur gear (S1) onto the shaft. This should be a very tight push fit.
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STEP:
22
Insert a 6203 bearing
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STEP:
23
Insert Qty2, M2 x 8mm screws into the R4 sliding plate and secure the hall slider
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STEP:
24
Insert the assembly into the RHS
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STEP:
25
Place the Hall sensor rail R3 over the top to secure the hall sensor.
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STEP:
26
Insert Qty 3, M4 x 10mm screws to secure the sensor rail R3
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STEP:
27
Insert a 6203 bearing
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STEP:
28
Place the R5 gear onto the shaft
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STEP:
29
Place the RHS support on the frame
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STEP:
30
Secure the support with QTY 2, M4 x 20mm screws
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STEP:
31
Insert a 25mm diameter tube (approx 420mm in length) into the pole base adapter PBA1
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STEP:
32
Use an 8.2mm drill bit to create the orifice in the tube
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STEP:
33
Use a step drill to create the orifice in the base of the tube. This is used for the wiring loom exit.
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STEP:
34
Insert an M8 threaded rod (81mm long) into the rear orifce of the PBA1, Place an M8 washer and lock nut on to the end. Ensure 1 thread protudes from the nut.
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STEP:
35
Place another M8 washer and standard M8 nut onto the threaded rod on the opposite side
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STEP:
36
Place an 608 bearing onto the rod
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STEP:
37
Secure it with an M8 lockunt
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STEP:
38
Ensure any excess rod protrudes from the rhs and not the left
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STEP:
39
Insert an M4, 35mm screw, place an M4 nut onto the shaft first and position the nut so the screw is equally displaced both sides of the PBA.
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STEP:
40
Place a further two M4 nuts onto the screw. These hold the balance springs.
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STEP:
41
The unit should look like this, at this stage
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STEP:
42
Insert the collective grip onto the tube. The AW139 grip is rotated clockwise by 15 degrees toward the pilot. It is not horizontal
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STEP:
43
Use a 5.2mm drill bit to create the orifce for the securing bolt
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STEP:
44
Insert a M5 x 45mm allen bolt throght the collective grip and tube, Secure with an M5 locknut.
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STEP:
45
Insert an M8 x 30mm bolt into the front plate F1
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STEP:
46
Screw the bolt most of the way in, This is used to set the lower hard stop of the collective
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STEP:
47
Place the Front plate assy onto the LHS assembly
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STEP:
48
Insert the PBA assy into the force fell unit
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STEP:
49
Place the spacer PB2 onto the PBA shaft
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STEP:
50
Place the PBA complete assy into the 6203 bearing in the LHS frame
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STEP:
52
Place the RHS frame onto the PBA shaft and sure the front F1 to the RHS frame with QTY 8, M4 x 20mm screws
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STEP:
53
Place the base onto the bottom of the assembly and secure it with Qty 14, M4 x 20mm screws.
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STEP:
54
Insert an M4 x 50mm screw into the base. This screw sets the collective up Hard stop. (Around 60 degrees of movement)
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STEP:
55
Insert an M8 threaded rod cut to 168mm through the PBA assembly
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STEP:
56
Place the cap PB3 over the end
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STEP:
57
Use an M8 washer and locknut to secure the rod on the RHS.
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STEP:
58
Place another PB3 cap onto the LHS
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STEP:
59
Use an M8 washer and locknut to secure the assembly
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STEP:
60
Use an M8 x 150mm threaded rod. Place an M8 washer and locknut at one end. Insert the rod through the RHS frame only!
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STEP:
61
Place Qty 2, springs onto the threaded rod in the centre section. Then insert the threaded rod through the LHS frame
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STEP:
62
Secure the rod on the LHS with an M8 washer and locknut. Do not overtighten!
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STEP:
63
Secure the springs to the PBA1 (pole base adapter M4 screw). These springs allow for the counter balance of the collective.
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STEP:
64
Connect the collective/cyclic as shown:
https://031b6b45-11f6-46a7-ab8e-17be9aef4dad.usrfiles.com/ugd/031b6b_e7677154324f447995dc696b15104c9e.pdf
The programming can be found here:
https://www.737diysim.com/build-guides-1/heli-controls-programming