Subject: Anatomy of an almost crash.]
From: Rotary Engine
Date: 1/17/2006, 12:07 PM
To: AA-me





        7 watts seems low.  Does your engine use a high pressure
   pump?  I would
        have guessed at least 3A, or about 40 watts..

        More about electrically dependent engines (mostly gleaned from Bob
        Nuckolls' aeroelectric list):

        You want fault tolerance in the electrical system - the failure
   of any
        single component shouldn't cause the system to crap out.  There are
        lots
        of ways to accomplish this.  Most design ideas have already
   been thought
        of.  No reason to invent new ones because the existing ones are
   quite
        good..

        Fault tolerance may imply a certain amount of redundancy in the
   system
        (for components that have a relatively high failure rate).

        As I said before, you want enough electrical capacity to maintain
        powered flight until the fuel tanks are empty.  There WILL be
   flights
        where having to land short of your intended destination is not
   a viable
        option.

        My opinion is that to have enough electrical endurance will
   mandate a
        second alternator of some sort.  Here's why: When you do the load
        analysis of an electrically dependent engine, you will come up
   with
        something on the order of 5-8 Amps of current demand.  A typical
        aircraft battery when new will have a nominal capacity of 20Ah -
        measured at low current demand - typically something like 10%
   of the
        capacity in Ah - maybe at 2A on a 20Ah battery.  At 5A draw,
   you won't
        get 20Ah from the battery.  Maybe you'll get 15Ah.

        On a brand new, fully charged battery, 15Ah at 5A is 3 hours of run
        time.  Add a difficult start, some idle time on the ground, and
   some
        other flight loads like radios and lights, and you may be lucky
   to get
        1.5hours of run time from the battery.  That's not enough in my
   book,
        and certainly won't allow you to use up all of your fuel.

        So, you may say that you'll just add another battery...  There are
        downsides.  Obviously, that directly adds significant
   weight.  It also
        is an item that must be periodically maintained/replaced.  In
   not very
        much time, the cost of swapping batteries will catch up with
   the cost of
        adding a second alternator.  You might say that you won't fly
   enough
        hours to warrant this, but batteries wear out on the calendar
   as much as
        they do from flight hours.  And even with the battery, the
   airplane has
        a finite limit of endurance that isn't driven by how much fuel is
        available.

        Another thing to consider is adding engine support systems that
   are able
        to operate independent of a DC power source.  Gravity
   feed/engine driven
        fuel pump, and a magneto are the classics, and hard to beat in
   terms of
        reliability.  Each can coexist with its modern replacement..


        Back to your regularly scheduled program...  :)


        Matt-


   I followed this same logic, but came to a different conclusion.  In my
   case, I asked myself what would make my primary alternator stop
   generating current.  There were two obvious scenarios that lept to mind
   -- either the alternator itself died, or the engine is not spinning the
   alternator.  If the alternator died, then the only critical element is
   to be aware that it is offline.  I can then plan a no-stress landing at
   a nearby airport.  If the engine is not spinning the alternator ( i.e.,
   the engine has conked out) then having a second alternator makes no
   difference whatsoever -- it is also not generating power & thus I am
   back to the batteries.  In this case, I am immediately aware there is a
   problem (gee, it's suddenly very quiet up here) and endurance on the
   electrons is only needed for however long it takes gravity to return me
   to the ground.

   So - based on that thinking, I decided the dual-battery arrangement was
   better than the dual alternator arrangement.  As per the AEC, I jettison
   one battery every annual.  Thus I am guaranteed one "new" battery that
   is storing close to spec'd AH.  At $35 per battery, I consider it cheap
   insurance compared to the $250 per battery I was paying for my old
   Cessna.  I never used cost of the second alternator in eliminating the
   dual alternator arrangement - just the logic above.  At 36 AH (18 AH +
   18AH) I will have more electrons than fuel in any case.  My current draw
   on the endurance bus is around 6 Amps as you suggest above -- so even if
   the second battery is down by half (9 AH) I still have 27AH to get
   me to
   the ground.  If I chew through that and am somehow still aloft, then I
   have very badly neglected my responsibilities as PIC.

   I might have decided the above differently if I was building a
   long-distance platform where getting there on-time & on-schedule was
   part of the mission requirements.  In that case, I could easily see
   redundancy of alternators in case one craps out or a belt breaks.  But
   in my case (as a fair-weather flier with all the time in the world to
   get from here to there) that wasn't a driver.

   My 2-cents, YMMV, and all the rest.

   Mark Supinski



I agree with your analysis.  I just decided that I don't want battery
capacity to be a factor when deciding where I need to land.  I have
fantasies of someday doing a fair amount of IFR and maybe some overwater
stuff.  To each there own.


Regards,

Matt-



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