Wednesday, September 21, 2016

EMG-6 Electric Motor Glider Webinar Hosted by EAA

Register now and block your calendar to be able to attend the EMG-6 Electric Motor Glider webinar hosted by EAA. The webinar will be on Wednesday, October 19, 2016 at 7 PM to 8:30 PM central daylight time.

Our moderator for the webinar will be Tim Bogenhagen from EAA.

Click Here to Go to the Registration Page



http://pages.eaa.org/WBN2016-08-23TheEMG-6ElectricMotorGlider_LP-Registration.html
EAA Registration

Tuesday, September 20, 2016

Solidworks 3D Modeling (Bing Carburetor) Step by Step (Videos)

 Bing Carburetor 3D Modeled In SolidWorks


These videos are a pre-release that are part of a larger series of videos compiling the step-by-step process of modeling all of the components on a Bing carburetor. The introductory video will not be completed until after all of the individual components have been modeled and we can provide a table of contents and a larger explanation along with links to each of of the individual videos.

If you are new to the SOLIDWORKS environment just watching the step-by-step process along with the trials and tribulations associated with trying to reverse engineer each 1 of these components can be helpful.

Each 1 of these videos are basically raw unedited video segments. As such there are a multitude of better ways to attack an approach the modeling of each of the components in this larger assembly. The idea behind the videos is to basically show a newcomer the thought process involved in being able to create each one of these individual components to a fairly high degree of accuracy.





Friday, September 16, 2016

EMG-6 "Shop Notes" September 2016

"EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.

September 16, 2016 Production of Kits Continues

kit production continues. Jason has been putting together the subassembly kits and in this picture here he is assembling the components necessary for the horizontal stabilizer subassembly.




These kits that are going together are basic kits that are not the fast build kits. The fast build kits include all of the holes predrilled so that it basically becomes an erector set.





Cutting of the horizontal stabilizer ribs using the ShopBot CNC router.




September 15, 2016

For the last couple of days we been working on kits for the horizontal stabilizer subassemblies. We needed to make up some shop drawings to assist in the bending process of the horizontal stabilizer leading edge. Even though the job of manufacturing the leading edges aren't that difficult the set up that is involved with rigging the tube bending machine can be quite elaborate. It's been a while since we've manufactured a set of leading-edge tubes and realize that we didn't have any notes in the builders database that we compile on our server for the tube bending set up. So we spent nearly the entire day re-rigging and testing the tube bending machine and then documenting the process of set up. Even though none of this is applicable to the individual builders I posted the PDF for the new documents that go along with the shop manufacturing documents to the builders database. Anyone interested can go check out the simple PDF with some pictures. I have also posted some lower resolution JPEG's that you can check out without downloading the PDF.

Link to Horizontal Stab Bending Instructions PDF and Drawing

Monday, September 12, 2016

Builder Charlie Becker S/N 15-024 Oshkosh Wisconsin

Builder Charlie Becker S/N 15-024 Oshkosh Wisconsin

September 12, 2016

Charlie gets his landing gear mounted to the fuselage 4130 chromoly steel frame. Charlie is still currently in the lead for the 1st customer built EMG-6. 

This picture is indicative of Charlie's enthusiasm for aviation in general. He has several projects that these currently working on you can see the super cub in the background. Charlie is director of communities for EAA in Oshkosh. And his enthusiasm and love of the sport is very encouraging.



Although we made this page to highlight the most recent progress on Charlie's aircraft and we will continue to update this page as he sends us new photos. You may want to check out Charlie's Facebook page which is a great deal of more information about the EMG-6 project that he's working on.


https://www.facebook.com/EMG6project/


Friday, September 9, 2016

3D Printed Vortex Generators Part 4 (Video)





In part 4 of 3D printed vortex generators video,  we go through the complete process of designing a vortex generator in SOLIDWORKS, exporting an STL file to the Zortrax software, and then printing and extracting the 3D printed vortex generator.

Wednesday, September 7, 2016

3-D Modeling Software “Home Built meets High-Tech” Sport Aviation / Experimenter "Technically Speaking" Article August 2016

3-D Modeling Software “home built meets high-tech”


In last month’s article we talked about the wide variety of opportunities available with 3-D printing. In this article, we want to talk about the process of creating those 3-D models. Within, literally, years of the initial offering of personal computers that software engineers started creating software for generating mechanical engineering drawings. And just like the computer industry itself, the exponential growth of CAD (computer-aided drafting) programs has blossomed into some of the most amazing collection of capabilities which only years ago were relegated to organizations such as NASA and Boeing. These capabilities have now become available to the average experimental aircraft builder/designer. If your aspirations revolve around being a component or aircraft designer, it is imperative that you recognize and embrace these new CAD technologies. For those holdouts, who do not wish to undergo the difficulty of learning to use a CAD program but still wish to be an aircraft designer, the only advice that we can offer is to lock yourself in the closet until you change your mind. Of course, we jest, but the capabilities of solid modeling software put the designer at such an advantage that the difficulties associated with learning the software are far outweighed by the results and capabilities that can be achieved.

Figure 1:  3D Solid Modeling Software Learning Curve

Friday, September 2, 2016

3D Printed Vortex Generators Part 3 (Video)






3-D printed vortex generators part 3. In this video we step through the installation process and placement of vortex generator using a template and commercial grade double sticky tape.

Monday, August 22, 2016

3D Printed Vortex Generators Part 2 (Video)




3-D printed vortex generators part 2. In this video we step through the installation process and placement of vortex generator version 1-150. We do a comparative analysis from the baseline tests that we conducted in part 1, and provide some analysis of the process. We are using the Quicksilver GT-500 that is currently being used as the tow aircraft for the EMG-6 electric motor glider as the test bed for our 3-D printed vortex generators.

Friday, August 19, 2016

EMG-6 "Shop Notes" August 2016

"EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.


August 29,2016

Jason hard at work making up sub assembly kits. In this picture here Jason has been boxing up elevator Kits.




Thursday, August 18, 2016

3D Printed Vortex Generators Part 1 (Video)




In this video we begin the baseline testing for the 3-D printed vortex generator article. The baseline test was to get a video of the tuft tested wing as a comparative analysis against the additional tests that will be conducted with different 3-D printed vortex generators.

Thursday, August 11, 2016

Icom IC-A6 / IC-A24A Radio Mount (3D Printed)

3-D Printed Handheld Radio Mount


Although originally designed for the a Piper J-3 Cub, hence the color.  This mount can be used on any aircraft including the EMG-6. The radio mount is designed with a split clamp system which allows the installation and positioning on to a 7/8" diameter tube. We can design other size clamps that are interchangeable with different sized tubing if anyone has a specific request. The mounting system requires (4) (3/16" Dia) Cap Head Screws. (4) (3/16") Washers under the head of the cap screw. additionally there is a hex cut out in the clamp that will automatically hold a 3/16" nylon nut. (4) required. Mount can be mounted either horizontal or vertical relationship to the tube.

You can download the STL files if you wish to print your own radio mount. the files are located under 02-90-10-10 ICOM Radio Mount in the builders database.

Link to 3-D printing  STL files.





Tuesday, August 9, 2016

"Stronger 3-D Printed Parts (Part 1)" Sport Aviation / Experimenter "Technically Speaking" Article July 2016

Stronger 3-D Printed Parts (Part 1)


With the extensive proliferation of LPD (Layered Plastic Deposition) 3-D printers, their use in experimental aircraft has begun to grow exponentially. One of the most commonly asked questions, is whether or not we can reliably produce structural components using a 3D printer. The answer is an emphatic yes. Just as with any other process or material, it has its limitations as well as its strengths. Learning to utilize the 3-D printer’s strengths and work within its limitations is the key to its successful utilization.

Because the LPD printers are laying down one layer of plastic at a time the resulting component has a “grain” to it.  And much like wood and other materials the direction of the grain can significantly change the structural characteristics. If you have ever tried to karate chop a board, you know the trick is to strike the board along or parallel with the grain. The amount of force required to break the board across the grain can be 10 times greater than breaking the board with the grain.


Tuesday, July 19, 2016

Sterna Propeller

3 Bladed Sterna Propeller



July 19, 2016   We Receive The 3 Bladed Sterna Propeller

We received one of the propellers that we will be testing on the R and D motor. We have had extensive consultation with Sterna propellers about the propeller that would work the best on the EMG-6 with the 20 hp electric motor. We have selected a propeller blade section that will optimize the performance at a very specific profile. Mainly the ability to operate in a cruise configuration at 45 mph.  We currently have 2 other propellers that are designed for the same motor that we will be testing as well. as we develop data once we begin the flight test program will use this page to accumulate information about this propeller. If the propeller works as expected we plan to offer this as one of the primary propellers for use on the EMG-6. We also plan to become an OEM dealer for the propeller and have them in stock or customers of the EMG-6. We are also working with Sterna for a propeller to be used on the Polini 250 motor as well.

I was first introduced to the Sterna propeller 2 years ago at Air Venture 2014. Sterna propellers are manufactured in China. Their footprint into the US is still somewhat small compared to other manufacturers but they are beginning to gain popularity. If you are at Air Venture, Sterna will have a booth set up and you can talk to them and see some of their other products in one of the big hangers.





EMG-6 "Shop Notes" July 2016


"EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.


July 19, 2016 Display Boards

Before every show we have to work on the advertising, brochures, and display boards to demonstrate some of the different capabilities and construction methods that we use. This year we have added to the display boards a 3-D printed parts board that shows some of the different components that are used both to manufacture the EMG-6 as well as components that are used directly on the aircraft. In addition after the show is over we have to stay a few days extra and do the "Homebuilder Hints" videos for EAA. This year They have requested that we do some videos on both the 3-D printing process as well is the Solid Works software.





Friday, July 15, 2016

EMG-6 Prototype #2 Test Flights Day 2 (Video)





EMG-6 Prototype #2 finishes certification on Thursday, we conduct 12 test flights on Friday, and aircraft is being disassembled on Saturday for the trip to EAA Air Venture 2016 in Oshkosh Wisconsin. This video is a compilation of the flights that occurred on Friday July 15, 2016

Thursday, July 14, 2016

First Test Flight of EMG-6 (Prototype #2) Video





Raw video of the first test flight on Prototype #2.  About 650 foot altitude on the tow. Just at sunset no lift left at all.  Aircraft handled well. Very Smooth, Stable and controllable.

Wednesday, June 29, 2016

EMG-6 "Shop Notes" June 2016

"EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.

June 29, 2016 Aft Fuselage Enclosure

we have finished the lower wing gap seals and are now proceeding to enclose the aft cabin area. The aft fairing will be covered with poly fiber covering just like the rest of the aircraft. The area from the aft fairing and aft fuselage bulkhead to the forward fuselage Bulkhead will be covered with a removable background sailcloth covering. We will be installing a window into this panel.



The 3D Printing Revolution Sport Aviation / Experimenter "Technically Speaking" Article June 2016

The 3D Printing Revolution


We are on the cusp of a new era in experimental aviation like we have never seen before. We often hear doom and gloom from those who have been in the general aviation market and who have seen the downturn in the number of active pilots and airplanes coming off the factory floor. The overused cliché “it’s always darkest just before the dawn” is really apropos in this circumstance. We are here to tell you that the future of aviation looks very bright. There are several paradigm shifting technologies that are changing the world of aviation equivalent to that the Wright brothers first flight, the dawn of the jet age, and Burt Rutan’s contributions to composite aircraft. Some of the most exciting of these new technologies which we have embraced, include, electric propulsion, 3-D solid modeling software, and 3-D printing. Over the next couple of months, we will be writing articles exploring, in-depth, some of these new technologies which are rapidly becoming tangible for the average aircraft builder. In this article, we’re going to take a closer look at the possibilities of using 3-D printing in experimental aircraft.


With today’s proliferation of 3-D solid modeling software available to the average experimental aircraft builder, we are now starting to see the leveraging of this technology into the average builder’s toolbox. We have been using 3-D modeling software for the past 30 years, and “Solidworks” extensively for the last 15 years. We have become so dependent upon it, that we feel it is one of the most valuable tools that we use on a daily basis. With the ability to 3-D model components virtually on your desktop, the cost of design has plummeted dramatically.  It allows us to import the 3-D models into other software and export g-code (computer numerical control (CNC) programming language) for manufacturing of components on different CNC machinery. Seeing this potential, we purchased our first CNC machine some 15 years ago. Since then, we have continued to exploit the advantages of this technology and we now operate 6 different CNC machines. The latest of these “machines” if you can call it that, is a 3-D printer.






Tuesday, June 28, 2016

3D Printing The EMG-6 (Video)





A look at the use of 3-D printing technology to build the EMG-6 Electric Motor Glider. All of the 140+ 3-D printed part files available for free download.




Monday, June 27, 2016

Tube Marking Tools

Tube Marking Tools

For the builders that are building the EMG-6 from plans and the basic kits, There are a lot of holes that need to be drilled in the tubing throughout the build process. As a result we have developed a series of tube marking tools to assist us in the shop for ensuring accuracy during the marking and drilling process. And although we have many of the parts being manufactured with CNC machinery, there are still a significant number of tubes that need to be marked and drilled during the manufacturing and especially assembly process.

We have found these tools to be so useful in the shop that we have decided to make them available to the builders of the EMG-6. This series of tube marking tools that can significantly improve the ease and accuracy of marking round tubing.
 
These tube marking tools have a multitude of features which can only be created practically through the use of  3-D printing technology.

The tube marking tools are manufactured from 3-D printed ABS plastic, and are color-coded to easily identify each size. From 1/2" up to 2" in 1/8" increments. These are the standard tubing sizes used in the aviation industry.

Features

1.  Color-Coded for Easy Identification
2.  Radial marking guide in 15° increments
3.  "V" marking slots for super precision.
4.   Alignment pin holes for   1/16, 1/8,  3/16, 1/4
5.  Non-marring 1/4-20 nylon thumbscrew for secure positioning.
6.  Center punch holding fixture.
7.  Lanyard attachment hole.
8.  Size markings embossed on housing.
9.  Perimeter marking guide on base.
10.  Manufactured from Non-marring ABS plastic.
11.  Precision marking slots at 90°, 180°, 270°, and 360°
12.  Available in all standard tube sizes from 1/2 inch to 2 inches.


Thursday, June 16, 2016

Ultraflight Batteries

 "Donald Lineback" Batteries

June 17, 2016

More information from Donald Lineback on his battery systems he has been developing.
Donald's latest email

"We can test 14 cells or 22 cells in one pack or add another to make a 36 cell with 150v. We can test DC or the better choice - AC sinusoidal.
We supply various controllers and provide programing and wiring for BMS or PCM protection. We offer various throttles and fuel gauges. 
Our new motor and variable pitch prop will be available soon. The battery pack sizes range from 30Ah to 180Ah in cylindrical and pouch. 
— Stay in touch to see our hybrid system for cross country electric flight. ---"




Sunday, June 12, 2016

"Video" EMG-6-250 Local Flights







Carol Carpenter Flies the EMG-6-250. These are the last flights on the EMG-6-250 . The engine and many of the parts were removed to complete Prototype #2 in order to start the Installation of the Polini 250 into the Cabin of Prototype #3. This will be a completely enclosed version similar to Prototype #2 but #2 is currently being fitted with the Electric Power Plant.

Saturday, June 11, 2016

"Video" Cutting Flight Control Gap Seals from Pool Noodles

Cutting Flight Control Gap Seals from Pool Noodles







In this video we go through the process of converting pool noodles into low-cost lightweight, and easy to install  foam gap seals for the EMG-6 electric motor glider.

Let's go through the detailed procedures on how we came up with the final results that we have been using on the EMG-6 electric motor glider. We have cut nearly 30 different dies and guide blocks to come up with the final results that we found that work very well.