Ward Aero generator

[Hank Jarrett]

Re: Ward Aero generator

What are the rules for a "strap on" that is not a permanent install? We joke about the "Certified Velcro" allowing us to attach things with Velcro that do not require approval (yea, I know, you can't mount this with Velcro). Can this be clamped on without approval and used in some way? I have a mounting post on the belly of my plane (from the factory) for a Ward Aero that allows me to pull the generator by removing two bolts and unplugging the connector. The Ward weighs a TON and the prop has been known to throw blades. A Ward never produced 20 amps, much less 40 unless it was in the terminal dive after the wings were pulled off. The Ammeter for it only reads to 15 amps!
In my case I wonder if I could use a smaller, lighter, more reliable generator in place of the Ward without jumping through too many hoops. Engineering and safety wise, it's a no brainer. What say the legal A&P, IA and FAA folks? Is there a way to do this? We aren't going to get killed doing it, are we going to loose out tickets or get our planes declared non-airworthy?
Hank

[Hank Jarrett]

Re: Ward Aero generator

I would start by getting as many planes as possible to be able to use it. Once you know from the Feds what they will want to make it "legal" you build the first ones for experimental to get your production going with minimal risk to your business plan. Marve is on the right track but I am figuring the FAA will want to see them proven in operation before they will allow them on a certified plane.
I would also design them so all of the electronics are in the "pod" making install and removal as simple as possible. If I was designing the Ward Aero today, I would have the voltage regulator inside the fairing with the outside unit. All you would have to do is make a connection for the Field switch and the power output. Three wires and some bolts to attach it.
Freeze the design before the first one is sold or you will end up with a whole series of prototypes. The only way to not loose money is to keep production standardized and get the volume up. Otherwise you get what we are talking about on the landing gear thread. Low production and high price.
Hank

[Larry Lyons]

Re: Ward Aero generator

Experimental is one good way to start. Flybaby's come to mind right now as a problem looking for a solution that your little baby would fill. There are a lot of small (i.e. simple) homebuilts that would benefit from something like this. Larry

[Edwin Otha]

Re: Ward Aero generator

I think the kicker would be the electrical bus, I don't know if this could be made as a temporary installation. If the wiring was properly installed and documented it should not be a problem. I might consider having the dynamo removed unless needed for the intended flight.
This is a pretty gray area and the inspector should be aware of your intent to install this item.
EO

[Hank Jarrett]

Re: Ward Aero generator

The buss is what I'm working on the design for now. I want to use the original wiring for the lights that was put in almost all the Taylorcrafts. From what I can tell they only hooked it up to a battery and switch on the sub panel.
What I want to do is be able to hook that system into "box" with everything needed for the generator system that can be pulled out in a few minutes with a few plugs.
I am hoping I can do it by modifying the wiring for the Taylorcrafts that came with the wind generators with a few connectors.
Hank

[Bird]

Re: Ward Aero generator

That Hyperon motor generator, thats the one that they use in the RC model electric planes and helo's isn't it?

[Hank Jarrett]

Re: Ward Aero generator

It's been a little while since I gave a status on the Ward Aero check out. Lew has two in the shop right now and he is waiting for some new parts for mine. Here is a good reason to get your generator checked. Mine had a fatigue crack in the output shaft and failed on the bench. To check it Lew puts the original pulley on in place of the prop (these were originally boat motor generators and use a special pulley). He ran the first test and all was OK. On the second run he was checking the voltage regulator I gave him (from 1941!) and the shaft let go. The pulley, belt and nut bounced around the shop for a while. Now imagine that happening under your legs as the prop flies off!
I'm sure glad it happened in the shop and not in flight.
Anyway, Lew had another shaft and he is finishing up the repairs now.
Hank

No word on if there is an extra laundry charge for the check-out.

I may have to help him make a safety cage for the test machine!

[Doc]

Re: Ward Aero generator

Hank: Thanks for the update. I assume my generator is surviving the testing process. Best. Doc

[Hank Jarrett]

Re: Ward Aero generator

Yea, yours is fine. He just has to fix the pulley that flew off when mine failed to finish the tests. I glad he has a stock of extra extra shafts and the field assembly wasn't damaged.
Hank

I'm also glad I wasn't there when it let go. There isn't a lot of room where the test is done. With two people in there I am betting at least one of us would have gotten hit by flying parts. We REALLY need to put a cage over that test rig. He said it had never happened before in several decades.

[Larry Lyons]

Re: Ward Aero generator

Yea, yours is fine. He just has to fix the pulley that flew off when mine failed to finish the tests. I glad he has a stock of extra extra shafts and the field assembly wasn't damaged.
Hank

I'm also glad I wasn't there when it let go. There isn't a lot of room where the test is done. With two people in there I am betting at least one of us would have gotten hit by flying parts. We REALLY need to put a cage over that test rig. He said it had never happened before in several decades.

No but he had never had a piece of genuine crap that some engineer was trying to put in the air!

Larry

[Mark Julicher]

Re: Ward Aero generator

Hank,
Doc's Ward Aero Generator mounting platform is nearly ready to fly. Has there been any word from RCS?
Tnx.

[40tcrate]

Re: Ward Aero generator

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