wing_designer_manual V1.1
Contents
1. Si LS ell Slols Since the spar of a cut wing 1s thinner than in the milled version it can be positioned at the highest point of the airfoil without colliding with the joiner At the end of the construction phase we will export the foam core data to the STEP FOUR polystyrene cutter The connecting ribs will also be output to the STEP FOUR milling machine and milled from 2mm sheets of epoxy 5 1 Modifying the Wing Data Delete superfluous parts 2001 STEP FOUR GmbH Open the wing file which you previously stored under the name Electric Glider Complete Sheeting Delete all the inter ribs With the right mouse button click on the joiner 4 entry and delete it Do the same for joiner 3 joiner 2 spar 3 and spar 2 Wing H Wing Joiner 1 Wing Joiner 2 er HI New wing joiner Delete wing joiner Deactivate the leading edges and the flaps The top view should now look like the screenshot below 200 _47 Apr Styrofoam Cutting optional module AOS SS CT Insert segment The 11mm hole for the wing joiner 1s to coincide with the core cut But as we do not want the hole to be drilled through the entire first segment an additional segment is inserted eee Click within the area of the first segment ngert single rib WEE E with the right mouse button to open the Distribute ribs evenly fly out menu Delete ribs Call the function Insert segment Insert segment2. AOST TET 3D View To check your construction data you can also display a wing in perspective in 3D For this you click on the 4 switch After activating the window hold down the left mouse button and rotate the wing anyway you like Click on the right mouse button to change the mouse function mode Watch out for the mouse pointer symbol on display In addition to the rotation function you can move the coordinate origin and enlarge or reduce the size of the display E Nurfliigel Nurflugel If you move the mouse pointer to the left edge of the window a menu will unfold with various features for displaying the wing S 0 Scaling T Proportional H x af Z To show the inter ribs start by calling the view for the set of ribs in the graphic display window because only then will all the inter ribs be calculated Elements IV Airfoil upper side i IV Airfoil lower side I J IV Wing joiner M Spars MV Leading edge MV Trailing edge IV Aileron flap IT Upper segment MV Lower segment lV Ribs MV Entire wing eee wl WO 4 2001 STEP FOUR GmbH 11 Hii Program Structure AOS G Leet i 2001 STEP FOUR GmbH 12 WING Wing Editor AOS OG ICI 3 Wing Editor The WING designer is purely a construction program In other words the user is assumed to have the necessary experience
3. Ge Portrait Landscape Tiled pages Overlap horizontal Ju frm The overlap values show by how many millimetres the printed areas of the sheets are Overlap vertically 0 000 mm Cancel Printer to overlap As you can see in the screen shot below the wing layout in our example can be output in eight separate sheets lli Wing Designer Test nach Handbuc eA lol al al DI Ges pormi JE Genen E terkinas ae 2001 STEP FOUR GmbH 4 Output of other views Alphanumerical output 2001 STEP FOUR GmbH Wing Editor All the other angles can be output as described for the top view All you have to do is select the required angle from the bar of switches Get ica eel ed Bajs in the graphic display window Ji Wing Designer Test nach Handbuch EAIA oela Dj Ge ISCH z ovewiow E Markings Stepfour Wing Designer File C Programme Wing Desiqner Wings Test nach Handbuch s4w Page 1 5 Seite 1 In the example below for example a 1 1 set of ribs is output If you have activated the alphanumerical input window instead of the graphic window and you call the E print preview function the data are output in the form of a list 4 Wing Desi fesigner Test na Test nach Handbuch E gt 11 0 al S PI Wing parameters Total length 1360 000 mwm with 3 segments Wing Joiner 1 Pocwmt Ciccle Diane ee 11 000 en X Stact positian cel to leading e e
4. smf sl Cancel Export options 1 Drawing unit mm 1 000 Data unit Ce Hib set C Top view C Front view Element Layer Element T Contour 4 Ribs i F Leading edge Orig contour Outline E F Trailing edge IT Name 2 TI Spars IT Sheeting Wing joiner qu KS T IT Ajleron flap AAT RRRRaRRIREIRbR RR IT Fixture support L E Upper sheeting r P TI Fixture support T E T Lower sheeting File formats Select to define the 296 a tpe file format in which the required data are to be exported You can choose between three different formats nave as type DF Dateien def SMF Dateien srt Export options glass BETT baer HPGL Dateien Te ot 1 Drawing unit mm 1 000 el Data unit SMF file STEP FOUR milling files DXF file Autocad Data eXchange Format commonly used import format for CAD systems HPGL file command language for HP plotter systems can be imported by many drawing and milling systems 2001 STEP FOUR GmbH 43 ANING wale a Export options Output units Alb set 2001 STEP FOUR GmbH SLT LET Output of DXF HPGL and Milling Files Export options 1 Drawing unit mm 1 000 z Data unit Ge Rib set C Top view Front view Element Layer Element Layer kg Contour Ribs f Leading edge E T Orig contour Outline E z F Trailing edge E m jame W spar Jk IT Sheeting E Wing joiner fe Alleron flap D The
5. H Segment 3 LL Help position root airfoil position tip airfoil C Bel to leading edoel 1277 CG ES C Bel to leading edge CG ES iC Bel to trailing edge 19 500 ES amp Bel to trailing edge 69 500 z 4 Ge At highest point position Ce At highest point position Starting segment f SS Ending segment I Align to airfoil W Upper side h lower side Spar dimensions at root ahe Jao Height PS mm width 6 000 i mm Spar dimensione at tip whi bom Height mm width 6 000 SP mm The main spar is to extend along the ribs on the top and bottom sides and is to be aligned with the airfoil The spar should also be aligned at the highest point on the airfoil To do this activate the corresponding option fields as indicated in the screenshot Spar in The spar in the second segment is defined in exactly the same SH wing segment way except that here number 2 is given as the starting and end position root airfoil position tip airfoil C Bel to leading edge 31 200 C Rel to trailing edge 69 800 Fa Bel to leading edge 2271 n ES Bel to trailing edge E9500 ES Ce At highest point f position Ce At highest point Z position Starting segment E ET Ending segment E Spar dimensions at tip Height 13 000 out Width 16 000 m rmm M Align to airfoil M Upper side Jh low
6. The coordinates are displayed in a table Here the coordinates are shown from the tip of the airfoil along the top to the L E and along the bottom back to the tip 100 0 100 This type of display is used for Eppler airfoils especially 6 2 Digitizing Unknown Airfoils To be able to digitize a scanned airfoil the airfoil must be available in a bitmap format BMP A sample file in this format is already stored in the airfoil directory To process the sample file proceed as follows Load background Click with the right mouse button on the graphic input window and then on Features Background Open Ed Lookin E Airfoil S Al cl Mi 1 93 575 ef 1205 575 fe Profscan File name Profscan Files of type Bitmaps D bel Cancel W Preview Width 2090 pixels Height 689 pixels Colors 2 mono Size 177 Kb Open the profscan bmp file in the Airfoil directory and 2001 STEP FOUR GmbH 56 ft Airfoil Editor optional module AOS ITED click in the features window on Show background image The lower section of the scanned picture is aligned along the red chord Move origin of Now the red chord must be placed in the center of the scanned zo coordinates airfoil With you zoom in the area of the L E Click on the origin of the coordinates between the H 1 two rulers hold down the left mouse button and place the origin exactly on the point of intersecti
7. airfoil Je programme rat 49 s4p D H Depth SE Depth 8 0 000 Thickness 2998 Thickness a994 Camber 1 554 Camber 1 584 Wacb pndout ie Wash infout CG Sweep angle Y shape P Automatic computation P Automatic computation Reference None Reference C None C Leading edge D om H mm Upper side 0 000 E MN 7 25 Line 67 500 MM IC Chord haa IMM Ge Trailing edge 5 000 mam C Lower side Lo m MM Behind each input field there are buttons with the units eet Et relative to segment root MM INCH absolute in relation to origin of coordinates BER and tal respectively Click on the switches to select the unit you require Now enter the parameters for each wing segment in turn Any change in value in an alphanumerical field means the data concerned have to be recalculated In the case of complex wings such changes would lead to considerable delays This is avoided by waiting a while after data input before carrying out a new calculation If entering a multidigit number is very slow the delay can be passed over and the input field reset To avoid problems caused by input errors you can set the time out to between one and five seconds in the Calculation time out field in the Options gt Basic settings menu dit View Options Window F el F General data Basic settings Update names irer Ari Font m T
8. consist of only one or two segments matching the top view In addition of course the geometric data can also be defined for objects such as the leading and trailing edges the sheeting rudder flaps etc seg 1 Seg2 l Segment3 Seg4 Segment5 Seg __ Le n tc a eee JL E E eg Lt LG 4 eee ee LJ _S a _ 4 spoiler Aileron For complex wings involving rudder flaps and complicated spar and dihedral V shapes therefore several segments are required to define the extra elements Apart from the segment related objects mentioned above there are also parts that are defined as overlapping several segments or overlapping the entire wing Spars and joiners belong to this category The starting and final point of a spar always coincides with a segment limit whereas joiners can be positioned freely within the wing ait Program Structure AEC SCEI 2 4 Displaying the Wing Structure A wing can be displayed using three different methods Alphanumerical Display Click on the switch to activate the alphanumerical display window In the upper section a wing is shown in the form of a hi
9. field 1 Drawing unit mm 1 000 Data unit defines how the numeric values are to be converted during output For SMF files the conversion is always 1 1 In other words Imm in the WING designer corresponds to Imm in the milling software In DXF files the measurement unit is not defined so that a value of 1 0 originating from a CAD program may be interpreted as 1 inch 25 4mm Depending on the units prescribed by your CAD or milling program you will have to adapt the value for the file units In the above example therefore you would have to enter 1 25 4 0 039370 Three basic export options are available In the set of ribs version the cross sections of all the ribs are output Using the checkboxes you can indicate which elements are to be output If you need the output file as a milling file for your STEP FOUR milling machine for instance simply click on the checkbox M Contour Ribs and if necessary TI Name The contour ribs elements contain the entire contour and taking all the sheeting spars etc into account If on the other hand you wish to use the data for further processing in a CAD program you can select the elements that are to be output individually In other words each element is available for further processing _44 ANING f 2S y d Zeep GE ACT Top view C Front view 2001 STEP FOUR GmbH Output of DXF HPGL and Milling Files In the section shown below that is separated by a line ad
10. of the segment required Layer J 3 setting will normally be the standard output setting The output options of individual objects will only serve for special applications C Single objects Element Element anamal ara E iraina edge E Airfoil and sheeting 3 Spare Wing anere Leading edge In this case the activated objects are output separately and the cutting procedure will have to be defined afterwards in the STEP FOUR professional cutting software 2001 STEP FOUR GmbH 53 ANING AOS EDP View of the cutting file Inverted cut 2001 STEP FOUR GmbH Styrofoam Cutting optional module BC STEPFOUR F3E ST 1 SCF File Handling Cut configuration Position Cutting Functions Options Help e 2 A X 0075 000 Y 0045 000 E E le W dia B X 0075 000 Y 0045 000 2 pee ry 0 5 10 150 200 E 200 360 u00 om oul w e l m AAP oor ry m Ki 2 T gt FORE Se evan sent zb D PA t Pe A E e i WE St K oP i ell ef gt fol overall size 256 641 22 875 mm 64222 KB The above screenshot shows a 3D view of the cutting file loaded into the STEP FOUR professional cutting software The block dimensions the coordinates at the corner points etc have all been preset The only thing that still has to be defined is how the joiner is to be cut in a single cut together with the top side or during its own cycle Thanks t
11. window is opened Since the F3B wing consists of three segments you must attach another two segments to the given segment K wing editorl Ioj x E 100 50 millimetre leer simge ne heet several niis Distribute ribs evenly Delete ribs hee segment Delete tegment Add segment millimetre Display Help Click with the right mouse button on the wing segment in the graphic window and then on Attach segment in the fly out window This generates the second segment Use the same method to attach the third segment Then click on Fit in to display all the segments in the graphic window E wing editori 7 2 Biel x P 100 200 300 400 500 E milimetre If you do not see the entry mask screenshot below on your screen click on the table icon in the symbol bar Click on the Segment 1 entry in the S SE SC hierarchic tree under E Bee Ht Wing to activate the ag input fields for this segment in the lower Segment 3 DER ANING ME SEG Leet Define wing contour Set units 2001 STEP FOUR GmbH Wing Editor The lengths depths and sweep angles have to be set for each of the wing segments E Test nach Handbuch 7 1 B iel x El Wing E Segment 1 E Segment 2 E Segment 3 Segment length 725 000 m mm E Modifiediantol M Cert segment divisible Root airfoil Je sprogramme Wa 49 sdp w F Modified airfoil Right segment divisible Tip
12. 35mm Once all the ribs have been inserted the wing for our electric glider will look like the one shown below Ribs with a joiner slot are not milled from 2mm balsa wood but from Airply with the same thickness E Test nach Handbuch 2 D H 100 200 300 400 500 600 700 800 5 x 130 Millimeter 1100 1200 100 200 100 300 34 ANING AOSC AR Look at set of ribs Store wing Millimeter 2001 STEP FOUR GmbH I x I sof E Test nach Handbuch 7 2 Iof x 0 T 100 200 D l i iii Bes RES Io ees Millimeter Wing Editor By clicking on je Set of ribs you can look at the layout of the whole set of ribs Use one of the four magnifying glasses gi g GE S to zoom one or several ribs or to look at a construction detail Click on to store the wing data on your hard disk Enter the file name E glider complete sheeting 35 ANING wale POT EH Wing Editor 3 10 Building a Wing with Partial Sheeting Top sheeting segment 1 If light wing loading is more important to you than stability you can use the WING designer to design a wing with partial sheeting Later you will iron light weight foil onto the wing If you intend building an oldtimer model then of course you will have to use tissue To facilitate the assembly of a partially sheeted wing it is recommended to pull the front sheeting over the main spar and to let th
13. Construction Software for Model Plane Wings STEP FOUR 1999 All rights reserved Version 1 1x User Manual VertriebsgmbH Haunspergstrake 90 A 5020 Salzburg Austria Tel 43 0 662 4593 78 0 Fax 43 0 662 459378 20 e mail office step four at Internet www step four at ANING AOS TET 1 Introduction Top performance without the need for special CAD know how Window technology for an improved overview Includes more than 1100 airfoils Airfoil editor optional Versatile output facilities 2001 STEP FOUR GmbH Introduction Most airfoil programs are based on the construction of individual airfoils or tapered wings The STEP FOUR WING designer however enables you to build complex wings including spars joiners leading and trailing edges the sheeting rudder flaps and fixrure supports etc interactively on your computer screen Simply click on your choice of airfoil in the airfoil data base provided which contains a fantastic selection of more than 1100 airfoils The WING designer has an impressive range of features enabling you to design aerodynamic wings using any geometric data quickly and efficiently When developing the program STEP FOUR made sure that the WING designer could be used by model builders at once including those who have no experience with CAD programs Several windows provide views not only of the top view of the wing but from every angle You use the
14. Delete segment Insert Segment EE Ge Rel to segment root 170 000 mrm C Centered Enter the values into the screen mask as shown in the screenshot With new segment limit is inserted at the end of the joiner C Rel to segment tip e e In the two first tapered sections the carbon fibre airfoil is to be mounted as the spar BI F3E Styro 7 1 OR x Adjust spar El wing Spar HI Segment H Segment 2 Segment H3 Segment 4 position tip airfoil C Bel to leading edge 1 20 ES C Bel to trailing edge E8800 ES position root airfoil Rel to leading edge 0 50 zi 63 500 Bel to trailing edge zal Fi Ce At highest point position Ce At highest point position Starting segment f l Wie Ending segment Tj M Align to airfoil W Upper side IY lower side Spar dimensions at tip Height 2 000 mm width 2 000 i m Spar dimensions at root Height 2 000 mm Width 2 000 i m Since the first tapered section consists of two segments the spar must therefore run from segment 1 to segment 3 To prevent the spar from protruding anywhere out of the foam core we will add 1mm to the thickness Instead of 7 x Imm enter 8 x 2mm for the spar measurement 2001 STEP FOUR GmbH 48 ANING See AREP Adjust segment Adjust sheeting 2001 STEP FOUR GmbH Styrofoam Cutting optional module As men
15. GmbH Styrofoam Cutting optional module As opposed to the milling procedure a wing core can be cut in various ways O The top and bottom sides of the core are always cut separately from the front In this version the cutting wire is unlikely to sag in the area of the leading edge As aresult the leading edge of the core is much more accurate A big disadvantage here are the extremely long dry runs required during the cutting procedure O The core is cut in one go starting at the rear edge of the core around the leading edge and back to the rear edge One disadvantage is that if the wire sags it can badly distort the L E To save time when handling blocks of raw material it is also possible to activate a mirror image cut In this version two cores are output above each other whereby the upper core 1s inverted along its longitudinal axis This enables a right and left core to be cut in a single operation Set the cutting parameters for the segments as shown in the following screenshots Should something in the graphic display window not be clear please refer to the online help system BI F3E Styro 1 Iof x Cutting Path Segment 2 2 Leading trailing edge ms Ajllerons Flaps D Sheeting Upper Side Sheeting Lower Side ne Cutting Path E Galeulation fram previous seqment Block length i 0 000 mm S Block depth E D00 mm Min block depth 23 873 mm Cutting path Mirr
16. ULE essesesesssecccccssececccssececccssecccccssececccssececcssseceeee 55 6 1 WORKING WITH THE AIRFOIL EDITOR cccecescececcececcececcscecescecescscesescecesceceecscusesceseseecasees 55 6 2 DIGITIZING UNKNOWN AIR FOULS EE 56 7 THE OPTIONS H Io REN 61 2001 STEP FOUR GmbH 65
17. V shape Lower side 3 5 Segment length 480 000 mm Modified airfoil Left segment divisible E tioditied airfoil M Right segment divisible Root airfoil e Sprogramme Mg1 49 s4n Ce A Depth 210 000 Thickness 6 998 Camber 1 584 Wash in out 0 000 Sweep angle 170 000 Thickness Ir Camber Wasbupout V shape Automatic computation Reference C None C Leading edge 47 000 C 9 Ei z Line 169 500 8 000 Automatic computation Reference C None Upper side D 133 C Chord E J26 Ge Lower side 3 SOU Mul e3500 3 wa H I Ge Trailing edge Do exactly the same thing for the third wing segment Segment length 155 mm Root airfoil Already defined for tip airfoil of segment 2 Tip airfoil RG14 10 depth 119mm Sweep angle tip edge 1 1mm Dihedral V shape lower side 3 5 Segment length 155 000 m mm ke kiodified arroil T Celt segment divisible E kiodiied anaill M Right seamen divisible Root airfoil RS Depth 170 000 Thickness m Camber 1 583 Wash in out Sweep angle Tip airfoil NEEN 410 s4p P H Depth 119 000 Thickness 10 000 Camber 1 583 Wash invouk 0 000 V shape Automate computation Reference None Leading edge ez OO M Md Ce z Line 116 750 MM Ce Trailing edge L 11 000 i m E Automate computation Reference None Upper
18. ae a 000 aen Y Stact pa saitin cenbeced on ake Length 000 m K i DE IC Dcegeee Y 8 angle 0 000 Degree Wing Joiner 2 Pocwmt Ciccle Oiamebee 4 000 om Stact positian ing ten D vm Stact pos aition casted gg Length 50 000 om 2 8 angle 0 000 Deegeee 2 8 angle 0 000 Begeee Wing Joiner 3 le ODiamebee 4 000 mm cel to leading edge 96 000 mm el eel to choed 31 000 mm Length 100 000 mm X 3 angle 0 000 Ocegeee Z angle 3 000 Degeee Wing Joiner 4 Poemet Ciccle OD ane ter 4 000 vm X Stact positian cel to leading edge 155 000 om Y Stact position cel to hoced 31 000 mn Teagth 100 000 X 2 angle 0 000 Deegeee 2 8 angle 3 000 beye baal 41 Spac uppec and limec aide feom segment no l to segment no l Spac Spac ame im Se ig KR ik Sr D we an Alignment align to aicfoil c H poaition caot aicfoil at highte Eya t iS DH R position tip aieioii at Seite e Cp AH Pile C Peageanm Wing Designec Winga Teat nach Handbuch a _42 ANING D tpnt of DXF HPGL and Milling Files AO SOGT ICT 4 Output of DXF HPGL and Milling Files Optional module With the aid of this optional module the wing data can be used for other purposes in a CAD program or transferred directly to your STEP FOUR milling machine as SMF milling files The export window SME SEAN RES Save in E Program c File name Save as type SMF Dateien
19. am core with balsa sheeting as ailerons In our example a very thin Make T E airfoil is used using sheeting A solid aileron cannot be used because of the weight so neither of the two trailing edge types is activated in the screen mask The T E is therefore formed by the top and bottom sheeting only 2001 STEP FOUR GmbH 22 WING Wing Editor i AOS CTET NN 3 6 Ailerons The STEP FOUR WING designer generates ailerons with a dihedral section at the lower side of the wing For this the program needs four parameters The flap position either related to the t leading edge of the airfoil or to the t trailing edge the sheeting thickness in the rudder slot marked s and the two angles o and B WW The rudder depths for the flap and aileron can be found in the Flap definition construction drawing at the beginning of the manual Segment 1 Flap position of root rib 51 mm Flap position of tip rib 46 mm Select 2 mm for the sheeting thickness To achieve large rudder amplitude set both angles to 10 and 25 Test nach Handbuch 7 2 Of x E Segment 1 gt Leading trailing edge Sheeting Upper Side pa Sheeting Lower Side hs Cutting Path Help Segment 2 E compute from previous seqment I Generate aileronsflaps Flap position related to leading edge Flap position t root rib i 79 000 UU BS A r A Ti Se Z Flap position IT tip rib Ge Flap pos
20. bute ribs evenly Ribs have fixed distance Reference point 5 Left C Right Number of ribs 4 max i i o Rib distance 40 000 mm CH Space between ribs 37 000 mm min 0 000 300 Enter the values as shown above Click on Accept to transfer the data 2001 STEP FOUR GmbH 32 Apr Ding Editor Me SEG TXT Fill up with The remaining ribs are to fill up the whole segment and are to have approx 60mm spacing between them Click again with the right mouse button in the empty area of the first segment Call the Insert several ribs function Activate the Distribute ribs evenly button If you now alter the remaining ribs E R Insert Ribs Limits Thickness of material 2 o00 m mm fe Distribute ribs evenly C Ribs have fixed distance Reference point G et C Fight Number of ribs max 220 Se SSES Rib distance e ea mm Space between ribs mm min fo 000 number of ribs the relevant rib distribution will be shown in the field Rib spacing The graphic window also displays a preview of the ribs Select 8 inter ribs This is equivalent to a spacing of just over 62mm Then click on Accept Ribs in outer Define the joiner in segment 2 as you did for the ribs in the wing joiner area root As the joiner is shorter only 22mm are indicated In addition you must activate the f Fight button for the Reference point to locate the ribs as calculated from the end
21. contour of each rib As a milled notch fixture support must be used as the leading edge it only has to be sanded a little At the same time the notch fixture support sets the distance between the ribs In the above screenshot the wing joiner has already been drawn so that you can see that the 9mm joiner tube made of brass for the 8mm carbon rod does not fit behind the main spar This is why the tube is simply placed in front of the main spar 26 ANING AL COO ERP 3 8 Wing Joiner Please note Insert joiner 2001 STEP FOUR GmbH Wing Editor You can choose between circular and rectangular wing joiners Wing joiners sometimes only protrude a little into a segment or serve to connect two wing sections thereby protruding into two segments That is why wing joiners are the only objects in the WING designer program that can be defined completely separately from the segment data or limits But this means that you must ensure that the joiner is really located at a sensible position when defining it In theory you could even locate a joiner a long way outside the wing The drawing shows the connection between a wing center piece and the outer wing In the top view the connection looks fairly adequate But seen in 3D the connection is clearly totallyimpractical To insert a joiner in the wing click with the right mouse button on Wing and New Joiner Mew spar Add segment Help e S
22. d in the four blocks of polystyrene 5 2 Exporting the Cutting Data Call export mask 2001 STEP FOUR GmbH With the aid of the export function the wing data can be used to create cutting files for the STEP FOUR professional cutting software Click on the switch to call the export mask for the cutting data SCF Export KEN Dave jr CH wt design Tl cl P51_ zeg a Sparcuke P amp l_sege zl test SEG_1 ja SEG_2 sparcut el sparcutl File name Je st save as type 1SCF Dateien P sc Cancel Export options C Single objects Element Element Layer E Griginal entail E trating edge E E Airfoil and sheeting i E Spas E ii ing omens gt Leading edge _52 ANING AOS TEP Setting the export options Styrofoam Cutting optional module Create a subdirectory in your S4cut program directory As the S4cut software runs under DOS and so only uses eight characters for the directory and file name you should also restrict your name to only eight characters SCF Export Ei Ei A c eE Save in CN ww design ap GpDarcul el test a PR zent el DEI zen SEG_1 SEG_2 el sparcut el sparcutl File name Ge mme save as pe SCF Dateien sch Y Lance S i SS OE irm mbm Ka Usually the segments vary in length so each segment is output in its own separate file Segment bh Enter a file name for the segment and in the E ei entry select the number
23. ding and trailing edges separately This makes it very easy to transfer the components to the actual material Alt ntroduction EE Interfaces for CAD sg the pg of special a the data EE ra a aed tems and STEP ormat for processing in programs Model builders who OR a t already own a STEP FOUR CNC milling or cutting machine really i i aca have an easy time since special export modules are available that optional generate files directly in the correct format for the machine concerned These export modules refer to the same basic data In other words simply press a button and the wing can be produced as a conventional rib construction or in the form of a foam core wing 2001STEP FOURGmbH ANING ACS TET Program Structure 2 Program Structure The WING designer has been designed for the Windows 95 und 98 operating systems so that Windows users will feel at home very quickly Before constructing your first wing however you should look at the following user instructions the main icons and hot keys Certain symbols will look familiar but get to know the special buttons The Wing designer is controlled mainly with the aid of symbols and hot keys from the symbol bars Here are the most important ones General 2001 STEP FOUR GmbH 2 1 L w Ri S OI S 8 hl I P D D pD Symbols and Hot Keys New Key combination STRG N create new airfoil or new wing Open file K
24. ditional objects can be output separately Fixture support L E g IT Upper sheeting D Fixture support T E E Lower sheeting iz Activate the checkboxes Fixture support L E and Fixture support T E to export the contours of these objects Using the Upper sheeting and Lowersheeting fields you can output the sheeting procedure This gives you the exact geometric data for producing matching sheeting components In addition to outputting individual components you can also output the top view or the front view of a wing in the form of a file which is useful if these data are to be processed further or implemented in a complete CAD drawing If one of these output options is selected the checkboxes for certain elements are blocked because there is no point in outputting a trailing edge or the definition of a flap in the front view _45 WIN Gm Out of DXF HPGL and Milling Files AOST IET 2001 STEP FOUR GmbH 46 ANING ale to a Lf Styrofoam Cutting optional module 5 Styrofoam Cutting optional module Cutting with the WING designer is even easier than milling Let us take the wing of an electric glider as our example We want to improve the wing s stability and make it a high tech wing The wing is to have a carbon spar and only 1mm of balsa sheeting For the spar we will use a carbon fibre airfoil from R amp G with a diameter of 7 x 1 mm and a length of 2 metres order no 600 130 2
25. e Eg a wi Delete selected points et Ert Smooth selected amol segment Fa Align chord FE Copy upper to lower side Fr Copy lower to upper side Fa vw Show upper side Chrl Shift O vw Show lower side Ctrl Shitt U vw Show Skeleton line Ctrl Shift k Show chord Ctrl Shitt S Skov amal in background Et ESHE vw Show image in background Chrl Shitt B Properties Alt E nter BEI Alternatively you can use function keys Position the mouse pointer at the required location and press the lt F3 gt key to insert a point in the top side Move the display range and so digitize the entire top side of the airfoil Nine to ten coordinates are quite sufficient Use the same method to set coordinates for the bottom of the airfoil Using the function keys set a point along the bottom with the aid of lt F4 gt 2001 STEP FOUR GmbH 58 ANING AOS SES Smooth airfoil Align chord 2001 STEP FOUR GmbH Airfoil Editor optional module At the L E and along the airfoil contour the rib still looks jagged But we can soon change this 10 10 i l If you click on the Symbol smooth airfoil The Wing designer smooths all the coordinates and calculates the curve of the L E background you will see a beautifully rounded digitized airfoil and curvature line on the screen 10 Look at the chord and you will see that it points slightly upward like the scan previously In order to be able to use the air
26. e data you input it is a good idea to change various values and check the results in the graphic view You can also use the mouse to alter the position of the joiner in the graphic window Position the mouse pointer on the end of the wing you wish to change hold down the left mouse button and drag the joiner into the desired position Observe the effects on the alphanumerical values too Insert a fourth joiner and define it as shown below ED Test nach Handbuch ek Mel E El Wing oo Wing Joiner 1 o gt Wing Joiner 2 Wing Joiner 3 g ing Joner H4 Hel Ge Spar 1 TEIE Spar 2 Format Dimension at joiner start Dimension at joiner en C Rectangle Ge Circle Width DO Height E 000 Dei mm d Width 4 000 Height f LU P Start position 7 Start position GG Bel to L E C Centered on skeleton line Ge Rel to chord 21 000 ror End pos Dist Coord s 155 000 T mm y 36 234 Imm 2 1254 863 z mamn C Rel toT E At thickest point Start pos Dist Coord x 155 000 mm velo mm z 1155 00 mm k 100 DUU e D DUU S i 13 000 p Y angle Ej N 30 WING Wing Editor AHO Sie HET Double In order to produce a removable segment 3 the rib involved has final rib to be made twice once as a final rib for segment 2 and once again as a root rib for segment 3 Do this as follows Se
27. e graphic display of a wing the wing data need to be recalculated whenever a numeric input field is altered The input of multidigit numbers would therefore call for a complete calculation after every number which would lead to considerable delays This is avoided by indicating a value between one and five seconds in the calculation timeout field Choose the time value that suits your purposes best In the file index cards for the various objects you can preset the values that are transferred automatically when the part concerned is inserted In addition to the dimensions positions etc various codes can be set for the ribs and L E T E In the Sp BS gt field an individual code sequence can be composed by indicating a combination of fixed and variable characters Variables begin with amp and a letter following this that stands for the text or number that is to be implemented Click on the gt button to display the list of all the possible variables Select the required variable and it will be transferred to the code field 2001 STEP FOUR GmbH 61 ANING ACSI ET Example 2001 STEP FOUR GmbH The Options Menu List of possible variables amp b Name The text for the name or rib code 1s entered amp B Airfoil file The file name for the airfoil used 1s inserted For inter ribs with different end airfoils tapered is included instead of the file name amp S Segment number The segment number is inc
28. e rear sheeting protrude by 10 to 20mm over the hinge slot of the ailerons and flaps This has to be done for both the top and bottom sheeting If the wing has been joined and dried out cut the flaps out along the hinge slot Enter the following parameters for the three wing segments Test nach Handbuch e g x Segment H z Leading tralling edge z Allerona Flaps d heeting Upper Side LL be Sheeting Lower Side i Help E Cutting Path H Segment 2 M Sheeting upper side E Galeulation from previous segment Thickness fi DUU mrn C Complete sheeting Ge Partial Sheeting M Partial sheeting at leading edge Foot Absolute om gt bei Ge Absolute foo jooo mm Upto E par Ge Up to first spar M Partial sheeting at trailing edge Foot Tip ie 71 000 af fe e opp E Absolute ei mm Absolute mm Up to last spar Up to last spar IT Cap strips Segment 1 top Top sheeting 1 5mm partial sheeting in front up to first spar Partial sheeting behind root 51 20 71mm Partial sheeting behind end 46 20 66mm 2001 STEP FOUR GmbH 36 Apr Ding Editor Se G 7 Top sheeting Deactivate the C Ealculation from previous segment checkbox as well segments 2 and 3 and use the same method to enter the data for segments 2 and 3 Segment 2 top Top sheeting 1 5mm Partial sheeting in front up to first spar Partial sheeting behind root 46 20 66mm Partial sheeting behi
29. egment 2 H Segment 3 Name f 360 000 mr Total length _27 Apr Ding Editor SE G DE Joiners at the We wish to insert a tube with an outer diameter of 11mm and a wing root length of 170mm as the main joiner in the root area of our wing A second joiner 4mm in diameter and 50mm long is to lock the two wing halves into place Such joiners can be positioned in the root area by using the fields underneath the Poston and M startposition entries In our example the two joiners are to be centered on the center line of the airfoil Enter the following parameters for joiner 1 First joiner E Test nach Handbuch 7 2 Mil Ei H Segment 1 H Segment 2 Format Dimension at joiner start width fioo he JP OO Ej Height omg j Dimension at joiner en d width 11 000 mm E El C Rectangle Ge Circle Height E 000 T Start position Ce Centered on skeleton line C Rel to chord o o00 Im End pos Dist Coord sg 62 000 Imm 3 469 em gt f 70 000 mm nin Stark position Ge Fel to L E C Rel to T E At thickest point Start pos Dist Coord x 62 000 rom y 2 463 mm z 0 000 mm Ee 170 000 mm aa 10 000 S die angle FS NM aa YZ angle 0 000 Li NM The Start pos Dist Coord and End pos Dist Coord fields are calculated automatically and so do not need our attentio
30. er side Spar dimensions at root Height 13 000 mm Width E 000 mn segment 2001 STEP FOUR GmbH 19 Wing Editor EL Segment 1 E Segment 2 H Segment 3 In the graphic view below you can see the position of the main spar in the wing 2001 STEP FOUR GmbH 20 ANING AOS TET EX 3 4 Leading Edge Cut off Tube Fixture support cut out Leading edge Ist segment 2001 STEP FOUR GmbH Wing Editor Click on the sign in front of Segment 1 to open the detailed structure of the segment Select the L E T E entry to display the input fields for these objects in the lower part of the window The WING designer features three leading edge formats Here the front of the L E is cut off vertically to the chord at the position indicated Using this format you can fit a CFK tube for example into the leading edge You can select any diameter for the tube With the aid of the fixture support format a leading edge with notches for the ribs is produced The notches in the L E and in the rib are always half the defined width Later when the wing is assembled the leading edge produced Serves as a fixture support for the exact space between the ribs Further options allow the alignment of the airfoils to be varied or an insertion under the sheeting A cut out merely means that the leading edge is not milled Usually a pine strip of a matching size is inserted T
31. erarchic component tree In the lower window section the corresponding data are displayed for the selected component By clicking on a certain object with the right hand mouse button the fly out menu corresponding to this object is opened In the drawing above for example the current segment is to be deleted E E Glider Wingspan 1900mm 1 Click on the or box to switch the display of the segment on or El wing off Wing Joiner 1 ce GL Segment length 201 In the case of certain mouse drivers the function of the right mouse button can be defined individually You must therefore set the function of the right mouse button in the lt context menu gt Otherwise you will not be able to open these fly out menus Graphic Display E Nurfliigel In order to work in a graphic DU U 100 20 300 400 S00 x window click on the 3 switch EE ER Here you can edit most parts and settings with the aid of the mouse The corresponding numerical values are updated automatically after inzana every graphic modification Insert several ibs At the same time numerical modifications to the alpha window are also always shown in the graphic display window Click on the right mouse button to open the fly out window related to the object concerned Distribute ribs everly Delete ribs 200 Insert segment Delete segment Add segment Display 300 2001 STEP FOUR GmbH 10 wait Program Structure
32. ey combination STRG O open existing airfoil or wing file Store file Key combination STRG S stores an airfoil or wing file Export Either DXF or STEP FOUR milling data For additional milling and DXF export module only Export STEP FOUR cutting data For additional cutting module only Print preview Print Key combination STRG P opens the printer dialog window Info General information about program version registration etc Help Call online help system Undo Key combination STRG Z undoes previous step Redo Key combination STRG Y Opposite of Undo function Zoom in Key combination NUM doubles size of section Zoom out Key combination NUM halves size of section Zoom window Function key F11 enlarges the section you have selected with the mouse Zoom Function key F12 fit in window ber Leed Koch Wing editing 2001 STEP FOUR GmbH Program Structure E Activate measurement function Object edit is deactivated Activate object edit Measurement function is deactivated a Display coordinate system Activate window Display edit wing data alphanumerically Activate window Display edit wing data graphically Possible graphic views E Top view Front view Location of airfoils in relation to each other gt View of airfoils above each other Segment view of polystyrene blocks d Display polystyrene blocks above each other Displa
33. foil in the database like any other airfoil you must ensure that the chord is horizontal Click anywhere in the display area with the right mouse button to open the fly out menu for processing the airfoil Click on the New point upper side New point lower side F4 Pelete selected ponite lotr tErt L Smooth selected ainail segment ES Align chord Copy upper to lower side Fr Copy lower to upper side Fa E vchange upper and lower sides F9 vw Show upper side Chrl Shitt O vd Show lower sida hla oh item Align chord This causes the airfoil coordinates to be converted and the chord becomes horizontal 59 ANING AOS de Leet i Scale airfoil Close end of airfoil Store airfoil data 2001 STEP FOUR GmbH Airfoil Editor optional module Finally the airfoil is scaled so that the X coordinates are exactly between 0 and 100 E Si Airtoil Parameters Fie Representation Background Image Background Airfoil Thickness 16 607 LS Position ESA UU E Chord 0 926 LS Position 45 000 E ero angle of attack 0 780955 Coefficient cml 25 Loo 0204 cancel _ Open the fly out menu again and click on Features Enter 100mm for the depth in the airfoil parameters card and the airfoil will be scaled to a standard depth of 100mm In the table you can see the coordinates that the WING designer has generated for you fully automatically The last two points of the top and bott
34. he width of the cut out in the rib matches the width of the strip ee Tn our F3B wing we will P Fisture support Name insert a fixture support Pow as the leading edge Enter the values shown width oo E mee a here Thickness f S00 l rmm Offset C Sheeting thickness Ge Free ong mm Alignment to C Chod fe Skeleton line Are Apr Ding Editor CEET ET Leading edge In most cases the follow on follow on segments d Segment 2 segments for the L E will have the same shape Leading trailing edge Allerons Flaps Sheeting Upper Side e Sheeting Lower Side To avoid having to enter Cutting Path the data again and again for SEET each segment click on the lh Compute from previous segment checkbox Compute from Leading edge H WER previous segment 3 5 Trailing Edge For the trailing edge there are two formats available which you can also combine If a bought milled T E is used a cut section is defined as the trailing edge Cut section The T E notch looks just like that of the leading edge Please note Airfoils with very thin trailing edges may have to have a very wide fixture support because of the Fixture support By combining the notch and Cut section and notch section types the necessary combination del EE Kee width can be reduced This type of construction is particularly suitable if you intend using ready milled solid balsa or a fo
35. hickness of lines line type etc for the screen and printouts 2001 STEP FOUR GmbH 63 NNG ne Options Menu AOST ET 2001 STEP FOUR GmbH 64 Content j NIESEN Hee 3 2 PROGRAWNES TRU eo RN E TA TEE 5 2 1 SYMBOLS ANDi Te TRE EE 5 2 FLY OUT WINDOWS AND FEATURE MENuUs rein T TE TAE a 8 23 THE DATA STRUCTURE OF A WING DESIGNER WING cccoscececcececcsceccecececcecesescecescecesceceecs 9 2 4 DISPLAYING THE WING STRUCTURE ccceccsceccececcececescececcececcecscescscseececeecscessscessscesesceceeces 10 Alphanim rical DUIS DI OY Bis eege 10 G7 A016 EE 10 3 ANS EE ECH eege 13 3 1 DEFINING THE GEOMETRIC DATA FOR THE WING 13 a DEFINING THE WING USING THE WING DESIONER 13 3 3 INSERTING Se CDR E TEEN 18 3 4 IE TENG A EDIE AEN IER EIEEE INE EE EEN 21 3 5 APAN EDE EE 22 3 6 PTI RONG ee eeben ereechen deet ddeelel E 23 3 7 DEFINING THE SHEETINOG 25 3 8 e OINERA E 21 3 9 MOUNTING THE RBS IN THE WING onnies ATE e ATATAU 32 3 10 BUILDING A WING WITH PARTIAL SHEETING ccccceccececcccecescecscececcececescecescecescsceceecececees 36 zll PENTOUP TO THE WINGIDA DA EE Eege 39 4 OUTPUT OF DXF HPGL AND MILLING FILES cccccccccccccccccccccees 43 5 STYROFOAM CUTTING OPTIONAL MODULE csssssccccccsssscccccccsssccccceeees 47 GE MODIFYING THE re DATA EE 47 5 2 EXPORTING THE CUTTING DATA aean a a T a AT E AEA AEREN 52 6 AIRFOIL EDITOR OPTIONAL MOD
36. imeout ER Apr Ding Editor AOS de DI Geometry segment 1 Segment length 725 mm Root airfoil RG14 9 depth 230 mm Tip airfoil RG14 9 depth 210mm Sweep angle tip 5mm Dihedral V shape top side 0 Select airfoil Use the switch to enter the airfoil data from your airfoil database Upen ki x Look in E Airfoil ES al ch rg1495 rgl4al47 GU ol Sai 1 rgl5a213 rg File name fig 45 Files of type airfoil files V2 s4p E Cancel W Preview File Type 54F Version V1 0 Filter Info ERE PEO Vy Once the M Preview option field is active you can see the contour of the selected airfoil on the screen The range of airfoil data is relatively large as over 1100 files are included To save time when searching enter the initials followed by an asterisk e g rg as the file name Then only the airfoil files from the Rg series will be shown Select the rg149 S4P airfoil The wing section is tapered from the second until the end of the third segment The first wing segment is not tapered Load rg149 S4P as the tip airfoil as well 2001 STEP FOUR GmbH 16 ANING Ae SCGTICT Geometry segment 2 Geometrie Segment 3 Wing Editor Enter the parameters for the second wing segment Segment length 480 mm Root airfoil Already defined by tip airfoil of segment 1 Tip airfoil Not defined tapered depth 170mm Sweep angle tip edge 8mm Dihedral
37. ing Lower Side Cutting Path Help Segment 2 M Sheeting upper side E Galenlation fran previous segment Thickness 11 500 mm Ge Complete sheeting Partial Sheeting Batal sheeting at leading edge Ronk Ei Celtes 2 000 mm f Absolute 0 000 Im Up o hret spar Ge Up to first spar E Pertal sheeting attrailing edade opt Absolute jO 000 mm Absolute 0 000 Trans Ge Up to lashenar pita lash soar Gap stipe Clicken on M Sheeting upper side enter 7 5mm as the sheeting thickness and click on P Complete sheeting In the following segments the i Calculation from previous segment switch is activated automatically Now the settings are valid for all the other segments as well If you want to apply different settings for a segment deactivate the switch Then you can modify the data for that particular segment In our example however it is not necessary to enter any more data 2001 STEP FOUR GmbH 25 ANING AL COO ERP Display rib contour 2001 STEP FOUR GmbH Wing Editor Click on the je Rib set button and the milling contours of the root and tip ribs for all three segments will appear on the screen E Vollbeplankung s44 2 Oy x Millimeter Ki T T E Look at the narrow outer rib of the third segment and you get a Pa anil good idea of the way in which the WING designer aligns the main spar to the airfoil contour and generates the outer
38. ion Subdivision i Uer b i yaf cancel CAE w E Mu 20 NAVIN Wing Editor Output of a ee To output a 1 1 1 1 drawing se SEN ei T Caen I Markings drawing switch to e 100 and 00 M1 d e Wi Desi 200 M21 SPLA ay asrga activate the 300 M31 a M41 Marking checkbox The drawing is now divided into single sheets according to the printer format In the case of an A4 printer using the landscape format the screen will look like the shot below i Wing Designer Test nach Handbuch ei i lt gt nf wl l Sl Dl cose Jha lr Gergen E Markings Stepfour Wing Designer DH File C Programme Wing Desiqner Wings Test nach Handbuch s4w Page 1 10 Seite 1 To see how the drawing is divided activate the checkbox and you will see the following display on your screen Overview aAa BS al DI Ge Jha Jr feed Evans 2001 STEP FOUR GmbH 40 Wing Editor The overview shows us that 12 A4 sheets are required to print the drawing 1 1 Presumably fewer sheets are needed to print in portrait format Set print P e 2 Click on the Dh age layout layout symbol to adjust the settings Select for the paper f Portrait and click on Paper UK Format e Paper feed The Margin entry indicates how much margin 1s to be left during the printout R nder Millimeter Left L Z nn Bight 4 82mm Top 512mm Bottom E1 2mm Format
39. ition related to trailing edge Flap position T root rib 51 000 Flap position t tip rib 46 000 Thickness let alpha ia BS E ES SS Si El E E beta Enter the data into the mask for the flaps as shown above 2001 STEP FOUR GmbH 23 Wing Editor As for the first segment enter the following data to define the flaps of the follow on segments Segment 2 Flap depth of root rib 46 mm Flap depth of tip rib 38 mm Soa be zl rei K BEZ mo j m p e po Jao Segment 3 Flap depth of root rib 38 mm Flap depth of tip rib 27 mm frm Fe zl ze ks zoo Si CS CES SSES You do not need to click on the entry in the component structure to switch from one flap to another Using the entry to another and keys you can switch from one component 2001 STEP FOUR GmbH 24 l WING Wing Editor AOS AOS FET 3 7 Defining the Sheeting Ve ere torsional strength of E Segment 1 i the wing we want to Leadingtrailing edge sheet the top and Ailerons Flaps F Sheeting Upper Side bottom sides s Sheeting Lower Side completely with i Cutting Path 15 bal Click EL Segment 2 mm balsa 1CK On l l Segment 1 and then I Sheeting upper side alent on Sheeting upper side ED Test nach Handbuch ek Mil x E Segment 1 gt Leadingrtrailing edge Allerons Flaps E z Sheeting Upper Side 2 Sheet
40. lect the input mask for segment 3 EI Test nach Handbuch 2 Of x H Segment He Hel Segment 3 UE Segment length 155 000 mm Tip airfoil Je programmes rg1 410 s4p e H SE Fe al i Now the view of the set of ribs should look like this Test nach Handbuch 1 O x E 60 80 100 120 140 160 180 200 220 millimetre 20 20 40 60 80 100 120 As you can see a final rib is output for segment 2 as well as a root rib for segment 3 2001 STEP FOUR GmbH 31 WING Wing Editor AL COO ERR 3 9 Mounting the Ribs in the Wing Now it is time to define the wing ribs In the vicinity of the joiners the ribs should be mounted somewhat closer together In the remaining areas a certain number of ribs are to be distributed evenly E E m Insert several ribs CH Distribute ibs evenly Delete ribs Inzert segment D Delete segment Add segment Display CH Di Help With the right mouse button click on the first segment of the wing This opens the fly out menu for editing the segment Select the menu item Insent several ribs Ribs with fixed In the joiner area the ribs are to be spaced at fixed 40mm spacing intervals The main joiner is 170mm long so that four ribs need to be inserted The material should have a thickness of 2mm x EI S Insert Ribs Limits St Thickness of material 2 000 mm Distri
41. luded amp n Element number related to the segment The current number related to the matching segment is included amp N Element number related to the wing The current number related to the entire wing is included amp g Rib total related to the segment The total number of ribs in a segment is included amp G Rib total related to the wing The total number of ribs in a wing is included To label the root ribs the following code sequence has been defined Text Seg Variable amp S segment number Text Variable amp b text defined in the name field Text R Variable AN consecutive rib number related to the wing Text of Variable amp G total number of ribs in the wing The entry in the screen mask is as follows FRoot ribs Hame eo 85 8 d DN of amp G gt Rib name Foot Preview sai Bot ribi of BE Material thickness 2 00 mm z6 ANING AOS TET Update names Display The Options Menu This generates the graphic text below for a rib CH 20 ESeg ARIIDAE 20 This method helps you compose rib codes that meet your personal requirements You can follow the same principle to construct names for the fixture support of leading and trailing edges This command enables you to update all your labels by merely pressing a button if you want to alter the structure of the label or select a new labelling font This function serves to adjust colours the t
42. mouse to click on the spars rudder flaps sheeting and joiners so as to make sure these are located correctly At a glance you can see if everything is perfect or if there is still a construction error You notice immediately for example if a spar joiner or maybe even the sheeting is perforated In a 3 D window it 1s also possible to rotate and move the wing inside a 3 D window anyway you like As a result you always know exactly what the wing will look like in when it 1s finished The WING designer package includes a database with more than 1100 wing airfoils In addition for those of you who want to use your own airfoils there is a powerful airfoil editor with which you can enter and edit airfoils using tables or graphs In the event of an airfoil without any coordinates you can scan it and load it as an image in the background with the airfoil editor and then vector it easily and quickly The WING designer is not only a comfortable construction tool but also allows designs to be output professionally If you have a plotter or large scale printer drawings can be output directly 1 1 If you only have an A3 or A4 printer the drawing is split up into several sheets that can be joined up into one large complete drawing This is really easy as the WING designer printouts are clearly marked to show where the sheets are to be joined up In addition to the top view set of ribs front or side view you can even output the sheeting and the lea
43. n here Enter the following data to lock the wing halves Format Second joiner Dimension at joiner start Width 14 000 T mrm width 14 000 ight O00 i ight g D Height 5 000 mm Height WU Stark position Dimension at joiner end C Rectangle Ge Circle Sr Ei Le mm Stark position zait 155 000 ben CG Bel to T E 75 000 5 Imm Atthickest point Ce Centered on skeleton line Bel to chord fo o00 ET imn End pos Dist Coord se 155 000 E mm 2 606 5 mm 50 000 Imm Start pos Dist Coord pe 155 000 mml GER Feel com 5 mml Length m fmm aa 10 000 S die angle el NM aa 10 000 S angle wal NM 2001 STEP FOUR GmbH 28 ANING AOSE ARP Joiner on outer wing Ist outer joiner 2001 STEP FOUR GmbH Wing Editor After completing the input you can view the wing in the graphic display window Simply click on the switches Graph Ki and Top view Ei Now you PERE EER CEE rer can see the position of the joiner tube and the lock To be able to produce a speed and or a thermic version of the wing it should be possible to exchange the end segment by inserting a joiner This is done by inserting two 4mm tubes into segments 2 and 3 To be able to position the joiners in relation to the origin of the coordinates you must activate the fields Sta
44. nd end 38 20 58mm Segment 3 top Top sheeting 1 5mm Partial sheeting in front up to first spar Partial sheeting behind root 38 20 58mm Partial sheeting behind end 27 20 47mm Enter the same parameters for the bottom sheeting of the three Bottom sheeting wing segments as well Test nach Handbuch _ O x Cutting Path Fl Segment 3 Leading trailing edge Allerons Flaps Sheeting Upper ge Sheeting Lower Side D Help Cutting Fath M Sheeting lower side IT Calculation from previous segment Thickness f 500 mm C Complete sheeting Ge Partial sheeting I Partial sheeting leading edge Foot Tip e ong 2 000 Absolute Sei mrm Abszolute ei mrm Ge Up to first spar Ge Up to first spar M Partial sheeting trailing edge Foot Tip m E m Pl f Absolute 58 000 mm f Absolute 47 000 mm Up to last spar Upto last spar Cap strips If you switch on the Cap strips switch the sheeting thickness is also deducted between the front and rear partial sheeting In the case of our sample wing this switch is not activated 2001 STEP FOUR GmbH 37 Wing Editor HOS STEP Check sheeting In the graphic display window click on je for the set of ribs to get a view of the location of the partial sheeting as shown in the screenshot below If the front sheeting only reaches the front edge of the main spar the main s
45. o the powerful functions in the professional cutting software these parameters can be set with a couple of clicks on the mouse Then you merely have to select the material and you can cut the core If you activate the option Inverted cut during the parameter definition a left and right hand segment will be cut above each other from the block By S TEPFOUR F3E ST LSCR File Handling Cut configuration Position Cutting Functions Options Help o 2 A X 0075 000 Y 0045 000 1 2 3 4 Ex HKH E AY 1 2 3 4 B X 0075 000 Y 0045 000 0 eg e 100 mm 200 250 E 0 0 AA A 2 A E o 0 v 0 s 2 3 Q l 4 0 i 2 3 k 5 i iy 6 P Gu 20 DL GEI mm 1 D 8 0 rh 4 Moe ree 10 ie dg e 11 Je RA Ee ee KI 12 aB 0 CS Cie a aT 2B Oo LOE LO Loren te 1 EX Ba ee x d ee f d d EE bh LA 0 og 23 D e an PARE P w Bu A 3 s lt a EN overall size 250 041 59 604 mm 380 000 55 000 64202 KB _ 54 WIN Gm Airfoil Editor optional module Me SEG J UCI 6 Airfoil Editor optional module 6 1 Working with the Airfoil Editor The airfoil editor enables you to modify more than 1100 airfoils in the airfoil data base provided and adjust their definitions But the main purpose of the airfoil designer is to digitize unknown airfoils from construction drawings and to prepare them for further processing by theWING designer as well as by the milling and cutting machines All you need is a scanner that st
46. of aerodynamic material durability and construction technology Before you start designing a wing you should therefore have a clear idea of its required appearance and design 3 1 Defining the Geometric Data for the Wing In the following example we will design the wing for a high speed electric plane The geometric data for the wing originate from an F3B glider with the following criteria Wing data Wingspan 290 cm Wing geometry triple tapered with laminated balsa tip outer segments 3 dihedral V shape Tapered wing RG14 9 on RG14 10 Rudders ailerons and flaps with 4 servos Root airfoil 250 mm Tip airfoil 180 mm Joiner 10mm carbon rod bearing in 11mm brass tube 0 5 mm wall thickness Rear edge swept forward by 5 13 and 24 mm straight hinge edge Make a sketch with the main dimensions for the wing geometry and enter all the relevant measurements 3 2 Defining the Wing using the WING Designer Start WING designer Start the wing editor by clicking on the L New file icon select the wing editor and confirm with Ok x Heu Cancel Hilfe arfoll editor 2001 STEP FOUR GmbH 13 ANING AOS oe alas Attach 2 segment Attach 3 segment Activate alphanumerical input part of the window 2001 STEP FOUR GmbH Wing Editor The STEP FOUR WING designer opens the graphic display window showing a wing segment In the other half of the screen the alphanumerical input
47. of the segment Properties oO Insert Ribs Limits Thickness of material 2 000 z mm Y Distribute ribs evenly Ge Ribs have fized distance Reference point Left Ce Right Number of ribs 2 z max P Bib distance Em z mm Space between ribs 20 O00 2 E The same method is used to position the two ribs in the third segment except that Left acts as the reference point here 2001 STEP FOUR GmbH 33 ANING AOS SS C7 Inter ribs Seo 2 and Seo 3 Ribs in Segments 2 and 3 Graphic control 2001 STEP FOUR GmbH Wing Editor Finally the remaining inter ribs in segments 2 and 3 are inserted With the right mouse button click in corresponding area of the segment and enter the following values Properties eg Thickness of material Insert Fibs Limit 2000 mm C Ribs have fixed distance Reference paint Gert Aight Ge Distribute ribs evenly Number of ribs ia mag P H Bib distance e SE mm Space between nbs z ee Segment 2 The vacant area in the second segment is filled with 6 ribs spacing is approx 62mm Segment 3 Thickness of material Insert Ribs Limits 2 000 m mm Ribs have fixed distance Reference point e C Biart P max ER Distribute ribs evenly Number of ribs Rib distance Space between ribs coca _ In the last segment two ibs are inserted spacing approx
48. om of the airfoil have been positioned approximately by hand As aresult these points will not usually be situated exactly on the zero line For certain airfoil editor calculations however the Wing designer needs a precisely closed contour To achieve this set the coordinate values for the last two points at X 100 and Y 0 0 000 EE airfoil editori 2 049 3 880 Format E T KEE S C N Cup rlkou 0 000 0 000 8 043 Fee C e 100 0 100 Normalize Insert point Help Delete point For further use you can now add the digitized airfoil to your airfoil database 60 ANING AOS Co dE The Options Menu 7 The Options Menu Options in the wing editor an Options Window P Basic settings S Update names Display General data Font Arial Timeout ji Basic Settings of Ribs ot Leading Trailing Er gt Root ribs Rib codes The Options menu provides various facilities depending on what section of the program you are currently working on If you are using the airfoil editor the Options menu will enable you to set the display parameters for processing the airfoil In the wing editor however a wider range of functions and settings are available In the submenu Basic settings you can set certain parameters to suit your requirements Labelling font Here you can select the font with which you wish to label the parts Calculation timeout In order to update th
49. on zt of the chord and the vertical line most in front If you click on you should be able to see the following window on the screen BR Profileditor1 Iof x 0 E 100 Millimeter EE EE EE EE EE aa E WB zx F Se At the rear of the airfoil the red center line and the tip of the airfoil in the scanned image do not as yet match up The chord of the scanned airfoil is clearly somewhat distorted and the depth is shorter than the 100mm of the red center line 2001 STEP FOUR GmbH 57 WIN Gm Airfoil Editor optional module AOS oe TiC Move end points Enlarge the rear section of the airfoil With the left mouse button click on the end point of the red line hold down the E 94 95 96 oF 98 99 100 101 102 Millimeter T pe E z i ae Best f TE l n p mmr m e rif Armei He e fe mouse button and drag the point to the end of the scanned airfoil contour Now you have moved the final coordinate of the top side of the airfoil to the end of the scanned chord Next move the end of the bottom of the airfoil into the same position too Digitize airfoil With the left mouse button click once on the outer contour of the airfoil Position the mouse pointer at the required location and press the right mouse button to open the fly out window and insert a coordinate for the top side New pont upper side Exchange upper and lower sides F9 _ E Hew paint lowen sid
50. or cutting path of left and right segment Ce Upper and lower side separated In one go from behind Runin distance 10 000 mim BupopGtoislene is 000 emt Run arc MER mm Biur aut Run out distance 15 000 mm Ge angential Ehad m Steleton line Fuuri out C Tangential Chord Ce Skeleton line 50 Vila Styrofoam Cutting optional module alae G 7 Segment 2 The same values are set for segment 2 Block parameters Block thickness 20 000 Offset leading edge 5 000 Offset trailing edge om Offset height 3 000 PEEP EERE Run out C Tangential Chord Ce Skeleton line Segment 3 should look like the screenshot below In our example the dihedral V shape of the wing should have been cut when the tapered areas were cut This means segments 3 and 4 require much thicker blocks of raw material than for the first two segments Block parameters Block thickness The following block parameters are set The run in and run out parameters are the same as those for the previous segment Segment 4 Segment 4 is different because it has a greater block thickness Block parameters Block thickness 70 000 mm 2001 STEP FOUR GmbH 51 ANING AL COO ERREP Styrofoam Cutting optional module The following screenshot shows the two final blocks graphically m The views of the blocks show you clearly how the wing segments are locate
51. ores the airfoil concerned as a BMP file on the hard disk Start airfoil editor With the left mouse button click on LU New Heu Heu OK atiol editar A selection window is displayed Select airfoil editor and click OK Display window The editor provides a tabular and a graphic view Click on one active Becky Zox S 0 E cam 0 000 0 000 22 nnn 2 707 Format x YupX Ylow C xunio PTT xY 100 0 100 it Hel 20 NNN annn In the table you can see the coordinates for the airfoil Three formats are available Table formats X Yo X Yu The coordinates are displayed in two tables The first table contains the top side coordinates from the leading edge until the tip The second table contains the lower side coordinates from the leading edge until the tip 2001 STEP FOUR GmbH 55 Apr Airfoil Editor optional module AOS de ICI X Yo Yu This display is only possible if the coordinates have been standardized with MOIES The coordinates are displayed in a three column table The first column contains the X coordinates from the L E until the tip The second and third columns contain the Y coordinates of the top and bottom sides Standardize means The airfoil editor generates a point with the same X coordinate on the bottom of the airfoil to match every point on the top of the airfoil and vice versa X Y 100 0 100
52. pars are not set lower but are aligned along the airfoil contour 2001 STEP FOUR GmbH 38 AOS SES Wing Editor 3 11 Print Output of the Wing Data Graphic output Output of top bottom view switch right left wing 2001 STEP FOUR GmbH Now you can print the entire wing including the set of ribs sheeting and fixture support either as an overview or to scale on your standard Windows printer Since the WING designer generates cutting marks joining the sheets up into a 1 1 scale construction drawing is not difficult What the printed output looks like basically depends on the printer settings format size portrait or landscape format etc In the normal graphic window switch IB to the top view Click on the print preview symbol rey Stepfour Wing Designer A screenshot like the one below is displayed Which elements are output depends on the setting of the levels Sein K Hime e R42 0 the graphic window of the WING designer Only the levels that are activated in the graphic window are printed If you use the standard settings the right half of a wing will be printed To print the left side you have to proceed as follows Switch to the Graph Ki window Click with the right mouse button into the cross k EE section of the rulers x A Change in the properties window Properties og Grid Rulers to Rulers and change the radio lt Ss e i mimere m button for the direct
53. r the command New gt wing click with the right mouse button in the empty area of the graphic display window to open a Fly Out window Insert single rib Insert several ribs Distribute ribs evenly Delete ribs Properties O O O zj ER Screen Print Layout Insert segment Delete segment _Interribs Wing Joiner TxLine Airfoil Contour Rib Sparr Add segment Screen layout Color Test Layout ie es Thickness fi e Print layout E Color a Layout HG Thickness 3 m Define as Default Load default values Accept Cancel 150 limetre In the above example the function for modifying the display features was called next Later on in the manual you will find further details about the various fly out menus including practical examples ANING TEP SOFT HOSTI LET Program Structure 2 3 The Data Structure of a WING Designer wing Wing segments Segment related objects Segment overlapping objects 2001 STEP FOUR GmbH Every wing in the WING designer consists of at least one or several segments Each segment defines a single construction section and can be defined geometrically dimensions dihedral V shape sweep angle airfoil etc segment segment 2 a gt a Eet d _ Simple wings will probably
54. rt position DG Rel to LE X0 and Start position f Rel ta chord YO The exact positioning is carried out by indicating the absolute values in the Start pos Dist Coord and End pos Dist Coord fields Add another joiner by clicking with the right mouse button on Wing and New joiner Next enter the data shown below into the mask Test nach Handbuch 2 e II x E Wing Wing Joiner 41 Dimension at joiner start width eooo 3 bell width bo ER Height E 000 fio Height E 000 mm Start position Dimension at joiner en C Rectangle Ge Circle A r sha BEBE eStart position Ge Rel to Le Centered on skeleton line i n E f Bel to chod 31 000 ES mrm End pos Dist Coord x 96 000 tau vy 26 234 mra z 1254 863 mm Rel toT E C At thickest point Start pos Dist Coord x 86 000 mm el om mm z 1155 000 mm nae 100 000 Imm 7 angle 0 000 ET NM YZ angle 3 000 29 ANING AOS G 7 Graphic control d e o 2 outer joiner 2001 STEP FOUR GmbH Wing Editor When switching to the graphic view and zoomin the joiner should look roughly like this from above Zoomed front view of the same joiner S S14 js ajs To become familiar with the effects of th
55. side D odz a S C Chord E 343 TMm S Ce Lower side DG SU sl 2001 STEP FOUR GmbH 7 WING Wing Editor AHO gt t KGET Switch to graphic In the graphic view d switch in the symbol bar you can view already see the wing geometry of the F3B wing after the adjustment with BH The dotted line stands for the T 4 line 25 0 200 1 milimetre of cord length With the aid of the button you get the front view of the wing The centre piece is not dihedral the two outer segments are 3 5 dihedral 3 3 Inserting Spars in the Wing Now insert the main spar into the wing Since this is a triple tapered surface with a varying sweep angle the spar is not straight so that a separate spar must be fitted for each segment Spar 1 is located in the Ist segment Spar 2 is located in the 2nd segment Spar 3 is located in the ME 30 1000 1200 1 millimetre Nem wing joiner Hew spar Add segment E Segme H Segme H Segme Help Hame Total length 1360 000 mm d Pj S le 3rd segment Click with the right mouse button on Wing and then on New spar 2001 STEP FOUR GmbH 18 ANING Wing Editor AOS SS PT Spar in For the spar we will use pine with a diameter of 6 x 3 mm Since 1 wing segment the wing is completely veneered the spar should disappear underneath the sheeting ED Test nach Handbuch 7 2 Ol x e Segment 1 E Segment 2
56. tioned earlier the joiner can be located at the highest point of the airfoil because of the thin spar BD F3E Styro 1 Miel x H Segment 1 H Segment 2 H Segment 3 Lek E Segment 4 Format Dimension at joiner start Dimension at joiner en C Rectangle Ge Circle mm d width 11 000 Imm E Width 11 000 mm Height 5000 mm Height Fr Start position Ce Centered on skeleton line C Bel to chord 2 425 imm End pos Dist Coord len an mm ES bam cc au E eg chan eil 2 170 000 re Activate the entry fr Atthickest point for the X starting position All the other entries can remain unchanged Start position C Rel to LE C Bel to TE Ge At thickest point Start pos Dist Coord y 68 930 a rnrn Length 170 000 mm i 0 000 j 0 000 For the sheeting we will select 1mm balsa complete sheeting E F3E Styro 1 lof x Segment 1 o be Leading trailing edge z Allerona Flaps i H Sheeting Upper Side z Sheeting Lower Side i Cutting Path Help H Segment 2 M Sheeting lower side aleuleton fam previous seqment Partial sheeting Partial sheeting leading edge ebe To Modify the sheeting values for both the top and bottom sides of the wing _ 49 ANING AOSE ARP Setting the cutting parameters Segment 1 2001 STEP FOUR
57. y set of ribs shows calculated ribs D for additional cutting editor module only Levels For a better overview individual graphic display levels can be switched on and off wait Program Structure AOS GT ICT zw Inter ribs st Joiners rn Tx line Contour View of ribs with segments H Spars mn Leading edges a Trailing edges pg Sheeting p Rudder flaps 42 Part names es Chord Sk Skeleton line P Original airfoil LE Coordinates cutting editor only 30 Activate window 3D view of wing Recalculate All the wing data are recalculated based on current data 2001 STEP FOUR GmbH 7 ANING w AOS GT LCT Airfoil editor Additional module Program Structure Smooth The line of the airfoil is smoothed Key combination Shift F5 Graphic view Tabular view Ga Copy upper side to lower side Function key F7 oe Copy lower side to upper side Function key F8 D Swap lower side with upper side Function key F9 2 2 Fly Out Windows and Feature Menus Example 2001 STEP FOUR GmbH Many edit functions are activated by means of fly out windows A fly out window is activated by clicking on the right mouse button Depending on which window or object is being selected where the mouse pointer is pointing etc a certain window or menu is opened Then certain features can be entered or modified directly in these windows or links to other functions are provided Afte
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