After
2 years of experiments we have developed reasonably priced four stroke power
plants for light aviation. More than 12 years of experience in converting the
auto engines for racing in Poland, we have gained great knowledge of engines
and with young team of engineers 2 years ago we decided to provide aviation
community alternative auto engines for aviation use.
We chose Suzuki engines because
of their compatibility, light weight, all aluminum construction. These engines
are produced in today's cars and are available in any quantity. By choosing
current production engines we have eliminated the worry of our customer about
spare parts, if some things goes wrong with our company, you can buy all over
the world spar parts for these engines. So we really do not need to establish
web of our distributors all over the world to provide service, any authorized
auto-shop in the world can handle this.
RELIABILITY AND EFFICIENCY
Auto industry have billions of
dollars of funds for research and development purpose and then they have very
tough competition with each other. So we believe that these engines are far
more superior in quality, performance and in technology than aircraft piston
engines. Then they are very fuel efficient thanks to water cooling and auto
fuel is 1/2 the price of Avgas.
MODERN TECHNOLOGY
All new modern engines are
water cooled having following benefits over air cooled engines
okwater cooled engines add few
more components but:
- They burn about 12 to 15
%less fuel than air cooled engine ,which means your endurance will be more with
water cooled engine or less mtow.
Pls note that MR.RUTAN ordered
specially for his around the world flight water cooled engine from continental.
Without that modification that flight with out refueling was not possible. He
would have been simply run out of the fuel.
- Water cooled engine works at
constant temperatures maintained by thermostats, regardless of altitudes, power
settings and air temperatures.
- Controlled temperatures means
tight internal clearance of the components, adding more efficiency and
reliability of the parts.
- Cabin heat can be provided
with out the risk of carbon monoxide poising. Which is associated with air
cooled engines where the heat is drived from the hot burning gases.
INNOVATIVE FEATURES
- Customized fuel injection
system to compensate for the temperature and atmospheric pressure differences
at different flying altitudes
- Integral toothed Gear
Reduction Drive with anti tensional resonance device to counter the shock loads
to the propeller
- Customized lightened fly
wheel
- 1000 hrs TBO
- Any reduction ration
available
- Flat positioned engine to fit
almost all the engine cowls containing Rotax or Jabiru, or HKS engines
- Very reasonable priced
- Spar parts available all over
the world
Diffusion
After great increasing demand
of our power plants. To meet the production dates and delivery schedules Bilsamaviation
has joined hand with legendary polish auto engine converter for racing and
producer of sports cam shaft producer magistrate
engineer. Mr. Lech Swiatek and his team.
this diffusion will enable us to increase our production volume and at the same
time Mr. Swiatek has taken the responsibility to make further improvements.
Here are the details:
1) all customers will get turn key
engines, which means all the wiring and all the harness are preinstalled with
all the engine instrument's sensors and senders
2) carbon fiber exhaust
3) carbon fiber manifold
4) carbon fiber oil sump
5) new light weight and better reduction
unit
6) increased hp for L-S 1300(now 120hp)
7) more better and favorable torque
curves ,thanks to new designed cam shaft
8) increased hp for the L-S 1300 now 100
hp and 120 hp versions at lower RPM's with help of new cam shaft and other modifications
9) guaranteed deliveries of up till 15
to 20 engines per month
10) complete fire wall forward packages
with engines mounts for following aircrafts from january 2004
a) sky ranger
b) cosmos trike
c) air creation trikes
d) zodiac ch701
e) zodiac ch601
f) air trophy stool 2000
and of course al bilsam flying
machines
L-S AERO ENGINES TECHNICAL INFORMATIONS
ENGINE MODEL |
|
L-S 1000 |
|
L-S 1300 |
|
L-S 1300XP |
Cylinders |
|
In line 3 cylinders OHC |
|
In line 4 cylinders, OHC |
|
In line 4 cylinders, OHC |
Cooling |
Water cooled |
Water cooled |
Water cooled |
|||
Displacement |
1000 CC (61 cm3 ) |
1300 CC (80 cm3 ) |
1300 CC (80 cm3 ) |
|||
Power output |
80HP @ 5900RPM |
100HP @ 6000RPM |
120HP @ 6000RPM |
|||
Maximum torque |
100.9NM @ 4722RPM |
130NM @ 4800RPM |
135NM @ 4800RPM |
|||
Bore |
73,9 mm |
73,9 mm |
73,9 mm |
|||
Stroke |
76,9 mm |
76,9 mm |
76,9 mm |
|||
* All up weight |
78,6 kg |
72,5 kg |
89,7 kg |
|||
Reduction ratio |
2,40:1 |
2,40:1 |
2,40:1 |
|||
Ignition |
Electronic Ignition |
Electronic Ignition |
Electronic Ignition |
|||
Alternator |
30 Amp |
30 Amp |
30 Amp |
|||
* Full consumption |
10 liters |
12 liters |
12 liters |
|||
Fuel system |
Multi port fuel injection |
Multi port fuel injection |
Multi port fuel injection |
|||
Compression ratio |
10:8 |
10:8 |
10:8 |
|||
Firing order |
1,2,3 |
1,2,3,4 |
1,2,3,4 |
|||
Advance angle |
10° BTDC |
10° BTDC |
10° BTDC |
|||
Electrode gap |
0,8 - 0,9 mm |
0,8 - 0,9 mm |
0,8 - 0,9 mm |
|||
Trans mission |
Toothed gear |
Toothed gear |
Toothed gear |
|||
Trans mission type |
Helical type gear with dynamic
vibration damper |
Helical type gear with dynamic
vibration damper |
Helical type gear with dynamic
vibration damper |
|||
Transmission oil / gear box |
SAE 85W90-API-GL4 |
SAE 85W90-API-GL4 |
SAE 85W90-API-GL4 |
|||
Transmission oil quantity |
0,35 liters |
0,35 liters |
0,35 liters |
|||
Lubrication system |
Wet sump (oil pump) |
Wet sump (oil pump) |
Wet sump (oil pump) |
|||
Lubrication oil type |
SAE |
SAE |
SAE |
|||
Cooling capacity |
4,5 liters |
4,5 liters |
4,5 liters |
|||
Fuel |
Minimum 98 octane |
Minimum 98 octane |
Minimum 98 octane |
ROUTINE MAINTENANCE FOR L-S 1000
AND L-S 1300
COMPONENTS |
|
CHECK |
|
RENEWAL |
Oil level |
|
Before every flight |
|
Every 100 hrs or, one year
period |
Coolant level |
Before every flight |
Every 100 hrs or, one year
period |
||
Oil leakage |
Every 150 hrs |
150 hrs |
||
Oil filter |
- |
Every 150 hrs |
||
Spark plugs |
- |
Every 150 hrs |
||
* Air Filter |
- |
Every 150 hrs |
||
Fuel filter |
- |
Every 150 hrs |
||
** Transmission gear box oil |
150 h |
|
||
*** Dynamic vibration damper
torque |
150 h |
|
* Not renew but
clean oil by using JR clean and change except oil leak
** Transmission do not
require oil level checking, or renewal except oil leak
*** Vibration damper must
be checked for elastic resistance by pulling propeller by hand with NO Running
ENGINE
REMANUFACTURING PROCEDURE
PARTS |
|
CONDITION |
Gaskets |
|
New |
Timing belt tensioner |
New |
|
Spark plugs |
New |
|
Timing belt |
New |
|
Piston rings |
New |
|
High tension cable |
New |
|
Starter |
New |
|
Pistons |
New |
|
Big end Biering |
Reconditioned |
|
Water pump |
Reconditioned |
|
Inlet value |
Reconditioned |
|
Exhaust value |
Reconditioned |
|
Distributor cap |
Reconditioned |
|
Oil pressure indicator |
Reconditioned |
|
Alternator |
Reconditioned |
|
Cam shaft |
Custom modified |
TUNING PROCEDURES FOR L-S 1000 AND
L-S 1300 AERO ENGINES
Cylinder head verification |
|
(i) Inlet and exhaust channels |
Cam shaft |
Sports cam shaft |
|
Inlet manifold |
One throttle sport inlet
manifold |
|
Exhaust |
3 in 1 sports carbon fiber
exhaust manifold |
|
Fuel and ignition system |
Multi port injection with
electronic ignition |
REDUCTION UNIT
Specially
hardened helical type toothed gear unit 25mm thick toothed wheels helical type
gear boxes are the best solution for low vibration and less noises which add
the components reliability and longer life we in cooperate special rubber
cushioned between the wheels to further improve the anti torsional effects of
whole system.
LS 1000 engine
The owners manual
1.General dimensions.
2.Details.
Origin of engine.
The base is Suzuki Swift G10 car engine.
Construction.
LS 1000 engine is predestined for ultralight aviation. Mega quality and
reliability of engine parts is guaranteed by origin from car industry. Engine
block and cylinder head are made of light alloy and this gives little weight.
Angle of inclination of engine is 20 degrees from level to close general
dimensions to boxer engines and secure little dimension between axis of
propeller and top line of engine.
Inlet manifold and oil sump are completely original constructions. They are
made of vinyl resins and strengthen by carbon fiber LS 1000 engine is feeded by
electronic fuel injection with electronic controller unit.
Reduction gear .
The helicoial gear with grinded teeth secure high reliability and
silent-running. It is equipped with dynamic anti vibration damper and separate
oiled.
3.Safety rules.
It is not allowed:
starting the engine without checking every flight operation and when routine
maintenance are not compete
starting the engine without propeller
starting the engine when any controller is not working
leaving the engine working
crossing maximum RPM
using the engine to acrobatics
starting flight when the engine is not working correctly
opening cooling system when the engine is hot
Necessary is:
do routine maintenance according with the instruction
use recommended spare parts only
use recommended fluids
secure engine and components for storage
4.Engine systems
Cooling system.
LS 1000 is water cooled engine. The cooling system is pressured pump-assisted
thermo-sypfon type.
The system consist of the radiator, water pump, thermostat and expansion tank.
Thermostat starts to open at the water temperature between 82-88 ° C.
TEMPERATURE RANGE =90-100°C
Diagram
Fuel system.
Fuel is inducted from fuel tank through the filter to the injectors. The fuel
pressure controller keeps up fuel pressure between 2,5-3,5 Mpa. Fuel charge is
controlled by computer.
Warning:
- fuel pump must be mounted under fuel level
- fuel pump must be fuel filled
- running the pump without fuel longer than 5 SEC . can cause serious failure
Reduction gear.
The helicoial gear with grinded teeth. Housing is made from light alloy.
The reduction gear is equipped with a dynamic anti vibration damper. It is oil
filled through the top gate (0,2-0,25 ltr.) There is no bottom outlet and level
gauge.
Oil system.
The oil system is pressured type with oil pump driven from crankshaft with full
flow oil filter.
The oil pressure indicator is checking oil pressure. Running engine without
minimum oil pressure can cause serious failure. The minimum oil pressure is 0,1
MPa about 2000 RPM (oil temperature 90 ° C.
TEMPERATURE RANGES
90-110degree centigrad
5.Exploitation and
service.
Starting.
Before start the engine every flight action and safety rules must be checked.
When the engine is cold or air temperature is below 20 ° C switch position
"1" on the computer.
After 5 sec. after starting the engine switch position "0". When the
engine is hot or air temperature is above 20 ° C switch position "0"
on the computer.
ROTARY
REVOLUTION
Bilsamaviation
has observing the development of rotary power plants in united
states for last 8 years and has decided to pursue this idea
further and develop the most reliable
power plant for light aviation This seems to be a deviation from
general trend in Europe where high fuel prices have motivated few companies
to develop diesel power plants for the light aviation but according to our
logic the diesel engine will always be heavier and average ultralight pilot
fly about 40-50 hours per year So
really there is very less fuel saving costs, and this can be compensated by
the longer TBO (2500hours and planned to be increased to 3000 hours in near
future) And
fixed general over haul cost of only 1999 euro for our rotary power plants |
|
History
Dr. Felix Wankel invented the engine in 1930 .after 20
years of development and improvements the first prototype was built in 1950
But it was odd looking engine (too futuristic for it’s
time)
And did not created any commercial success
But one company saw the superior kinematics of this
concept and bought the rights of the engine
This was japanese company named Toyo Kogyo or known as
Mazda motors to the world
Mazda created state of art computerized test facility
to further improve the concept and invested millions of dollars and thousand of
hours on rotary concept
After 17 years of long research and development Mazda
started selling cars with rotary engines in 1967
Over the years several engineering challenges were
encountered and lot of lessons were learned from every day use of this engine.
More than 2 millions cars were sold with this engine
in very short period (it took Lycoming and Continental more than 40 years to
sell about 400000 aircraft engines)
In 2003 Mazda introduced new sports car RX 8 with 4th
generation Renesis
rotary engine
This engine is the by product of 37 years of
experience in rotary technology and Bilsamaviation has fully confidence to the
concept. Let’s see why the rotary is perfect choice for aviation.
In aviation the most important factor should be safety not fuel costs (diesel concept)
rotary verses piston engine
Piston engines
In piston engines reciprocating action produces
tremendous stress on the engine parts like connecting rods, pistons, pins,
valves, valve springs, camshafts, lifters push rods, etc
In piston engine parts move, then stop, then up and
down and in all directions twice per revolution
So it’s impossible to perfectly balance the piston
engine
As the parts reciprocate, and oscillate, and they through
off their center of gravity and normal piston engine has about 44 moving parts
,so you can imagine what mess is inside when engine is working let’s
analyze the motion of typical piston engine, rotating at 5000RPM (cruise RPM of
Rotax
912 at 75%power)
The bore is 4 inches
Stroke is 3 inches
At 3, o clock position of the crank, the piston is
moving down the bore at maximum speed
At 9.0 clock position of the crank, piston is moving
up the bore at maximum speed
At 12.o clock and 6, o clock position its stopped at
the top and bottom of the bore
Now stay with me
The circumference of the crank is pi x 5inches
Which is 15.7 inches or 1.31feet
We have cruise RPM of 5000
5000RPM = 84
rps (rev.per second)
Crank pin is moving at
84 x 1.31 =110 feet/second moving in a circle
Piston speed is same as pin speed at 3, o clock and 9, o clock position.
Which means it takes crank1/84 second or 0.0119 seconds to rotate once
Now the rotation of the crank from 12,o clock to 3,o
clock will take one quarter(1/4) of 0.0119 seconds that is 0.0029 seconds
There fore piston accelerated from dead stop to 84
feet per second in only .0.0029
seconds so average acceleration of crank would be,
Crank acceleration=speed of crank insec. /time in
seconds=84/0.0029=28965
feet per second
This is tremendously fast and here is the night mare
We know (i hope)
1g=32 feet/sec. so 28965
feet per second / 32feet per second = 905g,s
Now lets assume that connecting rod, piston pin and
piston with rings weighs about 7 lbs and piston about 3 lbs.
So the inertial load of 3 pound piston to the
connecting rod=3x905=2715lbs=(1123kgs)
So poor connecting rod is pushing 2715 lbs of piston
in every0.0119 second
Then 7 lbs of collected load of connecting rod, piston
pin, piston with rings is exerting inertial load on the crankshaft=7x905 =6335lbs =(2879kgs)
So it’s only the miracle of metallurgy science and
almost 100 years of work and billions of dollars spent by auto industry that
the piston engine last so longer
But aviation is high risk business/hobby
And we can see the piston engines are very prone to
damage and any small minor maintenance problem/negligence can lead to engine failure
They last longer in the cars as they are working at
about 30% of the power
but in aviation we need 65%to 75%
the power
That's why Lycoming and Continental have stayed to
large displacement low RPM engines
(high RPM means, very high inertial loads on the parts)
but they are left behind as they have not modernized their engines with fuel
injections, water cooling and other high tech
goodies
Rotary
engine
Rotary
engines are not reciprocating engines, every parts move in a circle or in same direction
There
are only 3 moving parts,
not 44 to 46 as compared to piston engines
There
are no exhaust valves to melt or burn (in piston engine 80% of the engine failures are caused
due to exhaust valves problems)
These
poor valves run at extremely hot temperature's and opening and closing
about 1200-1500 times
per minute
Their
is no cam shaft to worry about in rotary as there isn't any Rotaries are
perfectly balanced just like turbine or electric motors
In rotary propeller gets 6 power impulses per
revolution which means it will take piston engine to have 12 cylinders to
have same smoothness as twin rotor, rotary engine
Best thing is rotary never fails like pistons engine
You
may lose partial power if you loose your coolant and
you will still have some power to get to the nearest landing place
misconcepts about rotaries engines
1. 2 stroke engine
Lot of people think its 2 stroke engine which
is not truth
It has four cycle like
1) intake
2) compression
3) expansion
4) exhaust
And
it fires twice per output shaft revolution
2. High fuel consumption
That
was true for the early models but new RX 8 engine has fuel burn very close to
today's modern piston engines as RX 8 has now side exhaust ports and any
residual un burned fuel is recirculated to next combustion cycle. The
exhaust port timing has been modified and RX 8 has lower exhaust temperatures
confirming the low fuel consumption
3. High oil use
The main reason for the high
oil use in the early models was the quick wear of the rotar seals, this problem
has been fixed by new ceramic silicon carbide seals and they are 700% stronger
than metal seals
4. Complicated engine
This reason is really very astonishing as really their
are no complication in construction,
lot of people do not under stand the engine and
they stamped it complicated engine
then why sky is not full with
rotary engine powered aircraft's?
Good
question or why Mazda does not certify this engine for
aviation use
The
main reason is commercial
As
aviation is such small market for Mazda and second they will never allow any
aviation authority to dictate them what to do or not as when you certify the
engine you have to go for very long and tiring procedure of approvals for any
small modifications and i think Mazda do not want to have this
headache, so here comes Bilsamaviation in the picture
Engine
itself is not a problem
To
convert the engine for aviation use following engineering challenges have to
be solved
Bilsamaviation
has taken up these challenges and developed the perfect light and reliable engine
for aviation use
Advantages
1. compact
2. high power to weight ratio
3. 2500 hours TBO as compared to 1200 to other piston engines
4. very low fixed over haul cost of about 19999 euros
5. reliability
6. simple
7. smooth like electric motor
8. high damage tolerance
9. low purchase cost
10. spare parts backed by one of the world's biggest company (Mazda
motors)
11. low cost auto fuel operation
Performance specifications
Engine type |
|
Rx8-SR |
|
Rx8-XP |
|
Rx8-TR |
|
|
|
|
|
|
|
All up dry weight |
|
68,9 kg |
|
68,9 kg |
|
120 kg |
Horse power |
|
100 hp |
|
120 hp |
|
240 hp |
Maximum RPM |
|
7500 |
|
8000 |
|
7500 |
Cooling |
|
Water &
oil cooling |
|
Water &
oil cooling |
|
Water & oil cooling |
Displacement |
|
650 cc |
|
650 cc |
|
1300 cc |
Maximum torque |
|
125 nm @ 4500 RPM |
|
140 nm @ 4500 RPM |
|
“ |
Reduction ratio |
|
3:1 |
|
3:1 |
|
3:1 |
Alternator |
|
24 amp |
|
24 amp |
|
30 amp |
Fuel consumption |
|
15 liters |
|
18 liters |
|
25 liters |
Fuel system |
|
Multi part fuel injection |
|
Multi part fuel injection |
|
Multi part fuel injection |
Compression ratio |
|
10:1 |
|
10:1 |
|
10:1 |
Transmission type |
|
Helical type gear with dynamic
vibration damper |
|
Helical type gear with dynamic
vibration damper |
|
Helical type gear with dynamic
vibration damper |
Transmission oil |
|
Sae 85 w 90-api-gl4 |
|
Sae 85 w 90 api-gl4 |
|
Sae 85 w 90 api-gl4 |
Lubrication system |
|
Wet sump Oil pump |
|
Wet sump Oil pump |
|
Wet sump Oil pump |
Fuel |
|
95 or higher octane |
|
95 or higher octane |
|
95 or higher octane |
TBO |
|
2500 hours |
|
2500 hours |
|
2500 hours |