Ron,

You asked:

>Can someone who is knowledgeable in this area explain why a geared 
>motor is (or can be) more efficient than a direct drive.  If you 
>consider the extra weight of the drive, say 30-35 grams for a good 
>planetary gear box, such as cosmotec or graupner(?), and the extra 
>weight of a larger prop, say 5-10 grams, and factor in the extra 
>drag from the gearbox, is a geared motor really better than a direct 
>drive?

I am also a novice in this area so I picked up Martin Simon's book, 
Model Aircraft Aerodynamics, and read the section on propellers.  The 
starting point is the fact that a motor has a limited range of rpm 
and torque over which it runs efficiently and puts out a high level 
of power.  For a direct-drive propeller, the pitch of the propeller 
has to be matched with the target rpm so as to pull the plane forward 
at the target speed of the airplane.  (The pitch is the distance that 
the propeller slices forward in one rotation.) For a propeller with a 
pitch that is too high, the torque increases, the motor slows down 
and the propeller flails away at the air with poor efficiency.  So 
the first step is to obtain the proper match between the motor, the 
propeller pitch and the speed of the plane.

With the pitch optimized, there is a second consideration. 
Larger-diameter propellers are more efficient as described in the 
book.  The total thrust is given by the area traversed by the 
propeller (a disk with a diameter equal to the length of the 
propeller) multiplied by the pressure differential between the front 
and back of the propeller.  The same thrust can be obtained with 
either a large-diameter propeller with a low pressure difference or a 
small-diameter propeller with a large pressure difference.  However, 
the efficiency of the propeller is directly related to the pressure 
difference.  The smaller pressure difference (larger diameter) gives 
higher efficiency.  High-rpm motors are not well matched to 
large-diameter propellers.  Therefore, the strategy is to allow the 
motor to run at a good rpm while the larger propeller rotates at a 
lower rpm.  This means using a gear box.

Dick
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Dr. Richard C. Williamson            Phone:  781-981-7857
Room C-317                           FAX:    781-981-0122
Lincoln Laboratory                   Email: [EMAIL PROTECTED]
Massachusetts Institute of Technology
244 Wood Street
Lexington, MA 02420-9108
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