Rotor Blades Of A Lift Rotor

Abstract

A foldable rotor blade includes a hinge element defining two hinge axes arranged in parallel, and two blade segments each coupled to the hinge element for hinging with respect to a respective one of the hinge axes. The rotor blade has an extended condition in which the blade segments are substantially aligned with each other, and a folded condition in which each blade segment is hinged with respect to the hinge element so that the blade segments are substantially parallel to each other. The blade has a cord and the hinge axes are substantially parallel to the chord. The blade segments have upper surfaces which in the folded condition are facing each other, and which in the extended condition are flush with each other and the intermediate hinge element.

Claims

1. A foldable rotor blade comprising: a hinge element defining two hinge axes arranged in parallel; and two blade segments each coupled to the hinge element for hinging with respect to a respective one of the hinge axes; wherein the rotor blade has an extended condition in which the blade segments are substantially aligned with each other; wherein the rotor blade has a folded condition in which each blade segment is hinged with respect to the hinge element so that the blade segments are substantially parallel to each other; and wherein the rotor blade has a chord and the hinge axes are substantially parallel to the chord.

2. The foldable rotor blade according to claim 1, wherein the extended condition of the rotor blade is defined by at least one stop between the hinge element and at least one of the blade segments.

3. The foldable rotor blade according to claim 1, wherein the blade segments have upper surfaces which in the folded condition are facing each other, and which in the extended condition are flush with each other and the intermediate hinge element.

4. The foldable rotor blade according to claim 1, wherein the hinge element comprises: a central body; at least one first coupling flange extending away from the central body in a first direction, with a first cylindrical hole extending perpendicular through the first flange; and at least one second coupling flange extending away from the central body in an opposite second direction, with a second cylindrical hole extending perpendicular through the second flange; wherein a first one of the blade segments has at one end a hinge portion comprising at least one coupling flange and a cylindrical hole extending perpendicular through the coupling flanges; wherein a second one of the blade segments has at one end a hinge portion comprising at least one coupling flange and a cylindrical hole extending perpendicular through the coupling flange; and wherein the rotor blade further comprises a first cylindrical hinge axle arranged in the aligned holes of the first blade segment and the hinge element, respectively; and a second cylindrical hinge axle arranged in the aligned holes of the second blade segment and the hinge element, respectively.

5. The foldable rotor blade according to claim 1 further comprising a preferential folding control arrangement to ensure a preferred hinging order of the first blade segment and the second blade segment.

6. The foldable rotor blade according to claim 5, wherein the preferential folding control arrangement has a first locking condition in which it locks the first blade segment in its extended condition with respect to the hinge element and allows hinging of the second blade segment.

7. The foldable rotor blade according to claim 5, wherein the preferential folding control arrangement has a second locking condition in which it locks the second blade segment in its folded condition with respect to the hinge element and allows hinging of the first blade segment.

8. The foldable rotor blade according to claim 5, wherein the hinge element has an axially displaceable locking pen having a first end and an opposite second end; and wherein either the first end engages the first blade segment to lock it or the second end engages the second blade segment to lock it.

9. The foldable rotor blade according to claim 8, wherein the first end and the second end each have a bevelled edge.

10. The foldable rotor blade according to claim 8 further comprising a bias member, arranged for exerting a bias force on the lock pin.

11. A vehicle comprising a lift rotor having two foldable rotor blades, each according to claim 1.

12. The vehicle according to claim 11 further comprising: a vehicle body; and a mast hinged to the vehicle body; wherein the lift rotor further comprises a rotor hub mounted at a top end of the mast; and wherein each foldable rotor blade has its proximal blade segment hinged to the rotor hub.

13. The vehicle according to claim 12, wherein the vehicle is a convertible vehicle having a flying condition and a road traffic condition; wherein in the flying condition, the mast is standing upright and the rotor blades are in their extended condition and are directed away from the rotor hub in opposite directions; and wherein in the road traffic condition, the mast is hinged down to a substantially horizontal direction and each foldable rotor blade is in its folded condition with its proximal blade segment hinged towards the mast.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] These and other aspects, features and advantages of the present invention will be further explained by the following description of one or more preferred embodiments with reference to the drawings, in which same reference numerals indicate same or similar parts, and in which:

[0017] FIG. 1A shows a schematic top view of a rotor blade;

[0018] FIG. 1B shows a schematic cross section of a rotor blade;

[0019] FIG. 2 is a perspective view of a convertible fly/drive vehicle according to the present invention in flying condition;

[0020] FIG. 3 is a schematic side view showing the mast structure of the vehicle in a first intermediate condition between flying condition and road driving condition;

[0021] FIG. 4 is a schematic side view showing the vehicle in a second intermediate condition between flying condition and road driving condition;

[0022] FIG. 5 is a schematic top view of the vehicle in this second intermediate condition;

[0023] FIG. 6 is a schematic top view of the vehicle in a third intermediate condition;

[0024] FIG. 7 is a top view comparable to FIG. 6, showing the righthand rotor blade of the vehicle in road driving condition;

[0025] FIG. 8A is a perspective view schematically illustrating main components of a hinge structure according to the present invention in taken apart condition;

[0026] FIG. 8B is a perspective view shows a more realistic view of said components in assembled condition;

[0027] FIG. 8C is a view comparable to FIG. 8B, with one blade segment attached to a blade connector;

[0028] FIG. 9A is a schematic perspective view of the central hinge portion of one rotor blade;

[0029] FIG. 9B is a view comparable to FIG. 9A, with one blade segment hinged up;

[0030] FIG. 9C is a view comparable to FIG. 9A, with both blade segments hinged up;

[0031] FIG. 10A illustrates two blade segments interfering with each other;

[0032] FIG. 10B illustrates two blade segments such that one blade segment allows hinging of the other without interference according to the present invention;

[0033] FIGS. 11A-C schematically illustrate the operational principles of an embodiment of a preferential folding control arrangement according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0034] FIG. 2 is a perspective view of a convertible fly/drive vehicle 100 according to the present invention. The vehicle 100 comprises a slender vehicle body 110, that contains an inner compartment for passengers, and that has a size comparable to the size of a car. The vehicle 100 has an undercarriage 120, comprising a front wheel 121 and two rear wheels 122, 123. At its rear end, the vehicle 100 comprises a propeller 130 for propulsion in fly mode, which propeller can be folded and accommodated within the vehicle body in drive mode.

[0035] The vehicle 100 accommodates an engine (not shown for sake of simplicity). In drive mode, the engine power is transferred to the rear wheels for propelling the vehicle as a normal car on a road. In fly mode, the engine power is transferred to the propeller 130 for providing propulsion in air.

[0036] The vehicle 100 has a mast 140, having its lower end 141 hinged to the top of the vehicle body 110, at a position close to the rear end of the vehicle body 110. At its top end 142, the mast 140 rotatably carries a lifting rotor 150 which, when rotating, provides a lifting force to the vehicle 100. While it is possible that the rotor 150 receives engine power for rotation, the rotor may also be of gyrocopter type. The rotor 150 comprises a rotor hub 151 and two rotor blades 152, 153.

[0037] The vehicle 100 further comprises an extendible tail structure 160, which includes two tail foils 161, 162 mounted to the distal end of an extendible tail boom 163. The tail boom 163 has its proximate end hinged to the mast 140, at a position close to the mast top end 142. At a position rearward from the mast 140, the tail structure 160 comprises a boom support 164, that has its lower end hinged to the vehicle body 110 and its upper end hinged to the tail boom 163.

[0038] FIG. 2 shows the vehicle 100 in flying condition. The propeller 130 is deployed. The mast 140 is hinged to an upright position, and so is the boom support 164. The tail boom 163 is extended, and is at a raised level to extend well over the deployed propeller 130. The rotor blades 152, 153 have their chord plane directed substantially horizontally.

[0039] FIG. 3 is a schematic side view showing the mast structure of the vehicle in a first intermediate condition between flying condition and road driving condition. The propeller 130 is folded and stored, and is not visible. The mast 140 is lowered to an angle of about 45° with the horizontal; the boom support 164 and the tail boom 163 have followed. The rotor blades 152, 153 extend in transverse direction with respect to the vehicle, i.e. perpendicular to the plane of drawing.

[0040] FIG. 4 is a schematic side view showing the vehicle in a second intermediate condition between flying condition and road driving condition. The propeller 130 is folded and stored, and is not visible. The mast 140 is lowered to a substantially horizontal position; the boom support 164 and the tail boom 163 have followed, so that the tail boom 163 now also lies substantially horizontally, close to the top of the vehicle. The rotor blades 152, 153 still extend in transverse direction with respect to the vehicle, i.e. perpendicular to the plane of drawing. The rotor blades 152, 153 are hinged to the rotor hub 151 about respective hinge axes 154, 155 that are substantially parallel to the chord planes of the rotor blades. FIG. 4 clearly shows that these hinge axes, commonly indicated by a dashed line, are now directed vertically.

[0041] FIG. 5 is a schematic top view of the vehicle in this second intermediate condition. Said hinge axes 154, 155 extend perpendicular to the plane of this drawing. The figure clearly shows that the rotor blades 152, 153 have a length substantially larger than the length of the vehicle body 110. According to the present invention, each rotor blade 152, 153 consists of two rotor blade segments 171, 172 hinged together at a hinge segment 173, as will be explained in more detail later. The two rotor blade segments 171, 172 have substantially equal length, although this is not essential to the invention. Further, it may be advantageous if the distal segment 172 is slightly shorter than the proximal segment 171.

[0042] FIG. 6 is a schematic top view of the vehicle in a third intermediate condition. As compared to the second intermediate condition of FIG. 5, one of the rotor blades 153 has (manually) been hinged towards the rear of the vehicle body 110, over an angle of about 60°, it being noted that the precise value of this angle is without relevance. Further, the distal segment 172 has been hinged forward with respect to the proximal segment 171, such as to “fold” this rotor blade. It is noted that it is possible that first the proximal segment 171 is hinged to the rear and that subsequently the distal segment 172 is folded forward with respect to the proximal segment 171, but it is also possible to first fold the distal segment 172 forward with respect to the proximal segment 171 and to subsequently hinge the folded blade 153 to the rear. It is also possible to do both hinging and folding actions simultaneously.

[0043] FIG. 7 is a top view comparable to FIG. 6, showing the righthand rotor blade 153 of the vehicle 100 in road travel condition. The distal segment 172 has been hinged forward with respect to the proximal segment 171 over 180°, and lies parallel to the corresponding proximal segment 171. In turn, the proximal segment 171 has been hinged rearward further, and now extends substantially parallel, in longitudinal direction of the vehicle, parallel to the mast 140. The hinge segment 173 is located at the rear end of the vehicle body 110, without necessarily extending beyond the rear. When both rotor blades 152 and 153 have been folded in this way, with the mast 140 in-between, the tail has a width wider than the vehicle body 110, and wider than the rotor blades in this folded condition, so that the tail boom 163 can be pushed in so that the tail foils take a position adjacent the vehicle body and adjacent the folded rotor blades, at the outside thereof, as shown. The vehicle as a whole is now nicely compact, suitable for being used as a “normal” car.

[0044] An important aspect of the present invention concerns the design of the hinge segment 173 in each rotor blade. In the following, a hinge structure for such hinge segment will generally be indicated by reference numeral 200. An objective of the invention is to provide a hinge design such that, in the stretched condition of the rotor blade 152, 153, the blade segments 171, 172 together with the hinge segment 173 provide an aerodynamically continuous outer blade surface, without interruptions, recesses or projections that could interfere with air flow and thus increase drag and reduce efficiency.

[0045] FIGS. 8A and 8B are perspective views illustrating the main components of an embodiment of a hinge structure 200 according to the present invention. FIG. 8A shows schematic representations of these components in taken apart condition, while FIG. 8B shows a more realistic view of these components in assembled condition.

[0046] The hinge structure 200 comprises a first blade connector 210, a central hinge element 240, and a second blade connector 270.

[0047] The central hinge element 240 has a central body 241, a first set of mutually parallel coupling flanges 242 extending away from the central body 241 in a first direction, and a second set of mutually parallel coupling flanges 243 extending away from the central body 241 in an opposite second direction. A first cylindrical hole 244 extends perpendicular through the first flanges 242, a second cylindrical hole 245 extends perpendicular through the second flanges 243. It is noted that the number of coupling flanges is not particularly relevant to the invention, and in fact a hinge with only one coupling flange per direction is also possible.

[0048] The first blade connector 210 comprises a blade attachment portion 211 and a hinge portion 212. The blade attachment portion 211 is designed to allow a first blade segment to be attached thereto; the precise shape will be designed in conjunction with the corresponding blade segment. The hinge portion 212 comprises a set of mutually parallel coupling flanges 213 attached to the attachment portion 211, either directly or through an intermediate body part. A cylindrical hole 214 extends perpendicular through the coupling flanges 213. Again, the number of coupling flanges here is not particularly relevant to the invention, and this number may again be as low as one.

[0049] The second blade connector 270 has a design comparable to, and possibly even identical to, the first blade connector 210. It comprises a blade attachment portion 271 and a hinge portion 272 with a set of mutually parallel coupling flanges 273 attached to the attachment portion 271, and a cylindrical hole 274 extending perpendicular through the coupling flanges 273.

[0050] The flanges 242, 243, 213, 273 have mutually parallel side surfaces extending perpendicular to the axes of the cylindrical holes 214, 244, 245, 275. The flanges match together, i.e. the width of the flanges 213, 273 of the blade connectors 210, 270 corresponds to the distances between the flanges 242, 243 of the central hinge element 240, and conversely the width of the flanges 242, 243 of the central hinge element 240 corresponds to the distances between the flanges 213, 273 of the blade connectors 210, 270.

[0051] In the assembled condition (FIG. 8B), said flanges are positioned in mutually engaged position, with the flanges 213, 273 of the blade connectors 210, 270 positioned in between the flanges 242, 243 of the central hinge element 240, and with the flanges 242, 243 of the central hinge element 240 positioned in between the flanges 213, 273 of the blade connectors 210, 270, the respective holes 214, 244 and 274, 245 being aligned with each other. A first cylindrical hinge axle 251 is pushed into the aligned holes 214, 244, while a second cylindrical hinge axle 252 is pushed into the aligned holes 274, 245. It should be clear that now the first blade connector 210 can hinge with respect to the central hinge element 240 about the first cylindrical hinge axle 251, and that the second blade connector 270 can hinge with respect to the central hinge element 240 about the second cylindrical hinge axle 252.

[0052] An important feature of the hinge structure 200 according to the present invention can be seen in FIG. 8B. The central hinge element 240 has an upper surface 246 that is common for the central body 241 and for all flanges 242, 243. The flanges 213 of the first blade connector 210 have flush upper surfaces 215, and the flanges 273 of the second blade connector 270 have flush upper surfaces 275. In the extended condition of the hinge structure 200, the flanges 213 of the first blade connector 210 extend to the central body 241 of the central hinge element 240 without any gaps and the flanges 273 of the second blade connector 270 extend to the central body 241 of the central hinge element 240 without any gaps. The upper surface 246 of the central hinge element 240 is flush and contiguous with the upper surfaces 215 of the flanges 213 of the first blade connector 210 and flush and contiguous with the upper surfaces 275 of the flanges 273 of the second blade connector 270.

[0053] FIG. 8C is a view comparable to FIG. 8B, with one blade segment (for instance 171) attached to the second blade connector 270. The outer skin of the blade segment 171 is completely flush with the flanges 273 of the second blade connector 270. The same applies to the other blade segment attached to the first blade connector 210, but this is not shown separately. It can be seen that, in forward and rearward direction, i.e. in the direction parallel to the hinge axles, the blade segment 171 extends beyond the contour of the hinge, and at these locations the blade segment extends further in longitudinal direction such that, in the extended state, the end portions of the two blade segments touch each other, or approach each other as close as possible, to obtain a near seamless transition between the two blade segments.

[0054] It should be clear that, in the extended state of the hinge, the two blade segments 171, 172 together with the hinge structure 200 define a seamless and flush upper blade surface, without interruptions. This is also illustrated schematically in FIG. 9A. At the underside, the outer skins of the blade segments 171 and 172 join each other in flush manner, so that the precise shape of the lower surfaces of the blade connectors and central hinge element is not particularly relevant.

[0055] FIG. 9A is a schematic perspective view of the central hinge portion of one rotor blade, showing the central hinge element 240 and the two blade segments 171, 172 with a single seam 174 where they touch.

[0056] Given the fact that the hinge structure 200 has two hinge axes arranged parallel at some distance from each other, with the two blade segments 171, 172 meeting each other at a position in between those two axes, the two blade segments 171, 172 must not be made to hinge simultaneously otherwise they would interfere with each other. This is schematically illustrated in FIG. 10A. The two blade segments 171, 172 meet each other at an upper point A above a hinge plane defined by the hinge axes 251, 152, and at a lower point B below said plane. Assume that the two blade segments 171, 172 are folded in upward direction, indicated by arrows P1. It will easily be seen that at the lower point B the two blade segments 171, 172 will move away from each other, as indicated by arrows P2, but that at upper point A the two blade segments 171, 172 will (try to) move towards each other.

[0057] To avoid this, the present invention provides that the end portions of the two blade segments 171, 172 facing each other, i.e. the proximal end of the distal blade segment 172 and the distal end of the proximal blade segment 171, are shaped so that one allows hinging of the other without interference, as schematically illustrated in FIG. 10B. Particularly, above said hinge plane, the end portions of the two blade segments 171, 172 may have a contour that follows a cylindrical shape around the first hinge axis 251, as indicated at 175. It will now be seen that the second blade segment 172 can not hinge, but the first blade segment 171 can be hinged up without interfering with the second blade segment 172—see FIG. 9B. After this hinging has been completed, the second blade segment 172 can be hinged up without interfering with the first blade segment 171—see FIG. 9C.

[0058] For hinging in the opposite direction, i.e. deploying, the hinging order should be opposite.

[0059] FIGS. 9A-C schematically show the rotor blade 153 in an orientation of normal operation, i.e. with the chord 14 substantially horizontal. It can be seen that, after folding, the upper surfaces 171u, 172u of the blade segments 171, 172 are facing each other (FIG. 9C), while in the extended condition said upper surfaces 171u, 172u are flush with each other and the intermediate central hinge element 240 (FIG. 9A). With reference to FIGS. 4-5-6-7 it is noted that, in reality, in the folding condition the blade has rotated over about 90° so that the chord 14 is substantially vertical.

[0060] From the above, it follows that the two blade segments 171, 172 should be folded and deployed in a correct folding order. It is preferred that the order of folding is not left to the skills of the user, but that the hinge structure 200 is provided with safety features that ensure the correct folding order without the user having to consider.

[0061] FIGS. 11A-C schematically illustrate the operational principles of an embodiment of a preferential folding control arrangement 300 according to the present invention. The first hinge axle 251 is provided with a first recess 311, and the second hinge axle 252 is provided with a second recess 312. The central hinge element 240 is provided with a lock pin 330, axially slideable in a chamber 320 of the central hinge element 240, positioned between the two hinge axles 251, 252, and having a length larger than the mutual distance between the two hinge axles 251, 252.

[0062] The angular position of the first recess 311 with respect to the first hinge axle 251 is such that this recess is aligned with a first end of the lock pin 330 when the first blade connector 210 is in the extended condition. The angular position of the second recess 312 with respect to the second hinge axle 252 is such that this recess is aligned with an opposite second end of the lock pin 330 when the second blade connector 270 is in the folded condition.

[0063] FIG. 11A illustrates the hinge structure 200 in the fully extended condition, i.e. the flying condition. The first end of the lock pin 330 extends into the first recess 311, such that the first hinge axle 251, which is attached to the first blade connector 210, is prevented from rotating with respect to the central hinge element 240. The opposite second end of the lock pin 330 abuts the outer surface of the second hinge axle 252, such that the lock pin 300 is prevented from releasing the first hinge axle 251. The second blade connector 270 is free to hinge up.

[0064] When the second blade connector 270 reaches its folded condition, the second recess 312 comes into alignment with the lock pin 330. The lock pin 330 is now shifted, with its second end entering the second recess 312 to lock the second blade connector 270 against folding. This condition is illustrated in FIG. 11B.

[0065] When the first end of the lock pin 330 has completely left the first recess 311, the first blade connector 210 is free to hinge up—see FIG. 11C.

[0066] It is noted that the user only needs to take hold of the outer blade segment and push it in the folding direction. In a first hinging stage (typically for the first 90° of hinging), hinging will take place with respect to the second hinge axle 252 as active hinge, after which the first hinge axle 251 automatically becomes the active hinge in a subsequent second hinging stage. In this respect, it does not really matter whether the outer or the inner blade segment is the first to hinge with respect to the central hinge element 240.

[0067] For hinging in the opposite direction, for employing the folded blade, the user again only needs to take hold of the outer blade segment and push it in the employment direction. At first, the first hinge axle 251 automatically is the active hinge, so that the first blade connector 210 employs to its extended state—going from FIG. 11C to FIG. 11B. When the first blade connector 210 reaches its extended state, defined by a stop not shown for sake of simplicity, the second hinge axle 252 becomes active after shifting of the lock pin.

[0068] It is possible that shifting the lock pin 330 requires a user action. To assist the user, the folding control arrangement 300 may comprise a bias member 340, for instance a spring, arranged in the chamber 320 or at another suitable position, exerting a bias force on the lock pin 330 for pressing the lock pin 330 towards the second hinge axle 252. Alternatively or additionally, in a preferred embodiment, the second end of the lock pin 330 has a bevelled edge, as does the second recess 312, so that exerting some force on the second blade connector 270 will force the second end of the lock pin 330 out of the second recess 312 while at the same time the first end of the lock pin 330 enters the first recess 311, and the second blade connector 270 can hinge further—going from FIG. 11B to FIG. 11A. Similarly, in a preferred embodiment, the first end of the lock pin 330 has a bevelled edge, as does the first recess 311, forcing the first end of the lock pin 330 out of the first recess 311 at the end of the folding operation from the position in FIG. 11A to the position in FIG. 11B; in such case, the bias spring can be dispensed with.

[0069] It is possible that the extended, deployed state of the hinge structure 200 is defined and secured by a first pin-in-hole arrangement for defining the extended position of the first blade connector 210 with respect to the central hinge element 240, and by a second pin-in-hole arrangement for defining the extended position of the second blade connector 270 with respect to the central hinge element 240, respectively. This would mean that, before the user is able to fold a blade, he would have to remove these two pins, and after deploying the blade he would need to place these pins. In a further elaboration of the present invention, such securing arrangement is not needed, in that the extended, deployed state of the hinge structure 200 is defined by stops, of which the precise design and position is not essential. Such stop may be arranged on the central hinge element, or on a blade connector, or both. A first such stop defines the extended position of the first blade connector 210 with respect to the central hinge element 240, and a second such stop defines the extended position of the second blade connector 270 with respect to the central hinge element 240. For the user, this has an advantage in that he can start folding the blade without first needing to remove a pin, and he can deploy the blade until it reaches the stop(s) without then needing to place any pin. Such pin-in-hole arrangement is not needed for keeping the blades deployed in the operative situation, because forces on the blades are such as to keep them extended automatically.

[0070] It is noted that, in an embodiment with the folding control arrangement 300, one of the above-mentioned stops can be dispensed with.

[0071] Summarizing, a foldable rotor blade comprises a hinge element defining two hinge axes arranged in parallel, and two blade segments each coupled to the hinge element for hinging with respect to a respective one of said hinge axes. The rotor blade has an extended condition in which the blade segments are substantially aligned with each other; the rotor blade has a folded condition in which each blade segment is hinged with respect to the hinge element so that the blade segments are substantially parallel to each other. The blade has a cord and said hinge axes are substantially parallel to the chord. The blade segments have upper surfaces which in the folded condition are facing each other, and which in the extended condition are flush with each other and the intermediate hinge element.

[0072] It should be clear to a person skilled in the art that the present invention is not limited to the exemplary embodiments discussed above, but that several variations and modifications are possible within the protective scope of the invention as defined in the appending claims. For instance, the inventive hinge structure can also be applied to fixed wing airplanes. Further, instead of a hinge structure 200 with blade connectors to be attached to blade segments, it is also possible that a blade connector is integrated with a blade segment, i.e. that the blade segment is provided with a hinge portion such as 212 or 272.

[0073] Even if certain features are recited in different dependent claims, the present invention also relates to an embodiment comprising these features in common. Even if certain features have been described in combination with each other, the present invention also relates to an embodiment in which one or more of these features are omitted. Features which have not been explicitly described as being essential may also be omitted. Any reference signs in a claim should not be construed as limiting the scope of that claim.