Unmanned Aerial Drone Crane
20220219815 · 2022-07-14
Inventors
Cpc classification
B64D1/22
PERFORMING OPERATIONS; TRANSPORTING
B64C2027/7294
PERFORMING OPERATIONS; TRANSPORTING
B64C39/024
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A UAV preferably has 6 rotors mounted on an H-Frame setup with two parallel longitudinally extending support beams with a cross beam. The rotors are mounted along the longitudinal extending support beams, with one rotor mounted at each end and one motor mounted at the cross beam. Such an arrangement is more efficient than a helicopter of similar disk size and will be more efficient than a traditional hex rotor setup when lifting heavy payloads at a construction site.
Claims
1. An unmanned aerial vehicle comprising: a frame including a longitudinal beam having a first end, a second end, an upper surface and a lower surface and a first lateral beam connected to the lower surface of the longitudinal beam at the first end, a second lateral beam connected to the lower surface the longitudinal beam at the second end and a third lateral beam connected to the upper surface of the longitudinal beam between the first end and the second end; a first propulsion unit mounted to an end of the first lateral beam of the frame and including a first motor configured to operate at a plurality of speeds, a shaft rotated by the motor, a first propeller, mounted above the first lateral beam rotatably coupled to the first motor via the shaft and having a first hub and a first plurality of blades mounted on the hub, the blades having a pitch that is varied by a rack gear; a second propulsion unit mounted to an end of the second lateral beam of the frame and including a second motor configured to operate at a plurality of speeds, a second propeller, mounted above the second lateral beam and rotatably coupled to the second motor and having a second hub and a second plurality of blades mounted on the second hub; a third propulsion unit mounted to an end of the third lateral beam of the frame and including a third motor configured to operate at a plurality of speeds, a third propeller mounted above the third lateral beam and rotatably coupled to the third motor and having a third hub and a third plurality of blades mounted on the third hub and having blade tips configured and located to create blade tip vortices that act on the first and second plurality of blades.
2. The unmanned aerial vehicle of claim 1, further comprising a second longitudinal beam having a first end, a second end, an upper surface and a lower surface, said second longitudinal beam connected to the first lateral beam, second lateral beam and third lateral beam.
3. The unmanned aerial vehicle of claim 1, wherein the upper surface of the first lateral beam supports the lower surface of the longitudinal beam and the upper surface of the second lateral beam supports the lower surface of the longitudinal beam.
4. The unmanned aerial vehicle of claim 1, wherein the first, second and third plurality of blades are configured to cause the blade tip vortices of the third plurality of blades to reduce blade tip vortices formed by the first and second plurality of blades.
5. The unmanned aerial vehicle of claim 1, wherein the first propulsion unit further comprises a pinion motor driving a pinion mounted for connection with the rack gear, whereby rotation of the pinion motor varies the pitch of the first plurality of blades.
6. The unmanned aerial vehicle of claim 5, wherein the first propulsion unit further comprises a pitch slider connected to the rack gear and a plurality of pitch links extending between the pitch slider and a plurality of pitch levers.
7. The unmanned aerial vehicle of claim 6, wherein the pitch levers are configured to rotate the blades in response to movement of the pitch slider.
8. The unmanned aerial vehicle of claim 7, wherein the first propulsion unit further comprises a pitch slider connected to a second rack gear and the pitch slider.
9. The unmanned aerial vehicle of claim 8, wherein the first propulsion unit further comprises a second pinion motor and pinion connected to the rack gear.
10. A first propulsion unit configured to be mounted to an end of a first lateral beam of a frame of an unmanned aerial vehicle, said propulsion unit including a first motor configured to operate at a plurality of speeds, a shaft rotate by the motor, a first propeller, mounted above the first lateral beam rotatably coupled to the first motor via the shaft and having a first hub and a first plurality of blades mounted on the hub, the blades having a pitch that is varied by a rack gear.
11. The unmanned aerial vehicle of claim 10, wherein the first propulsion unit further comprises a pinion motor driving a pinion mounted for connection with the rack gear, whereby rotation of the pinion motor varies the pitch of the first plurality of blades.
12. The unmanned aerial vehicle of claim 11, wherein the first propulsion unit further comprises a pitch slider connected to the rack gear and a plurality of pitch links extending between the pitch slider and a plurality of pitch levers.
13. The unmanned aerial vehicle of claim 12, wherein the pitch levers are configured to rotate the blades in response to movement of the pitch slider.
14. The unmanned aerial vehicle of claim 13, wherein the first propulsion unit further comprises a pitch slider connected to a second rack gear and the pitch slider.
15. The unmanned aerial vehicle of claim 14, wherein the first propulsion unit further comprises a second pinion motor and pinion connected to the rack gear.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Detailed embodiments of the present invention are disclosed herein. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
[0021] When a feature or element is herein referred to as being “on” another feature or element, it can be directly on the other feature or element or intervening features and/or elements may also be present. In contrast, when a feature or element is referred to as being “directly on” another feature or element, there are no intervening features or elements present. It will also be understood that, when a feature or element is referred to as being “connected”, “attached” or “coupled” to another feature or element, it can be directly connected, attached or coupled to the other feature or element or intervening features or elements may be present. In contrast, when a feature or element is referred to as being “directly connected”, “directly attached” or “directly coupled” to another feature or element, there are no intervening features or elements present. Although described or shown with respect to one embodiment, the features and elements so described or shown can apply to other embodiments. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.
[0022] Spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms “upwardly”, “downwardly”, “vertical”, “horizontal” and the like are used herein for the purpose of explanation only unless specifically indicated otherwise.
[0023] Although the terms “first” and “second” may be used herein to describe various features/elements (including steps), these features/elements should not be limited by these terms, unless the context indicates otherwise. These terms may be used to distinguish one feature/element from another feature/element. Thus, a first feature/element discussed below could be termed a second feature/element, and similarly, a second feature/element discussed below could be termed a first feature/element without departing from the teachings of the present invention.
[0024] Throughout this specification and the claims which follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” and “comprising” means various components can be co-jointly employed in the methods and articles (e.g., compositions and apparatuses including device and methods). For example, the term “comprising” will be understood to imply the inclusion of any stated elements or steps but not the exclusion of any other elements or steps.
[0025] As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word “about” or “approximately,” even if the term does not expressly appear. The phrase “about” or “approximately” may be used when describing magnitude and/or position to indicate that the value and/or position described is within a reasonable expected range of values and/or positions. Any numerical values given herein should also be understood to include about or approximately that value, unless the context indicates otherwise. Any numerical range recited herein is intended to include all sub-ranges subsumed therein.
[0026] The following detailed description should be read with reference to the drawings in which similar elements in different drawings are numbered the same. The detailed description and the drawings, which are not necessarily to scale, depict illustrative embodiments and are not intended to limit the scope of the disclosure. Instead, the illustrative embodiments depicted are intended only as exemplary. Selected features of any illustrative embodiment may be incorporated into another embodiment unless clearly stated to the contrary. While the disclosure is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit aspects of the disclosure to the particular illustrative embodiments described. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the disclosure.
[0027] With initial reference to
[0028] Drone crane 10 also comprises a first propulsion unit 61 mounted to an end 62 of first lateral beam 41. First propulsion unit 61 includes a first motor 64 configured to operate at a plurality of speeds. Motor 64 is securely attached to first lateral beam 41 with a mounting plate 65. A first propeller 66, mounted above first lateral beam 41 is rotatably coupled to first motor 64. First propeller 66 has a first hub 67 and a first plurality of blades 68 mounted on hub 67. First plurality of blades 68 has a pitch that is varied. A second propulsion unit 71 is mounted to an end 72 of second lateral beam 42. Second propulsion unit 71 includes a second motor 75 configured to operate at a plurality of speeds, a second propeller 76, mounted above second lateral beam 42 and rotatably coupled to second motor 75 and having a second hub 77 and a second plurality of blades 78 mounted on second hub 77. A third propulsion unit 81 is mounted to an end 82 of third lateral beam 43 and includes a third motor 85 configured to operate at a plurality of speeds. A third propeller 86 is mounted above third lateral beam 43 and is rotatably coupled to third motor 85 and having a third hub 87 and a third plurality of blades 88 mounted on the third hub and having blade tips 89 configured to create blade tip vortices 90 that act on the first and second plurality of blades 68, 78.
[0029] Second longitudinal beam 32 also has a first end 151, a second end 152, an upper surface 153 and a lower surface 154. Second longitudinal beam 32 connected to first lateral beam 41, second lateral beam 42 and third lateral beam 43. Upper surface 155 of first lateral beam 41 supports lower surface 154 of second longitudinal beam 32 and upper surface of second lateral beam 42 supports the lower surface of second longitudinal beam 32. The first, second and third plurality of blades 68, 78, and 88 are configured to cause blade tip vortices 90 of third plurality of blades 88 to reduce blade tip vortices 190, 191 formed by the first and second plurality of blades 68, 78.
[0030] Referring back to
[0031] The drone is equipped with landing gear 410. As shown landing struts 411 are located in a rectangular pattern and are attached to the laterally first and second extending beams 41, 42. As shown landing struts 411 are fixed. Preferably, landing struts 411 are long enough so that load 400 carried by drone crane 10 will not touch the ground when drone crane 10 has landed. However, the landing struts 411 could be shorter for when drone crane 10 will pick up and drop off payload 400 supported by a sling while flying. Landing struts 411 could also be retractable. Details of such a landing gear can be found in U.S. Patent Application Publication No. 2018/0281933 incorporated herein by reference.
[0032] A power source or battery 415 is also provided. Battery 415 may be centrally located on longitudinal beams 31, 32 and contains a plurality of stacks of lithium battery cells 420. Alternatively, battery 415 is comprised of multiple smaller cells (not shown) each located on lateral beams 41, 42 to reduce the length of cable from the cells to the propulsions unit, thus providing redundancy while increasing efficiency and decreasing weight. Preferably battery 415 is a rechargeable smart battery having a controller 421 that tracks battery usage, charging and temperature. More details of a rechargeable battery for a drone are found in U.S. Patent Application Publication No. 2019/0233100 incorporated herein by reference.
[0033] Frame 20 preferably supports a control unit 510 in addition to, propulsion units 61, 71, 81, 361, 371, and 381, battery 415 payload securing bracket 401, and other components.
[0034] Through control of the individual propulsion units 61, 71, 81, 361, 371, and 381, drone crane 10 is controlled in flight. In the central processor 520 there is located a navigation controller 525 configured to determine the present position and orientation of drone crane 10, the appropriate course towards a destination, etc.
[0035] Optionally a camera apparatus 526 is coupled to drone crane 10 for providing image data to an image processing system 526 within or coupled to the processor 520. Image processing system 526 is preferably a separate image processor, such as an application specific integrated circuit, configured for processing images, such as stitching together images. Alternatively, image processing system 526 is implemented in software executing within the processor 520.
[0036] Control unit 510 preferably includes one or more transceivers 530, which may be coupled to an antenna 522. Transceiver 530 is preferably capable of communication with other drones, smart phones, a drone controller and other devices or electronic systems. Transceiver 530 may include a GPS receiver configured to provide position information to navigation unit 525 and include a GNSS receiver configured to provide three-dimensional coordinate information to drone crane 10 by processing signals received from three or more GNSS satellites. Navigation controller 525 may use an additional or alternate source information from processed images to determine speed and direction of travel and attitude information by processing images of the ground.
[0037] An avionics component 540 of navigation controller 525 may be configured to provide flight information, such as altitude, attitude, airspeed, heading and similar information that may be used for navigation purposes. Navigation controller 525 may include or be coupled to sensors 523 configured to supply data to navigation controller 525. For example, sensors 523 could include one or more accelerometers or gyroscopes to provide information to the navigation unit. Sensors 523 could also include barometers, thermometers, audio sensors, motion sensors, etc. Sensors 523 may provide information regarding accelerations and orientation (e.g., with respect to the gravity gradient and earth's magnetic field) to enable navigation controller 525 to perform navigational calculations of drone crane 10 during flight. A barometer may provide ambient pressure readings used to approximate elevation level (e.g., absolute elevation level) of drone crane 10.
[0038] The details of propulsion unit 61 can be best seen in
[0039]
[0040] Turning back to
[0041] A hub coupler 785 is connected to shaft 650 by hub retaining pins 765. Hub 67 is trapped between hub cap 760 and hub coupler 785. Shaft 650 is provided with motor coupler retaining pin holes 785. When assembled, shaft 650 passes through motor 64 motor coupler retaining pins pass into a motor coupler and then into the motor coupler retaining pin holes 785 to secure the motor to shaft 650. Shaft 650 is connected to hub 67 which supports blades 66 by a blade cuff and spacer assembly 715.
[0042] Blade cuff and spacer assembly 715 is one of three assemblies mounted on hub 67. Blade cuff and spacer assembly 715 is shown separated from hub 67 at the upper right of
[0043] The examples and illustrations included herein show, by way of illustration and not of limitation, specific embodiments in which the subject matter may be practiced. As mentioned, other embodiments may be utilized and derived there from, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. Such embodiments of the inventive subject matter may be referred to herein individually or collectively by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventive concept, if more than one is, in fact, disclosed. Thus, although specific embodiments have been illustrated and described herein, any arrangement calculated to achieve the same purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description.
[0044] For example, with minor modifications, namely a specific non-slung payload mount, drone crane has the potential to be an extremely powerful and nimble aircraft. The drone crane can support a 400 lb payload with a 2.0× safety factor. This safety factor could not only be drastically reduced for military use, but simply reducing the payload carried would allow the aircraft to operate at far greater speeds than in ‘crane configuration’. Alternative rotor blades could also be designed that have a symmetrical airfoil. The total lifting capacity would be slightly reduced, but the drone would then have the ability to fly inverted and perform maneuvers that create immense G-Forces that most other aircraft and pilots cannot withstand. This still allows the entire aircraft and payload to weigh at least as much as 400 lbs. A VTOL aircraft with this mass would become one of the largest and most capable in its class.
[0045] Although various illustrative embodiments are described above, any of a number of changes may be made to various embodiments without departing from the scope of the invention as described by the claims. For example, the order in which various described method steps are performed may often be changed in alternative embodiments, and in other alternative embodiments one or more method steps may be skipped altogether. Optional features of various device and system embodiments may be included in some embodiments and not in others. Therefore, the foregoing description is provided primarily for exemplary purposes and should not be interpreted to limit the scope of the invention as it is set forth in the claims.
[0046] As can be seen from the above description a drone crane has been described that can lift a large payload at a worksite with low risk to work crews working at the site. The drone takes advantage of rotor placement to increase lift and payload capacity. The drone also provides a mechanism to rotate blade pitch which also increases payload capacity.