Remotely controlled co-axial rotorcraft for heavy-lift aerial-crane operations

• US 10,112,707 B1
• Filed: 04/19/2017
• Issued: 10/30/2018
• Est. Priority Date: 10/03/2014
• Status: Active Grant

• Current Assignee: John V. Howard
• Original Assignee: John V. Howard
• Inventors: Howard, John V.
• Primary Examiner(s): Davis, Richard G
• Application Number:
  US15/491,701
• Time in Patent Office: 559 Days
• CPC Class Codes: B64C 2025/325 specially adapted for helicopters
• CPC Class Codes: B64C 27/10 arranged coaxially
• CPC Class Codes: B64C 27/14 Direct drive between power plant and rotor hub
• CPC Class Codes: B64C 29/02 having its flight directional axis vertical when grounded
• CPC Class Codes: B64C 39/024 of the remote controlled vehicle type, i.e. RPV
• CPC Class Codes: B64U 10/10 Rotorcrafts
• CPC Class Codes: B64U 10/17 Helicopters flying platforms B64U10/13
• CPC Class Codes: B64U 2101/60 for transporting passengers; for transporting goods other than weapons
• CPC Class Codes: B64U 2101/67 the UAVs comprising tethers for lowering the goods
• CPC Class Codes: B64U 30/24 Coaxial rotors
• CPC Class Codes: B64U 40/10 for adjusting control surfaces or rotors
• CPC Class Codes: B64U 50/12 using turbine engines, e.g. turbojets or turbofans
• CPC Class Codes: B64U 50/19 using electrically powered motors

Abstract

An unmanned rotorcraft has a lift module having a propulsion system and coaxial rotors driven in rotation by the propulsion system. The rotorcraft includes a payload support system adapted to couple an external payload directly to the lift module. The rotorcraft is devoid of provisions for human passengers.

Claims

1. A helicopter comprising:

a lift module having a propulsion system comprising two coaxial, counter-rotating rotors and at least one engine, each rotor having a plurality of blades, each blade being of the same length, the rotors being driven in rotation about a mast axis by the engine, the rotors generating a total thrust along a thrust vector;

a support module for supporting the helicopter when landed, the support module having at least three support members assembled in a radial array about the mast axis, in that the longitudinal axis of each support member intersects the mast axis;

a payload support system adapted to couple an external payload directly to the lift module;

wherein loads on the support module and associated component weights are significantly reduced, such that a ratio of the total thrust of the rotor to an empty weight of the helicopter is greater than about 3.5 to 1.

2. The helicopter of claim 1, wherein a ratio of the total thrust of the rotor to a weight of the helicopter carrying 70 minutes of fuel, but no payload, is greater than about 2.7 to 1.

3. The helicopter of claim 1, comprising a collective control system coupled to the rotor for varying a magnitude of the thrust vector, and a cyclic control system coupled to the rotor for varying an angle of the thrust vector in a forward direction such that when operated selectively in combination, the thrust vector of the rotors accelerates the helicopter along the initial vertical mast orientation and progressively tilts the helicopter, so that the thrust vector follows along an arced flight path until the helicopter reaches a horizontal cruise orientation.

4. The helicopter of claim 3, wherein the acceleration of the helicopter along the arced flight path causes the helicopter to increase both its vertical and horizontal velocity, thereby progressively tilting the mast from the vertical, so that it follows the arced flight path, until the helicopter reaches the horizontal cruise orientation.

5. A helicopter, comprising:

a lift module having a propulsion system and at least one rotor driven in rotation about a mast axis by the propulsion system, the rotor generating thrust along a thrust vector; and

a support module for supporting the helicopter when landed, the support module having at least three support members, each support member being of the same size and shape, extending outwardly in a radial array about the mast axis, each support member having an airfoil-shaped cross-section with its chord parallel to the mast axis, wherein during flight, increased velocity of the helicopter along an inclined and arced flight path permits the support members to develop a normal lifting force, further increasing inclination of the helicopter, and a vertical component of the lifting force in combination with a vertical component of the thrust provides sufficient lift to sustain the helicopter in horizontal flight, such that the mast axis is oriented in a substantially horizontal direction;

wherein a ratio of the total thrust of the rotor to an empty weight of the helicopter is greater than about 3.5 to 1.

6. The helicopter of claim 5, wherein the propulsion system comprises an at least one engine or propulsion means the primary axis of which is adapted to remain parallel to the plane of the arced flight path while maintaining a horizontal orientation regardless of the inclination of the rotor mast.

7. The helicopter of claim 5, wherein a ratio of the total thrust of the rotor to a weight of the helicopter carrying 70 minutes of fuel, but no payload, is greater than 27 to 1.

8. The helicopter of claim 5, comprising a collective control system coupled to the rotor for varying a magnitude of the thrust vector, and a cyclic control system coupled to the rotor for varying an angle of the thrust vector in a forward direction such that when operated selectively in combination, the thrust vector of the rotors accelerates the helicopter along the initial vertical mast orientation and progressively tilts the helicopter, so that the thrust vector follows along an arced flight path until the helicopter reaches a horizontal cruise orientation.

9. The helicopter of claim 5, wherein the acceleration of the helicopter along the arced flight path causes the helicopter to increase both its vertical and horizontal velocity, thereby progressively tilting the mast from the vertical so that the helicopter follows the arced flight path, until the helicopter reaches a horizontal cruise orientation.

10. A helicopter, comprising:

a lift module having a propulsion system and at least one rotor driven in rotation about a mast axis by the propulsion system the rotor generating thrust along a thrust vector; and

a support module for supporting the helicopter when landed, the support module having at least three support members extending outwardly in a radial array about the mast axis, each support member having an airfoil-shaped cross-section with its chord parallel to the mast axis, wherein during flight, increased velocity of the helicopter along an inclined and arced flight path permits the support members to develop a normal lifting force, further increasing inclination of the helicopter, and a vertical component of the lifting force in combination with a vertical component of the thrust provides sufficient lift to sustain the helicopter in horizontal flight, such that the mast axis is oriented in a substantially horizontal direction;

counter-rotating rotors;

a transmission for transferring torque to the rotors through a differential with two ring gears, each ring gear coupled to an output shaft coupled to one of the rotors; and

a yaw control system comprising;

a balance shaft rotatably carried by the transmission, the balance shaft coupling the ring gears for balancing torque between the ring gears; and

a rotary actuator coupled to the balance shaft for selectively rotating the balance shaft relative to a housing of the transmission, wherein rotation of the balance shaft causes rotation of the housing about the differential, thereby causing yaw rotation of the helicopter generally about the mast axis.

11. The helicopter of claim 10, wherein the balance shaft couples the output shafts by engaging the ring gear associated with each output shaft, so that there is no rotation of each ring gear relative to the other ring gear.

12. The helicopter of claim 10, wherein the balance shaft comprises:

pinions that each engage the ring gear of each output shaft.