UAV CONFIGURATIONS AND BATTERY AUGMENTATION FOR UAV INTERNAL COMBUSTION ENGINES, AND ASSOCIATED SYSTEMS AND METHODS

• US 20170066531A1
• Filed: 09/09/2016
• Published: 03/09/2017
• Est. Priority Date: 03/13/2014
• Status: Active Grant

• Current Assignee: Endurant Systems, LLC
• Original Assignee: Endurant Systems, LLC
• Inventors: McAdoo, Gregory Leonard
• Granted Patent: US 10,351,238 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B64C 27/08 with two or more rotors
• CPC Class Codes: B64C 27/26 characterised by provision of fixed wings
• CPC Class Codes: B64C 29/0033 the propellers being tiltable relative to the fuselage
• CPC Class Codes: B64C 39/024 of the remote controlled vehicle type, i.e. RPV
• CPC Class Codes: B64C 39/04 having multiple fuselages or tail booms
• CPC Class Codes: B64D 2045/0085 Devices for aircraft health monitoring, e.g. monitoring flutter or vibration
• CPC Class Codes: B64D 2221/00 Electric power distribution systems onboard aircraft
• CPC Class Codes: B64D 27/026 comprising different types of power plants, e.g. combination of a piston engine and a gas-turbine Hybrid electric aircraft B64D27/33
• CPC Class Codes: B64D 27/04 of piston type
• CPC Class Codes: B64D 27/24 using steam or spring force jet aircraft B64D27/16
• CPC Class Codes: B64D 45/00 Aircraft indicators or protectors not otherwise provided for camouflage F41H3/00
• CPC Class Codes: B64U 10/13 Flying platforms
• CPC Class Codes: B64U 10/16 with five or more distinct rotor axes, e.g. octocopters
• CPC Class Codes: B64U 10/20 Vertical take-off and landing [VTOL] aircraft flying platforms B64U10/13; helicopters B64U10/17
• CPC Class Codes: B64U 10/25 Fixed-wing aircraft VTOL aircraft B64U10/20
• CPC Class Codes: B64U 2201/10 autonomous, i.e. by navigating independently from ground or air stations, e.g. by using inertial navigation systems [INS]
• CPC Class Codes: B64U 30/12 Variable or detachable wings, e.g. wings with adjustable sweep
• CPC Class Codes: B64U 50/11 using internal combustion piston engines
• CPC Class Codes: B64U 50/19 using electrically powered motors
• CPC Class Codes: B64U 50/33 generated by combustion engines
• CPC Class Codes: H02J 2310/44 : for aircrafts
• CPC Class Codes: H02J 7/14 : for charging batteries from dynamo-electric generators driven at varying speed, e.g. on vehicle
• CPC Class Codes: H02J 7/34 : Parallel operation in networks using both storage and other dc sources, e.g. providing buffering H02J7/14 takes precedence
• CPC Class Codes: H02K 7/1815 : structurally associated with reciprocating piston engines general aspects of generating sets, e.g. housing, F02B63/04
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 50/60 : Efficient propulsion technologies, e.g. for aircraft

Abstract

UAV configurations and battery augmentation for UAV internal combustion engines, and associated systems and methods are disclosed. A representative configuration includes a fuselage, first and second wings coupled to and pivotable relative to the fuselage, and a plurality of lift rotors carried by the fuselage. A representative battery augmentation arrangement includes a DC-powered motor, an electronic speed controller, and a genset subsystem coupled to the electronic speed controller. The genset subsystem can include a battery set, an alternator, and a motor-gen controller having a phase control circuit configurable to rectify multiphase AC output from the alternator to produce rectified DC feed to the DC-powered motor. The motor-gen controller is configurable to draw DC power from the battery set to produce the rectified DC feed.

Claims

1. A multi-rotor vehicle system comprising:

a direct current (DC) powered motor coupleable to a rotor;

an electronic speed controller coupled to the DC-powered motor to control the speed of the DC-powered motor by regulating electric current supplied to the DC-powered motor; and

a genset subsystem coupled to the electronic speed controller to power the electronic speed controllers through a DC motor bus, wherein the genset subsystem includes;

a battery set including one or more batteries;

an alternator having a mechanical movement input and a multiphase alternating current (AC) output; and

a motor-gen controller having a phase control circuit configurable to rectify the multiphase AC output of the alternator to produce a rectified DC feed to the DC-powered motor; and

wherein the motor-gen controller is configurable to draw DC power from the battery set to produce the rectified DC feed.

2. The multi-rotor vehicle system of claim 1, wherein the motor-gen controller is configured to commutate the alternator by drawing DC power from at least one battery in the battery set.

3. The multi-rotor vehicle system of claim 1, wherein the motor-gen controller is configurable to draw the DC power from only a subset of the batteries in the battery set.

4. The multi-rotor vehicle system of claim 1, wherein the alternator is a brushless DC (BLDC) alternator.

5. The multi-rotor vehicle system of claim 1, wherein the genset subsystem further comprises:

an augmentation controller configured to fill in voltage ripples in the rectified DC feed from the phase control circuit using the DC power from the battery set.

6. The multi-rotor vehicle system of claim 5, wherein the augmentation controller is configurable to provide that the alternator produces less voltage than a nominal voltage of a battery in the battery set.

7. The multi-rotor vehicle system of claim 1, wherein the phase control circuit further comprises phase controllers implemented by transistors to thereby enable lossless rectification.

8. The multi-rotor vehicle system of claim 1, wherein the phase control circuit further comprises diodes.

9. The multi-rotor vehicle system of claim 1, further comprising:

a fuel-based power source that generates mechanical movement and is coupled to the mechanical movement input of the alternator.

10. The multi-rotor vehicle system of claim 9, wherein the fuel-based power source is an internal combustion engine.

11. The multi-rotor vehicle system of claim 1, further comprising:

an autopilot module to execute a flight plan for the multi-rotor vehicle system; and

a flight controller operatively coupled to the autopilot module and the electronic speed controller to control the electronic speed controller based on a command from the autopilot module.

12. The multi-rotor vehicle system of claim 11, further comprising:

a sensor coupled to the electronic speed controller or the DC-powered motor; and

wherein the flight controller implements a health monitor system that detects a failure or impending failure based on at least a reading of the sensor.

13. The multi-rotor vehicle system of claim 12, wherein the sensor is at least one of a current sensor, a voltage sensor, or a temperature sensor coupled to the electronic speed controller.

14. The multi-rotor vehicle system of claim 12, wherein the sensor is at least one of a temperature sensor or an inertial sensor coupled to the DC-powered motor.

15. A direct current (DC) power supply system comprising:

a battery bus coupled to a battery;

an internal combustion engine;

an alternator coupled to the internal combustion engine to convert mechanical movement of the internal combustion engine into at least an alternating current provided through an alternator phase terminal;

a motor-generator controller comprising;

phase controllers, coupled to the alternator phase terminal, configurable to rectify the alternating current into direct current at an output motor bus; and

an augmentation controller configurable to prevent the direct current from the motor bus from flowing into the battery bus, and to allow current to flow from the battery bus to the motor bus when a first voltage of the motor bus falls below a second voltage of the battery bus; and

a microcontroller configured to throttle the internal combustion engine to maintain the rectified direct current below a nominal voltage at the battery bus.

16. The DC power supply system of claim 15, wherein the microcontroller is configurable to switch the motor-generator controller from a first mode to a second mode.

17. The DC power supply system of claim 16, wherein the first mode and the second mode are selected from a ground-level engine start mode, an inflight engine start mode, a generator-only mode, a generator with ripple mitigation mode, a generator with battery augmentation mode, and a battery-only mode.

18. The DC power supply system of claim 17, wherein the generator-only mode, the generator with ripple mitigation mode, and the generator with battery augmentation mode are operable to operate under a battery-charging sub-mode, wherein the direct current produced by the phase controllers are used to charge the battery.

19. The DC power supply system of claim 16, further comprising a sensor at the internal combustion engine, and wherein the microcontroller is configured to control the internal combustion engine based at least on a sensor reading from the sensor.

20. The DC power supply system of claim 19, wherein the sensor is configured to monitor at least one of engine rotational speed, exhaust gas temperature, cylinder head temperature, or battery bus current.

21. The DC power supply system of claim 19, wherein the microcontroller is configured to control power output and rotational frequency of the internal combustion engine when throttling the internal combustion engine.

22. The DC power supply system of claim 19, wherein the microcontroller is configured to control ignition, throttle, fuel/air mixture, or any combination thereof, of the internal combustion engine.

23. The DC power supply system of claim 15, further comprising a sensor at the output motor bus to measure current or voltage at the output motor bus, and wherein the microcontroller is coupled to the sensor and configured to control at least one of the internal combustion engine or the motor-generator controller based on sensor reading from the sensor.

24. The DC power supply system of claim 15, further comprising a sensor at the battery bus to measure current or voltage at the battery bus, and wherein the microcontroller is coupled to the sensor and configured to control the internal combustion engine or the motor-generator controller based on sensor reading from the sensor.

25. A direct current (DC) power supply system comprising:

a battery bus coupled to a battery;

a first alternator phase terminal electrically coupled to a phase of an alternating current from an alternator; and

a motor-generator controller comprising;

phase controllers, coupled to the first alternator phase terminal and configurable to rectify the alternating current into direct current for output to a motor bus; and

an augmentation controller to prevent the direct current from the motor bus from flowing into the battery bus, and to allow current to flow from the battery bus to the motor bus when a first voltage of the motor bus falls below a second voltage of the battery bus.

26. The DC power supply system of claim 25, wherein the phase controllers are configured to provide active and dynamic cancelation of synchronous reactance from the direct current outputted to the motor bus.

27. The DC power supply system of claim 25, further comprising two additional alternator phase terminals, and wherein the alternator phase terminals, including the first alternator phase terminal, are adapted to transport power to or from the alternator.

28. The DC power supply system of claim 25, wherein the phase controllers are configured to provide active mitigation of ripple in the direct current outputted to the motor bus.

29. An unmanned aerial vehicle (UAV), comprising:

a fuselage;

a first wing coupled to and pivotable relative to the fuselage;

a second wing coupled to and pivotable relative to the fuselage; and

a plurality of lift rotors carried by the fuselage.

30. The UAV of claim 29, further comprising:

a first motor operatively coupled to the first wing to rotate the first wing relative to the fuselage; and

a second motor operatively coupled to the second wing to rotate the second wing relative to the fuselage.

31. The UAV of claim 29, further comprising a tractor rotor carried by the fuselage toward a forward end of the fuselage.

32. The UAV of claim 29, further comprising a pusher rotor carried by the fuselage toward an aft end of the fuselage.

33. The UAV of claim 29 wherein the lift rotors have rotation axes that are fixed relative to the fuselage.

34. The UAV of claim 29 wherein the lift rotors have rotation axes that are movable relative to the fuselage.

35. The system of claim 34 wherein two of the lift rotors are carried by a first pod and two of the lift rotors are carried by a second pod, and wherein each of the first and second pods is rotatable relative to the fuselage.

36. The system of claim 29, further comprising:

a direct current (DC) powered motor coupled to at least one of the lift rotors;

an electronic speed controller coupled to the DC-powered motor to control the speed of the DC-powered motor by regulating electric current supplied to the DC-powered motor; and

a genset subsystem coupled to the electronic speed controller to power the electronic speed controller through a DC motor bus, wherein the genset subsystem includes;

a battery set including one or more batteries;

an alternator having a mechanical movement input and a multiphase alternating current (AC) output; and

a motor-gen controller having a phase control circuit configurable to rectify the multiphase AC output of the alternator to produce a rectified DC feed to the DC-powered motor; and

wherein the motor-gen controller is configurable to draw DC power from the battery set to produce the rectified DC feed.

37. The system of claim 29, further comprising:

a DC-powered motor coupled to at least one of the lift rotors;

a DC power supply coupled to the DC-powered motor, the DC power supply comprising;

a battery bus coupled to a battery;

an internal combustion engine;

an alternator coupled to the internal combustion engine to convert mechanical movement of the internal combustion engine into at least an alternating current provided through an alternator phase terminal;

a motor-generator controller comprising;

phase controllers coupled to the alternator phase terminal and configurable to rectify the alternating current into direct current at an output motor bus;

an augmentation controller configurable to prevent the direct current from the motor bus from flowing into the battery bus, and to allow current to flow from the battery bus to the motor bus when a first voltage of the motor bus falls below a second voltage of the battery bus; and

a microcontroller configured to throttle the internal combustion engine to maintain the rectified direct current below a nominal voltage at the battery bus.

38. An unmanned aerial vehicle (UAV), comprising:

a fuselage;

a first wing carried by the fuselage;

a second wing carried by the fuselage;

a first pod carrying first and second lift rotors, the first pod being pivotable relative to the first wing; and

second pod carrying third and fourth lift rotors, the second pod being pivotable relative to the second wing.

39. The UAV of claim 38, wherein the first pod is carried by the first wing and the second pod is carried by the second wing.

40. The UAV of claim 39, further comprising:

a first elevator coupled to and pivotable relative to the first pod; and

a second elevator coupled to and pivotable relative to the second pod.

41. The UAV of claim 39 wherein the first pod is carried at an outer tip of the first wing, and wherein the second pod is carried at an outer tip of the second wing.

42. The UAV of claim 39 wherein:

the first wing has an inboard portion and an outboard portion, and the first pod is carried between the inboard and outboard portions of the first wing; and

the second wing has an inboard portion and an outboard portion, and the second pod is carried between the inboard and outboard portions of the second wing.

43. The UAV of claim 42 wherein:

the first and second pods are fixed relative to the fuselage;

the outboard portion of the first wing is pivotable relative to the first pod; and

the outboard portion of the second wing is pivotable relative to the second pod.

44. The UAV of claim 38 wherein the first and second pods are carried by the fuselage.

45. The UAV of claim 38 wherein the first and second pods are each pivotable relative to the fuselage.

46. The UAV of claim 38, further comprising a pusher rotor carried by the fuselage.

47. A method for operating an unmanned aerial vehicle (UAV), comprising:

changing an angle of attack and center of lift of a first wing of the UAV by changing a configuration of the first wing;

changing an angle of attack and center of lift of a second wing of the UAV by changing a configuration of the second wing; and

propelling the UAV with a plurality of lift rotors.

48. The method of claim 47 wherein:

changing the configuration of the first wing includes rotating the first wing relative to a fuselage of the UAV; and

changing the configuration of the second wing includes rotating the second wing relative to a fuselage of the UAV.

49. The method of claim 47 wherein the lift rotors are rotatable about corresponding rotation axes, and wherein the rotation axes are fixed relative to a fuselage of the UAV while the angle of attack and the center of lift of the first and second wings are changed.

50. The method of claim 47 wherein the lift rotors are rotatable about corresponding rotation axes, and wherein the rotation axes rotate relative to a fuselage of the UAV while the angle of attack and the center of lift of the first and second wings are changed.

51. A method for operating an unmanned aerial vehicle (UAV), comprising transitioning between a hover mode and a forward flight mode by:

rotating a first pod relative to a first wing of the UAV, the first pod carrying first and second lift rotors; and

rotating a second pod relative to a second wing of the UAV, the second pod carrying third and fourth lift rotors.

52. The method of claim 51 wherein the first pod is carried by the first wing and the second pod is carried by the second wing.

53. The method of claim 51 wherein the first and second pods are both carried by a fuselage of the UAV.

54. The method of claim 51 wherein:

rotating the first pod includes pivoting a first elevator carried by the first pod; and

rotating the second pod includes pivoting a second elevator carried by the second pod.

55. The method of claim 51 wherein rotating the first and second pods includes rotating the first and second pods while the first and second wings remain fixed relative to a fuselage of the UAV.

56. The method of claim 51 wherein transitioning between the hover mode and the forward flight mode further includes rotating the first and second wings relative to a fuselage of the UAV.