Intentionally imbalancing propellers for performance and noise-shaping

• US 9,902,490 B2
• Filed: 07/24/2017
• Issued: 02/27/2018
• Est. Priority Date: 12/18/2015
• Status: Active Grant

• Current Assignee: Amazon Technologies, Inc. (Amazon.com, Inc.)
• Original Assignee: Amazon Technologies, Inc. (Amazon.com, Inc.)
• Inventors: Beckman, Brian C., Ko, Allan
• Primary Examiner(s): Figueroa, Jaime
• Application Number:
  US15/658,168
• Publication Number:
  US 20170334546A1
• Time in Patent Office: 218 Days
• Field of Search: 701 1, 701 5
• CPC Class Codes: B64C 11/00 Propellers, e.g. of ducted type; Features common to propellers and rotors for rotorcraft
• CPC Class Codes: B64C 11/20 Constructional features
• CPC Class Codes: B64C 2230/14 achieving noise reductions
• CPC Class Codes: B64C 27/08 with two or more rotors
• CPC Class Codes: B64C 27/32 Rotors
• CPC Class Codes: B64C 27/473 Constructional features
• 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 10/13 Flying platforms
• CPC Class Codes: B64U 10/14 with four distinct rotor axes, e.g. quadcopters
• CPC Class Codes: B64U 20/20 for noise reduction
• CPC Class Codes: B64U 2101/60 for transporting passengers; for transporting goods other than weapons
• CPC Class Codes: B64U 2101/64 for parcel delivery or retrieval
• 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 30/20 Rotors; Rotor supports
• CPC Class Codes: G05D 1/101 specially adapted for aircraft
• CPC Class Codes: G05D 13/00 Control of linear speed; Control of angular speed; Control of acceleration or deceleration, e.g. of a prime mover
• CPC Class Codes: Y02T 50/10 Drag reduction

Abstract

Aerial vehicles may be operated with discrete sets of propellers, which may be selected for a specific purpose or on a specific basis. The discrete sets of propellers may be operated separately or in tandem with one another, and at varying power levels. For example, a set of propellers may be selected to optimize the thrust, lift, maneuverability or efficiency of an aerial vehicle based on a position or other operational characteristic of the aerial vehicle, or an environmental condition encountered by the aerial vehicle. At least one of the propellers may be statically or dynamically imbalanced, such that the propeller emits a predetermined sound during operation. A balanced propeller may be specifically modified to cause the aerial vehicle to emit the predetermined sound by changing one or more parameters of the balanced propeller and causing the balanced propeller to be statically or dynamically imbalanced.

Claims

1. A method for operating an aerial vehicle, wherein the method comprises:

identifying information regarding at least one attribute of a mission for the aerial vehicle having a first motor and a second motor;

rotatably coupling a first propeller to a first shaft of the first motor, wherein the first propeller is statically balanced and dynamically balanced;

predicting a noise to be emitted during a rotation of a second propeller above a critical speed of the second propeller, wherein the second propeller is statically balanced and dynamically balanced;

determining that at least one of a frequency spectrum of the noise or a sound pressure level of the noise is not consistent with the at least one attribute of the mission;

executing a modification to the second propeller, wherein the modified second propeller is at least one of statically imbalanced or dynamically imbalanced after executing the modification;

rotating the modified second propeller above a critical speed of the modified second propeller;

determining that a noise emitted during the rotation of the modified second propeller above the critical speed is consistent with the at least one attribute of the mission;

rotatably coupling the modified second propeller to a second shaft of the second motor; and

causing the aerial vehicle to perform the mission,

wherein the at least one attribute includes at least one of;

a location of an origin for the mission;

a location of a destination for the mission;

a location of an intervening waypoint between the origin and the destination;

at least one course to be traveled during the performance of the mission;

at least one air speed of the aerial vehicle required during the performance of the mission;

or

a mass of a payload to be carried by the aerial vehicle during the mission.

2. The method of claim 1, wherein a first center of mass is aligned along an axis of rotation along the first shaft,

wherein centrifugal forces acting upon each of a first plurality of blades of the first propeller are equal to and counteract one another when the first propeller is rotated above the critical speed of the first propeller,

wherein a second center of mass of the modified second propeller is not aligned along an axis of rotation of the second shaft, and

wherein centrifugal forces acting upon each of a second plurality of blades of the modified second propeller are not equal to or do not counteract one another when the modified second propeller is rotated above the critical speed of the modified second propeller.

3. The method of claim 1, wherein causing the aerial vehicle to perform the emission comprises:

causing a rotation of the first propeller above a critical speed of the first propeller;

determining a position of the aerial vehicle;

determining that the position of the aerial vehicle is within a predetermined range of one of the location of the origin, the location of the destination or the location of the intervening waypoint;

in response to determining that the position of the aerial vehicle is within a predetermined range of one of the location of the origin, the location of the destination or the location of the intervening waypoint,

stopping the rotation of the first propeller; and

causing a rotation of the modified second propeller above the critical speed of the modified second propeller.

4. The method of claim 1, wherein the second propeller comprises a first blade and a second blade, and wherein executing the modification to the second propeller comprises at least one of:

removing a core from the second blade;

inserting a slug into the second blade, wherein a density of the slug is greater than a density of a material from which the second blade is formed;

drilling at least a first hole in the second blade;

or

exposing, by a retractable cover disposed within the second blade, at least a second hole in the second blade;

or

modifying at least one of a blade angle or a rake angle of the second blade.

5. A method comprising:

prior to an operation of an aerial vehicle, predicting an attribute of the aerial vehicle during the operation, wherein the aerial vehicle comprises a first motor and a second motor;

coupling a first propeller to a first shaft of the first motor, wherein the first propeller is statically balanced and dynamically balanced;

determining a modification to a second propeller based at least in part on the predicted attribute;

modifying the second propeller in accordance with the determined modification, wherein the second propeller is statically balanced and dynamically balanced prior to modifying the second propeller in accordance with the determined modification, and wherein the second propeller is at least one of statically imbalanced or dynamically imbalanced after modifying the second propeller in accordance with the determined modification;

coupling the modified second propeller to a second shaft of the second motor; and

initiating the operation of the aerial vehicle, wherein the operation of the aerial vehicle comprises;

rotating the first propeller above a critical speed at a first time; and

rotating the modified second propeller above a critical speed at a second time.

6. The method of claim 5, wherein a center of mass of the modified second propeller is not aligned with an axis of rotation of the second shaft after the second propeller has been coupled to the second shaft.

7. The method of claim 5, wherein the predicted attribute is one of:

a predicted position of the aerial vehicle during the operation;

a predicted course of the aerial vehicle during the operation;

a predicted air speed of the aerial vehicle during the operation;

a predicted environmental condition around the aerial vehicle during the operation;

a predicted operating condition of the aerial vehicle during the operation;

or

a predicted sound emitted by the aerial vehicle during the operation.

8. The method of claim 5, further comprising:

prior to modifying the second propeller,

rotating the second propeller above the critical speed;

capturing information regarding a first sound emitted by the second propeller while rotating above the critical speed, wherein the information regarding the first sound comprises at least one of a first frequency spectrum of the first sound or a first sound pressure level of the first sound;

determining that at least one of the first frequency spectrum or the first sound pressure level is not desired based at least in part on the predicted attribute of the aerial vehicle during the operation; and

determining the modification based at least in part on the first frequency spectrum or the first sound pressure level.

9. The method of claim 8, wherein determining that the at least one of the first frequency spectrum or the first sound pressure level is not acceptable based at least in part on the predicted attribute of the aerial vehicle during the operation comprises:

identifying information regarding a second sound based at least in part on the predicted attribute of the aerial vehicle during the operation, wherein the information regarding the second sound comprises at least one of a second frequency spectrum of the second sound or a second sound pressure level of the second sound, and wherein at least one of the second frequency spectrum or the second sound pressure level is desired based at least in part on the predicted attribute of the aerial vehicle during the operation; and

identifying a difference between the first sound and the second sound based at least in part on the information regarding the first sound and the information regarding the second sound,

wherein the modification is determined based at least in part on the difference.

10. The method of claim 8, further comprising:

after modifying the second propeller,

rotating the modified second propeller above the critical speed;

capturing information regarding a second sound emitted by the modified second propeller while rotating above the critical speed, wherein the information regarding the second sound comprises at least one of a second frequency spectrum of the second sound or a second sound pressure level of the second sound; and

determining that at least one of the second frequency spectrum or the second sound pressure level is acceptable based at least in part on the predicted attribute of the aerial vehicle during the operation,

wherein the modified second propeller is coupled to the second shaft in response to determining that the at least one of the second frequency spectrum or the second sound pressure level is acceptable.

11. The method of claim 5, wherein the second propeller comprises a hub having a mounting bore, a first blade mounted about the hub and a second blade mounted about the hub, and

wherein modifying the second propeller in accordance with the determined modification comprises:

modifying the first blade in accordance with the determined modification; and

not modifying the second blade.

12. The method of claim 11, wherein the determined modification is a reduction in at least one of a length or a width of at least one blade of the second propeller, and

wherein modifying the first blade in accordance with the determined modification comprises:

reducing at least one of a length or a width of the first blade.

13. The method of claim 11, wherein the determined modification is an increase in mass of at least one blade of the second propeller, and

wherein modifying the first blade in accordance with the determined modification comprises:

inserting a slug into the first blade at a predetermined distance from the mounting bore of the hub, wherein a density of the slug exceeds a density of a material from which the first blade is formed.

14. The method of claim 11, wherein the determined modification is a reduction in mass of at least one blade of the second propeller, and

wherein modifying the first blade in accordance with the determined modification comprises:

removing a core from the first blade at a predetermined distance from the mounting bore of the hub.

15. The method of claim 11, wherein the determined modification is a reduction in mass of at least one blade of the second propeller, and

wherein modifying the first blade in accordance with the determined modification comprises:

opening a hole through at least a portion of the first blade at a predetermined distance from the mounting bore of the hub.

16. The method of claim 5, further comprising:

determining an actual attribute of the aerial vehicle during the operation of the aerial vehicle at the first time;

determining that the actual attribute of the aerial vehicle is consistent with the predicted attribute; and

in response to determining that the actual attribute of the aerial vehicle is consistent with the predicted attribute,

stopping the first propeller; and

rotating the modified second propeller above the critical speed at the second time,

wherein the actual attribute is one of;

an actual position of the aerial vehicle during the operation;

an actual course of the aerial vehicle during the operation;

an actual air speed of the aerial vehicle during the operation;

an actual environmental condition around the aerial vehicle during the operation;

an actual operating condition of the aerial vehicle during the operation;

or

an actual sound emitted by the aerial vehicle during the operation.

17. A method comprising:

rotating a propeller above a critical speed, wherein the propeller comprises at least two blades mounted about a hub;

capturing information regarding an observed noise emitted by the propeller while rotating above the critical speed, wherein the information regarding the observed noise comprises at least one of a frequency spectrum of the observed noise or a sound pressure level of the observed noise;

identifying information regarding a desired noise, wherein the information regarding the desired noise comprises at least one of a frequency spectrum of the desired noise or a sound pressure level of the desired noise;

determining that the observed noise is not consistent with the desired noise based at least in part on the information regarding the observed noise and the information regarding the desired noise;

in response to determining that the observed noise is not consistent with the desired noise,

identifying at least one difference between the observed noise and the desired noise;

determining an adjustment to one of the blades of the propeller based at least in part on the at least one difference;

modifying the one of the blades of the propeller in accordance with the adjustment;

rotatably coupling the modified propeller to a motor of an aerial vehicle; and

causing the aerial vehicle to travel at a desired altitude, along a desired course, at a desired air speed or to a desired location,

wherein causing the aerial vehicle to travel at the desired altitude, along the desired course, at the desired air speed or to the desired location comprises;

rotating the modified propeller above the critical speed.

18. The method of claim 17, wherein the propeller is statically balanced and dynamically balanced prior to modifying the one of the blades of the propeller in accordance with the adjustment, and

wherein the modified propeller is at least one of statically imbalanced or dynamically imbalanced.

19. The method of claim 17, wherein the adjustment is one of:

drilling a hole in the one of the blades of the propeller;

removing a core from the one of the blades of the propeller;

inserting a slug into the one of the blades of the propeller;

changing a rake angle of the one of the blades of the propeller;

changing a blade angle of the one of the blades of the propeller;

shortening a length of the one of the blades of the propeller;

or

reducing a width of the one of the blades of the propeller.

20. The method of claim 17, wherein identifying the information regarding the desired noise comprises:

identifying at least one noise restriction for the aerial vehicle, wherein the noise restriction for the aerial vehicle is associated with at least one of the desired altitude, the desired course, the desired air speed or the desired location; and

determining the at least one of the frequency spectrum of the desired noise or the sound pressure level of the desired noise based at least in part on the at least one noise restriction.