U.S. patent application number 16/223061 was filed with the patent office on 2019-08-01 for reconfigurable battery-operated vehicle system.
This patent application is currently assigned to AeroVironment, Inc.. The applicant listed for this patent is AeroVironment, Inc.. Invention is credited to Pavel Belik, Christopher E. Fisher, Justin B. McAllister, Marc L. Schmalzel, Phillip T. Tokumaru, Gabriel E. Torres, Jeremy D. Tyler, John Peter Zwaan.
Application Number | 20190233100 16/223061 |
Document ID | / |
Family ID | 50186070 |
Filed Date | 2019-08-01 |
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United States Patent
Application |
20190233100 |
Kind Code |
A1 |
Fisher; Christopher E. ; et
al. |
August 1, 2019 |
RECONFIGURABLE BATTERY-OPERATED VEHICLE SYSTEM
Abstract
A quadrotor UAV including ruggedized, integral-battery,
load-bearing body, two arms on the load-bearing body, each arm
having two rotors, a control module mounted on the load-bearing
body, a payload module mounted on the control module, and skids
configured as landing gear. The two arms are replaceable with arms
having wheels for ground vehicle use, with arms having floats and
props for water-surface use, and with arms having pitch-controlled
props for underwater use. The control module is configured to
operate as an unmanned aerial vehicle, an unmanned ground vehicle,
an unmanned (water) surface vehicle, and an unmanned underwater
vehicle, depending on the type of arms that are attached.
Inventors: |
Fisher; Christopher E.;
(Simi Valley, CA) ; Tokumaru; Phillip T.;
(Thousand Oaks, CA) ; Schmalzel; Marc L.; (Simi
Valley, CA) ; Zwaan; John Peter; (Simi Valley,
CA) ; Tyler; Jeremy D.; (Thousand Oaks, CA) ;
McAllister; Justin B.; (Seattle, WA) ; Torres;
Gabriel E.; (Seattle, WA) ; Belik; Pavel;
(Simi Valley, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
AeroVironment, Inc. |
Simi Valley |
CA |
US |
|
|
Assignee: |
AeroVironment, Inc.
Simi Valley
CA
|
Family ID: |
50186070 |
Appl. No.: |
16/223061 |
Filed: |
December 17, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15911146 |
Mar 4, 2018 |
10155588 |
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16223061 |
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14949805 |
Nov 23, 2015 |
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15911146 |
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13694388 |
Nov 26, 2012 |
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14949805 |
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PCT/US2011/000953 |
May 26, 2011 |
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13694388 |
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61399168 |
Jul 7, 2010 |
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61396459 |
May 26, 2010 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B63G 2008/005 20130101;
B64C 27/00 20130101; B64C 2201/108 20130101; B60K 17/356 20130101;
B60K 2007/0092 20130101; B60K 7/0007 20130101; B64D 27/24 20130101;
B64C 39/024 20130101; A63H 27/12 20130101; B64C 2201/042 20130101;
B63B 2035/008 20130101; B64C 2201/027 20130101; B63H 21/17
20130101; B64D 27/00 20130101; B60K 1/00 20130101; B63G 8/08
20130101; B60Y 2200/52 20130101; B60K 1/04 20130101 |
International
Class: |
B64C 39/02 20060101
B64C039/02; B60K 1/00 20060101 B60K001/00; B60K 1/04 20060101
B60K001/04; B60K 7/00 20060101 B60K007/00; B60K 17/356 20060101
B60K017/356; B63H 21/17 20060101 B63H021/17; B64D 27/00 20060101
B64D027/00; B64C 27/00 20060101 B64C027/00; A63H 27/00 20060101
A63H027/00; B63G 8/08 20060101 B63G008/08; B64D 27/24 20060101
B64D027/24 |
Claims
1. An unmanned vehicle configured for a range of missions,
comprising: a battery module having battery capacity adequate to
provide motive force for the vehicle over the range of missions,
the battery module having a plurality of electronic connection
ports; a control module including a control system configured to
control the operation of the vehicle over the range of missions,
the control module being directly and removably structurally
carried by the battery module, and the control module being
directly and removably electronically connected to the battery
module via a first connection port of the plurality of connection
ports; and a first propulsion module including a motor configured
to provide propulsive force to move the vehicle through one or more
missions of the range of missions, the first propulsion module
being directly and removably structurally connected to the battery
module via a second connection port of the plurality of connection
ports.
2. The vehicle of claim 1, and further comprising a second
propulsion module including a motor configured to provide
propulsive force to move the vehicle through the one or more
missions of the range of missions, the second propulsion module
being directly and removably structurally connected to the battery
module via a third connection port of the plurality of connection
ports.
3. The vehicle of claim 2, wherein the first propulsion module is
electronically connected to the battery module via the second
connection port, the second propulsion module is electronically
connected to the battery module via the third connection port, and
the first and second propulsion modules are electronically
connected to the control module via the battery module.
4. The vehicle of claim 2, wherein: the first propulsion module
includes a first arm with a centrally located first-arm connector
connected to the second connection port, and two substantially
vertically oriented propellers at opposite ends of the first arm;
and the second propulsion module includes a second arm with a
centrally located second-arm connector connected to the third
connection port, and two substantially vertically oriented
propellers at opposite ends of the second arm.
5-11. (canceled)
12. The vehicle of claim 2, wherein: the first propulsion module
includes a first arm with a centrally located first connector
connected to the second connection port, and two wheels at opposite
ends of the first arm; and the second propulsion module includes a
second arm with a centrally located second connector connected to
the third connection port, and two wheels at opposite ends of the
second arm.
13. The vehicle of claim 2, wherein: the first propulsion module
includes a first arm with a centrally located first connector
connected to the second connection port, two floats at opposite
ends of the first arm; and the second propulsion module includes a
second arm with a centrally located second connector connected to
the second connection port, and two floats at opposite ends of the
second arm.
14. The vehicle of claim 2, wherein: the first propulsion module
includes a first arm with a centrally located first connector
connected to the second connection port, two props at opposite ends
of the first arm, and two motors configured to independently
control a pitch angle of the respective props; and the second
propulsion module includes a second arm with a centrally located
first connector connected to the third connection port, two props
at opposite ends of the second arm, and two motors configured to
independently control a pitch angle of the respective props.
15. The vehicle of claim 2, wherein the battery module has a round
cross section.
16. The vehicle of claim 15, wherein the battery module extends
longitudinally between its second and third connection ports,
wherein the first connection port is located longitudinally between
the second and third connection ports, and wherein the control
module is structurally attached to the battery module both near the
second connection port and near the third connection port.
17. The vehicle of claim 2, wherein the battery module has an
elliptical cross section.
18. The vehicle of claim 2, wherein the battery module carries
substantially all structural loads between the first propulsion
module, the second propulsion module and the control module.
19. A reconfigurable unmanned vehicle system configured for a range
of missions, comprising: a body including a control system
configured to control the operation of the vehicle and a power
source having a power capacity adequate to provide complete motive
force for the vehicle over the range of missions, the body
including a set of one or more body connectors; a first set of one
or more propulsion modules removably attachable to the set of body
connectors, the first set of propulsion modules being one
propulsion module type selected from the group of unmanned aerial
vehicle propulsion modules, unmanned ground vehicle propulsion
modules, unmanned surface vehicle propulsion modules, and unmanned
underwater vehicle propulsion modules; and a second set of one or
more propulsion modules removably attachable to the set of body
connectors, the second set of propulsion modules being one
propulsion module type selected from the group of unmanned aerial
vehicle propulsion modules, unmanned ground vehicle propulsion
modules, unmanned surface vehicle propulsion modules, and unmanned
underwater vehicle propulsion modules; wherein the first set of
propulsion modules are of a different propulsion module type than
the second set of propulsion modules.
20-22. (canceled)
23. An unmanned vehicle, comprising: a body including a control
system configured to control the operation of the vehicle and a
power source having a power capacity adequate to provide complete
motive force for the vehicle over the range of missions, the body
including a first body connector and a second body connector on
opposite longitudinal ends of the body; a first propulsion module
removably attached to the first body connector, the first
propulsion module including a first arm configured to support the
body, one or more motors configured to use power from the power
source to provide propulsive force to move the vehicle through the
range of missions, and a first end cap; a second propulsion module
removably attached to the second body connector, the second
propulsion module including a second arm configured to support the
body, one or more motors configured to use power from the power
source to provide propulsive force to move the vehicle through the
range of missions, and a second end cap; wherein the first body
connector is configured with a first groove adapted to conformingly
and longitudinally receive the first arm, the first groove being
configured to directly bear all vertical loads from the first arm
without vertical loads being carried by the first end cap; wherein
the second body connector is configured with a second groove
adapted to conformingly and longitudinally receive the second arm,
the second groove being configured to directly bear all vertical
loads from the second arm without vertical loads being carried by
the second end cap; and wherein each end cap is configured to
longitudinally hold its respective arm onto the body.
Description
[0001] This application is a Continuation application of U.S.
patent application Ser. No. 15/911,146, filed Mar. 4, 2018, which
is a Continuation application of U.S. patent application Ser. No.
14/949,805, filed Nov. 23, 2015, now abandoned, which is a
Continuation application of U.S. patent application Ser. No.
13/694,388, filed Nov. 26, 2012, now abandoned, which is a
Continuation application of International PCT Application No.
PCT/US2011/000953, filed May 26, 2011, which claims the benefit of
U.S. Provisional Application No. 61/399,168, filed Jul. 7, 2010,
and also claims the benefit of U.S. Provisional Application No.
61/396,459, filed May 26, 2010, each of which are incorporated
herein by reference for all purposes.
[0002] The present invention relates generally to an unmanned,
battery-operated vehicle (e.g., a UAV) and, more particularly, to a
battery-operated vehicle that can be reconfigured for a wide
variety of purposes.
BACKGROUND OF THE INVENTION
[0003] Quadrotor UAVs (unmanned aerial vehicles) are typically
characterized by a center body having four arms coming out
laterally in an X configuration (when viewed from above). Each arm
supports one helicopter-type rotor directed upward. Typical control
for a quadrotor aircraft is accomplished by varying the speed of
each rotor, which typically is counter-rotating with respect to the
rotors on either side of the rotor (and rotating in the same
direction as the rotor on the opposite side).
[0004] For example, hovering is accomplished by having pairs of
opposite corner blades operating together, in a rotational
direction opposite of the other blades, and at equal speeds. Yawing
is accomplished by relatively speeding up one opposing-corner pair
with respect to the other, while pitch and roll is accomplished by
relatively varying the speed of adjacent pairs of blades. Forward,
reverse and side-to-side motion is accomplished by tilting the
craft in pitch or roll to cause the sum of the forces of the motors
to include a lateral component. Various other control protocols are
known in the art.
[0005] A typical battery-operated unmanned vehicle is characterized
by a primary structural body member (e.g., a fuselage) into which
all of the command and control hardware and software are
individually, integrally or removably attached. The batteries are
typically provided in a lightweight package such as a shrink-wrap
tube, which is removably received into a battery slot of the
fuselage. The fuselage typically provides structural support and
protection to the batteries once they are received in the battery
slot.
[0006] Lithium batteries are typically considered a preferred
battery type. Due to the risks in shipping lithium batteries, there
are strict Department of Transportation requirements on shipping
containers for lithium batteries and battery packs (i.e., groups of
interconnected batteries). A copy of the UN Manual of Test and
Criteria, 4th Revised Edition, Lithium Battery Testing Requirements
is incorporated herein by reference for all purposes. Because of
the strict shipping requirements for lithium batteries, robust
shipping containers meeting the shipping requirements are typically
used for carrying multiple batteries and/or battery packs during
shipping.
[0007] Once the shipping is completed and the batteries are
disseminated to end users, the batteries and/or battery packs may
lose the protection of the robust packing container, and be subject
to damage until they are installed into their respective vehicles.
Typically, each battery pack is both specifically configured for
and provided to a single type of vehicle or device. Thus, the
provision of batteries is susceptible to damage, and meeting
shipping requirements can be challenging when a wide array of
battery types must be shipped.
[0008] Accordingly, there has existed a need for a battery-operable
vehicle system in which batteries are not vulnerable to damage when
unprotected by shipping containers, and which they may be freely
usable by a multitude of vehicles and other devices. Preferred
embodiments of the present invention satisfy these and other needs,
and provide further related advantages.
SUMMARY OF THE INVENTION
[0009] In various embodiments, the present invention solves some or
all of the needs mentioned above, providing a battery-operable
vehicle system in which batteries are not vulnerable to damage when
unprotected by shipping containers, and which they may be freely
usable by a multitude of vehicles and other devices as primary
structural members.
[0010] In one aspect, an unmanned vehicle of the present invention
may be configured for a range of missions, by including a body
forming a battery module, a control module and one or more
propulsion modules. The battery module provides a battery capacity
adequate to provide motive force for the vehicle over the range of
missions. The battery module has a plurality of structural and
electronic connection ports for connecting other components. The
control module includes a control system configured to control the
operation of the vehicle, and is directly and removably connected
to the battery module via a first connection port of the plurality
of connection ports. The propulsion modules each include a motor
configured to provide propulsive force to move the vehicle through
one or more missions of the range of missions, and are directly and
removably connected to the battery module via additional connection
ports of the plurality of connection ports.
[0011] Advantageously, this configuration, in which the propulsion
modules and control module each connect to the battery module,
provides for the battery module to be the primary structural member
of the vehicle, carrying the structural loads between the
propulsion modules, and supporting the (generally very light)
control module and payload. Because of the robust structure of the
battery module, it may be designed to meet strict transportation
requirements for batteries. The use of this robust battery module
as the primary vehicle structure avoids the need for using two
robust structures--one for the battery (for safe transportation),
and another for a separate vehicle body.
[0012] In another aspect of the invention, a first set of
propulsion modules may each include two substantially vertically
oriented propellers at opposite ends of an arm, with a centrally
(on the arm) located connector. A second set of propulsion modules
may each include two wheels at opposite ends of an arm, with a
centrally (on the arm) located connector. A third set of propulsion
modules may each include two floats at opposite ends of an arm, a
motor driven prop, and a centrally (on the arm) located connector.
A fourth set of propulsion modules may each include two
pitch-controlled props at opposite ends of an arm, with a centrally
(on the arm) located connector. Advantageously, the vehicle may
convert between a quadrotor aircraft, a wheeled ground vehicle, a
water-surface vehicle, and a submersible vehicle simply by changing
the type of propulsion module attached to the battery module.
[0013] In yet another aspect of the invention, the vehicle forms a
quadrotor aircraft having four propellers that each angled slightly
toward a front end of the vehicle. This pitched-down configuration
makes the aircraft pitch up to hover, while it allows a cruising
forward flight with the battery and control modules substantially
level. Advantageously, this maximizes backward viewing during
hovering, while minimizing air resistance during cruise flight.
[0014] In another aspect of the invention, each propulsion module
is interchangeably usable at either end of the vehicle. Thus, a
single replacement propulsion module may be used to replace either
a broken front propulsion module or a broken back propulsion
module.
[0015] In yet another aspect of the invention, the arms connect to
the battery module on opposite longitudinal ends of the body. Each
arm connector is configured with an end cap affixed to its
respective arm. Each body connector is configured with a groove
adapted to conformingly and longitudinally receive the arm when the
arm connector is connected to the body connector. The body
connector groove is configured to directly bear all vertical loads
from the arm connector arm without loads being carried by the arm
connector end cap. As a result, the primary structural forces
substantially transfer directly between the arm and the battery
unit, and the end caps do not need to be as robust as the arms
themselves. This saves on weight, and provides for a more reliable
structure.
[0016] Other features and advantages of the invention will become
apparent from the following detailed description of the preferred
embodiments, taken with the accompanying drawings, which
illustrate, by way of example, the principles of the invention. The
detailed description of particular preferred embodiments, as set
out below to enable one to build and use an embodiment of the
invention, are not intended to limit the enumerated claims, but
rather, they are intended to serve as particular examples of the
claimed invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view of a UAV (unmanned aerial
vehicle) embodying the present invention.
[0018] FIG. 2 is an exploded perspective view of the UAV depicted
in FIG. 1.
[0019] FIG. 3 is a perspective view of a ruggedized,
integral-battery, load-bearing body of the UAV of FIG. 1.
[0020] FIG. 4 is an end view of the ruggedized, integral-battery,
load-bearing body of FIG. 3.
[0021] FIG. 5 is a perspective view of a UAV propulsion arm of the
UAV of FIG. 1.
[0022] FIG. 6 is a rear view a connection module of the UAV
propulsion arm of FIG. 5.
[0023] FIG. 7 is a schematic top view of the UAV depicted in FIG.
1.
[0024] FIG. 8 is a top view of a control module of the UAV of FIG.
1, with the upper surface treated as translucent.
[0025] FIG. 9 is a bottom view of the control module depicted in
FIG. 8, with the lower surface treated as translucent.
[0026] FIG. 10 is a side view of the UAV depicted in FIG. 1, as
oriented for forward flight.
[0027] FIG. 11 is a side view of the UAV depicted in FIG. 1, as
oriented for hovering or landed.
[0028] FIG. 12 is a front view of the UAV depicted in FIG. 10.
[0029] FIG. 13 is a top view of the UAV depicted in FIG. 10.
[0030] FIG. 14 is an exploded perspective view of the UAV depicted
in FIG. 1.
[0031] FIG. 15 is a perspective view of a UAV propulsion arm of the
UAV of FIG. 1.
[0032] FIG. 16 is a perspective view of a UGV propulsion arm usable
to convert the UAV of FIG. 1 into the UGV of FIG. 17.
[0033] FIG. 17 is a perspective view of the UAV of FIG. 1 converted
into a UGV.
[0034] FIG. 18 is a representation of several variations of the UAV
depicted in FIG. 1.
[0035] FIG. 19 is a top view of the UAV depicted in FIG. 1, as
packaged for carrying in a container.
[0036] FIG. 20 is a front view of the packaged UAV depicted in FIG.
19.
[0037] FIG. 21 is an exploded perspective view of the UAV of FIG. 1
converted into a USV.
[0038] FIG. 22 is a top view of the USV of FIG. 21.
[0039] FIG. 23 is a perspective view of the USV of FIG. 21.
[0040] FIG. 24 is a side view of the USV of FIG. 21.
[0041] FIG. 25 is a front view of the USV of FIG. 21.
[0042] FIG. 26 is an exploded perspective view of the UAV of FIG. 1
converted into a UUV.
[0043] FIG. 27 is a top view of the UUV of FIG. 26.
[0044] FIG. 28 is a perspective view of the UUV of FIG. 26.
[0045] FIG. 29 is a side view of the UUV of FIG. 26.
[0046] FIG. 30 is a front view of the UUV of FIG. 26.
[0047] FIG. 31 is a perspective view of a second embodiment of a
UAV embodying the present invention.
[0048] FIG. 32 is an exploded perspective view of the UAV depicted
in FIG. 31.
[0049] FIG. 33 is an exploded perspective view of a body that is
part of the UAV depicted in FIG. 31.
[0050] FIG. 34 is a partial cross-sectional view of a connection
between the body of the UAV depicted in FIG. 31 and a propulsion
module of the UAV depicted in FIG. 31.
[0051] FIG. 35 is an exploded partial perspective view of the
connection depicted in FIG. 34.
[0052] FIG. 36 is a perspective view of a ground control station
for any of the vehicles embodying the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0053] The invention summarized above and defined by the enumerated
claims may be better understood by referring to the following
detailed description, which should be read with the accompanying
drawings. This detailed description of particular preferred
embodiments of the invention, set out below to enable one to build
and use particular implementations of the invention, is not
intended to limit the enumerated claims, but rather, it is intended
to provide particular examples of them.
[0054] With reference to FIGS. 1 & 2, the first embodiment of
the invention includes a body 101 configured both as a battery and
as a primary structural element for the vehicle, two UAV (Unmanned
Aerial Vehicles) propulsion arms 103, a control module 105, a
payload module 107 and two landing gear 109.
[0055] With reference to FIGS. 1-3, the body 101 is a
multifunctional battery structure configured to work as the core
vehicle structure for a variety of vehicles. The body includes a
round (cylindrical) carbon tube structure 111, and integrally
contains a plurality of interconnected (in parallel) stacks of
in-series lithium battery cells 113 forming a smart lithium battery
(i.e., battery pack of one or more batteries and a battery board
forming a battery controller). The structure of the body meets all
necessary shipping requirements for shipping the batteries
integrally contained within the body, and in particular, the UN
Manual of Test and Criteria, 4th Revised Edition, Lithium Battery
Testing Requirements, which is incorporated herein by reference for
all purposes, and thus any shipping container carrying one or more
of the bodies (i.e., the batteries) would only have standard
container shipping requirements.
[0056] The battery controller tracks battery usage, battery
charging, monitors battery temperature via gages incorporated into
the structure of the battery, and conducts other battery functions
as are known for a smart battery. The round shape of the body
provides for high strength and rigidity. The body also incorporates
a large fuse, and all battery heat is dissipated passively.
[0057] The body includes three connectors, including two side
connectors 121 and an intermediate connector 123. The two side
connectors are positioned at the longitudinal ends of the
cylindrical body, and are each configured for structurally and
electronically connecting to a propulsion arm 103. The intermediate
connector is centrally located along the length of the body, and is
configured for electronically connecting to the control module 105.
The intermediate connector is reinforced so as to maintain the
strength and rigidity of the body despite the opening that it
provides for the electronic connection. The intermediate connector
includes a spring 124 extending up to make an initial ground
contact prior to connection between functional electrical
connectors. The intermediate connector's central location helps to
minimize the weight of wires running between the batteries.
[0058] With reference to FIGS. 3-6, each UAV propulsion arm
includes a carbon tube support rail 131, an arm connection module
133 in the center of the support rail, a pair of motors 135, a pair
of motor mounts 137, each being at a longitudinal end of the
support rail, and each mounting one of the motors to the support
rail, and a pair of propellers 139, each being affixed to one of
the motors such that that motor can drive its respective propeller
in rotation with respect to the support rail. The connection module
may include a dual motor controller configured to control the
operation of the two motors. Alternatively, separate motor
controllers may be incorporated into each motor mount. The
propellers are large enough to extend back almost to the connection
module, and the overall system is configured to blow air down over
the various parts of the propulsion arm and thereby providing any
cooling that might be needed. The motors can be operated at
different speeds (including operating in reverse) to control the
craft.
[0059] The connection module 133 of each arm is configured for
connection to either of the two side connectors 121 of the body,
forming an end cap for either end of the body. That connection
includes mated electronic connectors (a side connector electronic
connector 141 and a connection module electronic connector 143) for
passing power, control signals, and the like. That connection
further includes a groove 145 in each side connector, that groove
being configured to conformingly receive a portion (and possibly a
majority) of the circumference of the support rail 131 such that
significant vertical and torsional loads may pass between the
support rail and the side connector without being significantly
carried by the connection module 133. The connection module
connects to its respective side connector via a thumb screw 147 in
the connection module that is received in a threaded hole 149 in
the side connector, thereby longitudinally holding the support rail
onto the side connector and in the groove.
[0060] As is depicted in FIG. 7, each propulsion arm will have one
clockwise-rotating propeller one counterclockwise-rotating
propeller. Because the connection modules 133 are configured to
connect to either side connector 121, the propulsion arms 103 may
connect to either end of the body 101, and only one spare
propulsion arm is needed to serve as a replacement part for the two
primary propulsion arms. It is anticipated that most deflection
during flight loading occurs in the propulsion arms, which are
significantly smaller in diameter than the body. As a result, the
propulsion arms are a weaker link, and will likely break first
under extreme loading.
[0061] With reference to FIGS. 2, 3, 8 and 9, the control module
105 typically contains most all command and control equipment. This
may include one or more printed circuit boards having antennas,
sensors and processing functionality for GPS/INS (Global
Positioning System/Inertial Navigation System) control, autopilot
functionality, as well as controls and processing for a variety of
different payloads. Each piece is positioned for efficient
connectivity and to limit wire weight. Typically the GPS/sensor
board will be in back, while the autopilot (which must communicate
with the propulsion arms) is in the center. The payload board is up
front, by the payload.
[0062] The control module 105 removably attaches to two handles 152
on the body 101 via a mated hook 151 and latch 153 system at the
longitudinal ends of the control module and body. Electronic
connections are provided by mated electronic connectors (a command
connector 155 on the command module, connecting to the intermediate
connector 123 of the body 101) for passing power, control signals,
and the like between the control module and the body.
[0063] The payload module 107 attaches to a front end 161 of the
control module at a slight offset (i.e., pitched down, as shown in
FIG. 10) angle (typically on the order of 10 degrees). A variety of
different payload modules may be interchangeably used. These
modules may include IR (Infrared), EO (Electro Optical), daytime
and/or nighttime cameras, as well as other equipment for tracking,
targeting and/or communication functions. A mating connector system
both structurally and electronically links the payload module to
the control module, providing for electronic communication and
power exchange with the control module.
[0064] Compared to the other modules (e.g., the body 101 and
propulsion arms 103), the control module 105 may be quite expensive
due to its significant electronics and software. The other units
may therefore be considered fairly expendable in comparison.
Advantageously, the control module only carries very low loads
(e.g., its own weight and the weight of the payload module), and
may therefore be made very lightweight. Because of the control
module's position on top of the body, and because the body protects
the control module from high loading (by connecting at both ends
and the middle), the control module can function as a very robust
and durable device without requiring its own robust structural
elements.
[0065] With respect to FIGS. 10-13, while being oriented in a
general upward direction, each propeller is angled slightly toward
the front end 161 at a slightly offset pitch angle downward from
level (on the order of 10 degrees, see, e.g., FIG. 10). Because of
this configuration, the UAV hovers at a slight nose-up pitch angle
(on the order of 10 degrees, see, e.g., FIG. 11), which compensates
for (i.e., levels) the slight offset angle of the payload and
partially removes the rear end of the control module from extending
into the rearward and downward looking view of the payload. In a
typical embodiment, the payload might be expected to have 360
degree viewing capabilities with a +/-25 degrees tilt angle for
digital zooming.
[0066] In this embodiment, the forward pitching of the propellers
is not achieved via a variation in the propulsion arm. Instead, the
side connectors 121 are slightly angled (on the order of 10
degrees) in a pitched down direction. It should thus be recognized
that while the propulsion arms are not end specific, the body 101
defines a front and a rear by the angling of the end connectors.
Moreover, while the craft can fly in any direction, flight in the
forward direction will typically be more efficient. It should also
be recognized that the control module attaches to the body 101 with
the front end 161 of the control module 105 at the front end of the
body, thus placing the payload module at the front end of the body.
The hook, the latch, and their respective handles have different
configurations to avoid attempts to attach the control module
backwards.
[0067] In forward flight at a cruise speed (see, FIGS. 10 &
12), the aircraft is pitched down from the hover orientation to be
in level flight such that each of the propellers is providing both
lift and thrust in the direction of the front end 161 of the
control module. Because the flight occurs in a level orientation of
the body (rather than angled as a typical quadrotor would do), it
flies forward with only a minimal wind resistance along its
body.
[0068] The propellers are typically the only moving primary parts
(or control surfaces) on the UAV of the present invention.
Nevertheless, other moving parts may include cooling-fan motors in
the control module, and positioning devices for reorienting the
camera(s) within the payload.
[0069] Each of the two UAV landing legs 109 extend between the two
propulsion arms 103. These legs are configured as skids, and are
configured to support the craft at an angle to provide for the
landed craft to be angled with the same upward angle as would be
used for hovering. Advantageously, this provides for smooth
vertical take-offs, as well as allowing the craft to land on a
tall, level object in the proper orientation for the payload to
perch and stare down at a target.
[0070] To assemble the UAV from a configuration with all elements
packed in a carrier (see, e.g., FIGS. 19 and 20), the battery unit
(the body) is removed from the carrier. The propulsion arms are
then removed from the carrier and affixed to the ends of the body.
More particularly, each propulsion arm is snapped into place and
its thumb screw is tightened down. The landing gear is then removed
from the carrier and affixed appropriately to the propulsion arms.
The command module is then removed from the carrier, hooked onto
the handle at the front end of the body, and swung down so that the
connectors mate and the latch locks into place at the rear end of
the body. Finally, the payload is snapped or clipped into
place.
[0071] With reference to FIG. 18, other payload configurations are
within the scope of the invention (for the various embodiments
described herein). For example, either using the previously
disclosed payload module, or an optional lower payload tray 301,
scientific payloads 303 such as acoustic or other SIGINT (signals
intelligence) sensors and/or transmitters, advanced ISR
(intelligence, surveillance and reconnaissance) sensors 305 (e.g.,
battlefield mapping), and other such payloads 307 (e.g., munitions
and droppable payloads).
[0072] In addition to using the body, the control module and
payload module for a quadrotor UAV, other possible uses and
configurations of this embodiment may be provided. With reference
to FIGS. 14-17, the UAV propulsion arms 103 may be replaced with a
pair of wheeled UGV (unmanned ground vehicle) propulsion arms 203.
As before, the propulsion arms are made from carbon tubes forming a
support rail 231, and include motors 235 and motor controllers (in
addition to wheels 239). The UGV propulsion arm also includes a
connection module 233 that connects to either side connector 121
(i.e., at either end of the body), so a spare UGV propulsion arm
can be used to replace either active UGV propulsion arm.
[0073] The motor controller software differs, but is contained in
the propulsion arm, so that distinction is invisible to the control
module. As before, there can be a dual motor controller, such as in
the connection module 233, or there can be separate controllers for
and by each motor. The motors can be operated at different speeds
(including operating in reverse) to directionally control the
craft.
[0074] The propulsion modules are plug-and-play, and the control
module 105 can sense which propulsion modules are attached, and
thereby make any necessary distinctions in its control commands
that it sends to the attached propulsion arms 103/203. The same
payload 107 might be usable, or a separate UGV payload 207 having a
different orientation might be preferred (to compensate for the
level viewing angle and to provide a more upward-looking view). If
the UGV is provided with large enough wheels and a GPS antenna that
can read in an inverted direction, it is possible for the UGV to be
configured to operate even if it is turned upside down. The method
of assembling the UGV is similar to that of the UAV, with the
exception that no landing gear need be installed.
[0075] With reference to FIGS. 21-25, another possible
configuration of this embodiment is provided by replacing the UAV
(quadrotor) propulsion arms 103 or UGV propulsion arms 203 with a
pair of USV (Unmanned Surface Vehicle) propulsion arms 303. To
minimize drag and improve stability, each propulsion arm is made
from a plurality of aerodynamically shaped (in the direction of
propulsion) carbon tubes forming support rails 331. The aerodynamic
shaping is adapted to minimize the cross section of the support
rails in a direction of travel (see, e.g., FIG. 25).
[0076] The support rails include a primary rail 361 and two legs
363 that connect the primary rail to a connection module 333. Each
primary rail carries a float 339 at each of its two ends. The
primary rail of at least one (and possibly both) propulsion arms
also carries one or more motors 335 (e.g., two), each of which
drives a prop 371 to produce thrust. Each propulsion arm includes
one or more motor controllers (in addition to motors). The
propulsion arm connection module 333 connects to either side
connector 121 (i.e., at either end of the body 101). The primary
rail is configured to extend the motors into a body of water (e.g.,
below the surface of the water) while the floats support the USV on
the surface of the water. Optionally, the floats and motors may be
configured so a spare propulsion arm can be configured to work on
either side of the body.
[0077] The motor controller software differs, but is contained in
the propulsion arm, so that distinction is invisible to the control
module. As before, there can be a dual motor controller, such as in
the connection module 333, or there can be separate controllers for
and by each motor. The motors can be operated at different speeds
(including operating in reverse) to directionally control the
craft.
[0078] The control module 105 senses which propulsion modules are
attached, and thereby make any necessary distinctions in its
control commands that it sends to the propulsion arms 303. The same
payload 107 might be usable, or a separate USV payload 307 having a
different orientation might be preferred (to compensate for the
level viewing angle and to provide a more upward-looking view). The
method of assembling the USV is similar to that of the UGV. Each of
the connectors has seals that protect all electrical connections
from contact with water, and each of the modules is water
tight.
[0079] With reference to FIGS. 26-30, another possible
configuration of this embodiment is provided by replacing the UAV
(quadrotor) propulsion arms 103, UGV propulsion arms 203, or USV
propulsion arms 303, with a pair of UUV (Unmanned Underwater
Vehicle) propulsion arms 403. As before, the propulsion arms are
made from carbon tubes forming a support rail 431. At each of two
ends of the support rail, the propulsion arm includes a propulsion
motor 435 that drives a prop 471, and an aiming motor 473 that
independently rotates its respective prop and propulsion motor
around a longitudinal axis of the support rail (to pitch the
motor). The propulsion arm again includes a connection module 433
that connects to either side connector 121 (i.e., at either end of
the body 101), so a spare propulsion arm can be configured to work
on either side.
[0080] Each propulsion arm includes one or more motor controllers
(in addition to the various motors). The motor controller software
differs, but is contained in the propulsion arm, so that
distinction is invisible to the control module. There can be a dual
(or even a quad) motor controller in each arm, such as in the
connection module 433, or there can be separate controllers for and
by each motor. The motors can be operated at different speeds
(including operating in reverse) to control the craft.
[0081] The control module 105 can sense which propulsion arms are
attached, and thereby make any necessary distinctions in its
control commands that it sends to the propulsion arms 403. The same
payload 107 might be usable, or a separate UUV payload 407 having a
different instrumentation appropriate to the underwater
environment. The method of assembling the UUV is similar to that of
the USV. Each of the connectors has seals that protect all
electrical connections from contact with water, and each module is
sealed to prevent water from getting in.
[0082] Any combination of the above-described vehicles forms a
man-packable, reconfigurable vehicle system with many common core
parts, under the present invention. Because of the common elements,
the expense of the control module can be limited to a single unit
(or a limited number if spares are maintained), even as a multitude
of different vehicles are available for use. The system may be
provided with only one battery for all vehicles, or a plurality of
battery units. Common spare parts, payloads, battery charger and
ground control station (including a ruggedized computer) simplify
the system's portability and use. The vehicle system is quickly
convertible from one vehicle configuration to another, and a single
set of vehicle components can be easily swapped from one battery
unit to another to allow for semi-continuous use while battery
recharging occurs. The control module can easily identify the
vehicle configuration and adapt to use the proper control
protocols, and a single GCS (ground control system) can be used for
controlling and communicating with the different vehicle types.
[0083] The vehicle system may also be configured for multivehicle
operation. For example, ground and water based vehicles (UGVs, USVs
and UUVs) might require airborne relay of communication signals for
increased range. The vehicle system may be configured for
coordinated control of a UAV along with a UGV, USV or a UUV
(optionally using a follow-me mode of operation) to provide that
airborne relay. Likewise, for explosive ordinance disposal, a UAV
can investigate the area, while a UGV delivers an explosive to
destroy the threat. Similarly, multiple vehicles of the same type
(e.g., multiple UAVs) may be made to operate in unison, such as in
a given flight configuration, through a search pattern to provide
for faster search operations.
[0084] A wide variety of military and civilian missions are
supportable by this efficient system, including many missions
typically available to UAVs, UGVs, USVs and UUVs. Some such
missions include tactical and covert surveillance, hover/perch and
stare surveillance, special payload delivery, checkpoint security
(including under-vehicle inspection), EOD (explosive ordnance
disposal), team situational awareness, IED (improvised explosive
device) inspection and destruction, costal surveillance, mine
searching, indoor hover reconnaissance, fire fighting assessment
and management, search and rescue activities, surveillance of
public gatherings, riots, crime scenes, traffic accidents, traffic
jams, and foot pursuits.
[0085] Alternative variations of the present invention could be
provided with other configurations, such as an X-shaped
configuration in which each rotor, wheel or prop connects
separately to a single core. Nevertheless, the H-shaped
configuration of the present embodiment tends to minimizes assembly
time and complexity. It also provides for the convenient use of
simple, tubular components with little aerodynamic cross-section.
This also provides for the device to be rapidly disassembled and
compacted into an easily cartable package, such as might be carried
around by military personnel in the field (see, e.g., FIGS. 19 and
20).
[0086] With reference to FIGS. 31-32, in a second embodiment of the
invention, the H configuration of the UAV is modified in a number
of aspects. As before, this embodiment includes a body 501
configured both as a battery and as a primary structural element
for the vehicle, two propulsion arms 503, a control module 505, and
a payload module 507. Optionally, the payload and control modules
may be integral, or may be stored in an attached state for fast
assembly. In this embodiment, each propulsion module has and two
landing gear 509, one affixed to each of its motors. In contrast to
the first embodiment, the control module and payload are oriented
for flight and observation in a direction perpendicular to the
longitudinal direction of the body.
[0087] With reference to FIGS. 31-33, the body 501 is configured
with an elliptical cross section (across its longitudinal
dimension) having its vertical measurement as its smallest
dimension. This configuration trades some structural stiffness for
a reduction in drag. The structure includes a molded carbon fiber
casing 511 conformingly received around a foam core 512, which
conformingly surrounds a plurality of interconnected stacks of
lithium battery cells 513 forming a smart lithium battery (i.e.,
battery pack of one or more batteries and a battery board 514
forming a battery controller). Optionally, the structure of the
body meets all necessary shipping requirements for shipping the
batteries integrally contained within the body, and in particular,
the UN Manual of Test and Criteria, 4th Revised Edition, Lithium
Battery Testing Requirements, and thus any shipping container
carrying one or more of the bodies (i.e., the batteries) would only
have standard container shipping requirements.
[0088] The battery controller tracks battery usage, battery
charging, monitors battery temperature via gages incorporated into
the structure of the battery, and conducts other battery functions
as are known for a smart battery. The shape of the body provides
for significant strength and rigidity. The body also incorporates a
large fuse, and all battery heat is dissipated passively.
[0089] The body includes three connectors, including two side
connectors 521 and an intermediate connector 523. The two side
connectors are positioned at the longitudinal ends of the
elliptical body, and are each configured for receiving a propulsion
arm 503. The intermediate connector is centrally located along the
length of the body, and is configured for electronically connecting
to the control module 505. The intermediate connector is reinforced
so as to maintain the strength and rigidity of the body despite the
opening that it provides for the connection. The intermediate
connector location (in the center) helps to minimize the weight of
wires running between the batteries.
[0090] With reference to FIGS. 31-35, each UAV propulsion arm
includes a support rail 531, an arm connection module 533, a pair
of motors 535, each being at a longitudinal end of the support
rail, and a pair of propellers 539, each affixed to one of the
motors such that that motor can drive its respective propeller in
rotation with respect to the support rail. The motors are exposed
for effective cooling and simplified inspection.
[0091] The connection module 533 of each arm is configured for
connection to either of the two side connectors 521 of the body.
That connection includes mated electronic connectors (a side
connector electronic connector 541 and a connection module
electronic connector 543) for passing power, control signals, and
the like. That connection further includes a wedge-shaped groove
545 in each side connector, that groove being configured to
conformingly receive a wedge portion 546 of the connection module
533 to form a reliable, tight connection without slop or vibration.
The connection module connects to its respective side connector via
a captive nut screw 547 of the connection module that is received
by a threaded section 549 of the side connector. The nut screw also
extracts the motor boom when it is unscrewed.
[0092] Each propulsion arm will have one clockwise-rotating
propeller one counterclockwise-rotating propeller. Because the
connection modules 533 are configured to connect to either side
connector 521, the propulsion arms 503 may connect to either end of
the body 501, and only one spare propulsion arm is needed to serve
as a replacement part for the two primary propulsion arms.
[0093] As in the first embodiment, the control module 505 typically
contains most all command and control equipment. This may include
one or more printed circuit boards having antennas, sensors and
processing functionality for GPS/INS (Global Positioning
System/Inertial Navigation System) control, autopilot
functionality, as well as controls and processing for a variety of
different payloads.
[0094] The control module 505 removably attaches to the body 501
via a mated snap-on (e.g., hook and latch) system 551 in the
longitudinal center of the body. The control module extends
longitudinally in a fore and aft direction that is perpendicular to
the longitudinal dimension of the body. Electronic connections are
provided by mated electronic connectors (a command connector not
shown on the command module, connecting to the intermediate
connector 523 of the body 501) for passing power, control signals,
and the like between the control module and the body.
[0095] The payload module 507 attaches to a front end 161 of the
control module. A variety of different payload modules may be
interchangeably used, and scanning payloads typically have the
ability to pan up and down to a high degree (e.g., on the order of
140.degree.). Lateral panning will typically rely on the UAVs
ability to yaw. The payload modules may include color, IR
(Infrared), EO (Electro Optical), daytime and/or nighttime cameras,
as well as other equipment for tracking, targeting and/or
communication functions. It may (directly, or via the command
module) be provided with digitally stabilized video. A mating
connector system both structurally and electronically links the
payload module to the control module, providing for electronic
communication and power exchange with the control module.
[0096] Compared to the other modules (e.g., the body 101 and
propulsion arms 103), the control module 105 might be quite
expensive due to its significant electronics and software. The
other units may therefore be considered fairly expendable in
comparison. Advantageously, the control module only carries
relatively low loads (e.g., its own weight and the weight of the
payload module), and may therefore be made lightweight. Because of
the control module's position on top of the body, and because the
body protects the control module from high loading (by isolating
the control module from loads between the propulsion arms), the
control module can function as a very robust and durable device
without requiring its own robust structural elements. Thus, the
control module may have a simple, injection-molded housing.
[0097] Unlike the first embodiment, each propeller is angled
straight up to provide for hovering when the UAV is level. Since
the payload extends out in front of the body and only looks in a
forward direction, a typical payload might be expected to have
unimpeded viewing over a large vertical pan in the forward
direction.
[0098] Each of the four landing legs 509 extend down from their
respective motor. These legs provide for the landed UAV to be
level, just as it would be while hovering. Advantageously, this
provides for smooth vertical take-offs, as well as allowing the
craft to land on a tall, level object in the proper position for
the payload to perch and stare down at a target. The legs are
constructed of lightweight foam, and are easily detachable and
replaceable for fast repair in the field.
[0099] As with the original embodiment, to assemble the UAV from a
configuration with all elements packed in a carrier, the battery
unit (the body) is removed from the carrier. The propulsion arms
are then removed from the carrier and affixed to the ends of the
body. More particularly, each propulsion arm is snapped into place
and its screw is tightened down. The command module is then removed
from the carrier and snapped onto the body so that the connectors
mate and lock into place. Finally, the payload is snapped or
clipped into place.
[0100] It is envisioned that the second embodiment of a UAV may
have corresponding compatible propulsion arms to form other
vehicles such as a UGV, a USV or a UUV, similar to the first
embodiment system. Likewise, embodiments formed with combinations
of features from the various embodiments are within the scope of
the invention.
[0101] With reference to FIG. 36, any of the above described
vehicles may be controlled from a single ground control station
571. The station includes a carry case 573, a laptop computer 575
received by an electrical connector within the case, a wireless
transmitter having an antenna box 577 that may swing up from a lid
of the case or be placed distant from the case via an antenna cable
579 that is coiled in a pocket of the lid, and a vehicle controller
581 (typically in the form of a game controller or RC vehicle
controller) that is connected to the laptop via a fixed, strain
relieved cable. The case is configured with an integral or
mountable, extendable tripod 583 such that the case may be opened
and set up as an operating station. A panel 585 provides external
access to a charge/power port and a communication (e.g., USB) port
of the computer. All components of the case are powered by the
battery of the laptop computer. The laptop may include training
software for instructing users on the operation of the vehicle, and
providing simulated practice sessions.
[0102] Other uses for the ruggedized, integral-battery,
load-bearing body are envisioned within the scope of the invention.
For instance, other propulsion arms could be configured with
continuous tracks for rugged terrain, aerodynamic surfaces for
traditional flight (rather than rotary flight), and the like.
Additionally, many military devices for use in the field, such as
high-luminosity flashlights, power tools, unattended ground
sensors, ground communication relays, emergency radios and the
like, may be configured to run off the battery power of the
load-bearing body.
[0103] For example, a bunch of the bodies could be fitted with
remote control aircraft landing lights on one end and ground spikes
on the other end to provide for rapid deployment of runway lighting
to create a makeshift runway. Indeed, having a control module
equipped with a solar charger, such a runway light might be
operable for and extended period without recharging the batteries.
This rechargeable aspect is usable to extend the operation of many
of the above-described field devices. In short, the ruggedized
battery primary structure body can be a core to a large toolkit of
useful products.
[0104] It is to be understood that the invention comprises
apparatus and methods for designing and producing reconfigurable
vehicles, as well as the apparatus and methods of the structurally
robust battery pack itself. Additionally, the various embodiments
of the invention can incorporate various combinations of these
features with other field equipment and/or other systems typically
incorporating battery packs. In short, the above disclosed features
can be combined in a wide variety of configurations within the
anticipated scope of the invention.
[0105] While particular forms of the invention have been
illustrated and described, it will be apparent that various
modifications can be made without departing from the spirit and
scope of the invention. Thus, although the invention has been
described in detail with reference only to the preferred
embodiments, those having ordinary skill in the art will appreciate
that various modifications can be made without departing from the
scope of the invention. Accordingly, the invention is not intended
to be limited by the above discussion, and is defined with
reference to the following claims.
* * * * *