AU784766B2

AU784766B2 - Universal VTOL power and rotor system module

Info

Publication number: AU784766B2
Application number: AU22464/00A
Authority: AU
Inventors: Michael W. Piasecki
Original assignee: Dragonfly Pictures Inc
Current assignee: Dragonfly Pictures Inc
Priority date: 2000-02-25
Filing date: 2000-03-22
Publication date: 2006-06-15
Anticipated expiration: 2020-03-22
Also published as: AU2246400A; CA2301350A1; GB2359533A; GB0006737D0

Description

P/00/01Il Regulation 3.2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Invention Title: 'Universal VTOL power and rotor system module' The following statement is a full description of this invention, including the best method of performing it known to us: FHPS9YrAFlNAThffl20M6A1 2 4 UNIVERSAL VTOL POWER AND ROTOR SYSTEM

MODULE

BACKGROUND

This invention broadly relates to aerial vehicles having vertical takeoff/landing (VTOL) capability, of which helicopters are a common type, and of which the described VTOL aircraft has a particularly useful capability :as an unmanned aerial vehicle (UAV) sometimes referred to as a "drone" aircraft.

More particularly, the invention is a common universal power drive and lifting rotor system module from which various types of single and multiple rotor VTOL aircraft can be produced. The simplicity and versatility of the power drive and lifting rotor system module of the invention is such that it has a particular adaptation to providing VTOL UAV aircraft of several types that *.:are highly suitable to carrying out military and commercial surveillance missions.

There is a particular need for a portable, remotely controlled

VTOL

UAV platform carrying visual and sen sing recording devices for performing a variety of military and commercial missions including transmitting or recording visual and other ground data information that is *not readily available or possible by other means. The capability of recently developed, simple and lightweight 2 5 devices for recording and transmitting a wide variety of visual and'other data is such that their u~sefulness can be greatly expanded by mounting them on a portable and remotely controlled VTOL UAV aircraft platform. Typical

%V.I

11. APR. 2006 17:33 FREEHILLS SYDNEY 3 +612 93224000 NO. 1888 P. 4 005050498v5.doo -missions for such VTOL UJAV units would be aerial intelligence gathering and reconnaissance, commercial cinematography, news coverage, aerial mapping law enforcement and anti-terrorism, augmentation, border patrol, disaster assessment, environmental assessment, utility inspection and maintenance, etc.

SUMMARY OF INVENTION According to the first aspect of the present invention there is provided: a universal power drive and lifting rotor system module for powering single and multiple rotor type VT OL aircraft comprising: an elongated module component support framework having a plurality of engine mounts arranged at one end for externally supporting an engine thereon -and other end adapted for connecting to auxiliary VTOL augmentation framework, said engine being supported on said engine mounts, 000 a main drive shaft supported for axial rotation within said component support framework to extend longitudinally thereof between said component support framework respectvens one end of said main drive shaft having coupling means for detachably connecting and 20 disconnecting said main drive shaft and said engine, said main drive shaft other end being adapted for connection to a rotatable shaft, a lifting rotor assembly and underlying transmission mounted atop said component support framework,* said rotor transmission having a power input shaft extending from within said transmission terminating in an outer end adjacent. said component support framework other end 0:0.wit said power input shaft outer end adapted for connection to said rotatable shaft, -000 power transfer means connected between said main drive shaft and said rotor 0 0: transmission power input shaft for transferring rotational power between said main drive and said rotor transmission input shafts and clutch means contained in said main drive shaft adjacent said power transfer means connection for selectively connecting and disconnecting said main drive shaft and said power transfer means.

2 COMS ID No: SBMI-03288028 Received by IP Australia: Time 17:32 Date 2006-04-11 005050496v8.doc The invention provides a universal power drive and lifting rotor system unit or module suitable for powering a variety of types of VTOL aircraft including both single and multiple rotor type VTOL aircraft, and both single rotor convention and compound helicopters.

The invention further provides a system capable of rapid assembly and disassembly into small modules for man portable transport and/or rapid maintenance without the use of hand tools.

The invention incorporates VTOL power producing and lifting rotor systems and their interconnections on and within a component support airframe. The component support airframe is configured for the detachable attachment of an engine and VTOL augmentation framework.

The lifting rotor assembly and transmission are mounted on the component support airframe and receive power from a power train comprising a main drive shaft detachably coupled to the engine and extending within the component support airframe. The main drive shaft and transmission are adapted for detachable connection to a drive shaft of a rotor torque compensating means mounted on any one of the VTOL conversion auxiliary frameworks affixed to the module component support airframe. Thus, a variety of types of VTOL aircraft can be powered by O attaching the versatile power drive and rotor system module to an auxiliary framework on which S is mounted the particular type of rotor torque oo .o o oo go• •oo •go compensating system utilized on the specific type of VTOL aircraft being produced.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a side elevation of one embodiment of the invention.

Figure 2 is a side elevation of a second embodiment of the invention.

Figure 3 is a side elevation of a third embodiment of the invention.

Figure 4 is an illustration of an embodiment of a quick disconnect fastener for use with the invention.

Figure 5 is an illustration of another embodiment of a quick disconnect fastener for use with the invention.

Figure 6 is an illustration of another embodiment of a quick disconnect fastener for use with the invention.

Figure 7 is an illustration of another embodiment of a quick disconnect fastener for use with the invention.

0* Figure 8 is an illustration of another embodiment of a quick disconnect fastener for use with the invention.

Figure 9 is an illustration of another embodiment of a quick disconnect fastener for use with the invention.

Figure 10 is a side elevation of one embodiment of a coupling for use with the invention.

DETAILED DESCRIPTION OF THE INVENTION The module 10 utilized to power various types of VTOL aircraft subsequently described is illustrated in Figure 1, in which a lifting rotor assembly 11 and transmission 12 are mounted onto a component support 6 airframe 13 on which the components of the module are supported.

Components of module 10 are preferably connected using quick disconnect fasteners 22. Fasteners 22 preferably provide a self aligning interface for the components of module 10 and allow quick connection and removal without use of hand tools.

The rotor assembly I1I is preferably of a conventional nature with rotor blades 14, 15 supported thereon. Rotor assembly 11 may also be multibladed, may be bearingless, or may employ a hollow -main rotor shaft or other apparatus commonly known or used in the art. The main rotor interface of rotor assembly 11I is preferably easily adaptable, to accommodate a variety of rotor head designs (including fully articulated, bearingless, teetering, off-set teetering, and co-axial designs) capable of providing variable rigidity in flapping and movement. This flexible design has a direct impact on the suitability of rotary wing aircraft to perform successful launch and retrieval in heaving, pitching, and rolling conditions on a boat landing or when landing on o ground inclines. The pitch of the rotor blades 14, 15 is preferably controlled 00.

by a linkage arrangement of a swash plate assembly 19 actuated by servo 9% motors 20 and of which the details will not be described is being well known 0. 00* in the art. Rotor assembly 11 is also preferably configured for quick zo disconn~ection and connection at point 16 using quick disconnect fasteners.

The rotor transmission 12 is preferably driven by a power input shaft 21 which preferably extends from the transmission 12. The power input shaft 21 is preferably adapted for detachable connection to the main power drive shaft 34 and for receiving an external rotatable shaft (not shown). The component supporting airframe 13 of the module on which the lifting rotor assembly 11 and transmission 12 and other components of the module are supported is preferably a cylindrical composite airframe structure which provides fuel storage as well as allows for increased space for payloads. This provides an innovative solution to the traditional design compromise over the location of the fuel tank vis-a-vis other supporting structures by actually making the fuel tank the airframe. Engine 30 is preferably mounted on airframe 13 using quick disconnect fasteners 22.

The support airframe 13 is preferably provided with bolt holes (not shown) and other facilities for attaching augmentation auxiliary framework using quick disconnect fasteners 22. The rotor assembly 11I and transmission 12 are preferably supported by a base plate 33 fastened to the lower side of the transmission housing 23 and to the component support airframe 13 using quick *5 disconnect fasteners 22. The component support airframe 13 preferably S provides space in which various control and operational components required for operation of a VTOL may be stowed and for which the consumption of fuel does not adversely affect the balance of the aircraft during operation.

A main power drive shaft 34 extending longitudinally of the component support. airframe 13 is preferably supported for rotation in the airframe structure. One end of the drive shaft 34 is preferably detachably connected to 5*the engine 30 by a flexible coupling (not shown) that de-links axially.

!0 A preferred powering unit mounted on the component support airframe 13 is a two-stroke air cooled engine with twin opposed cylinders. A more preferable powering unit is a diesel engine, but other engines suitable for mounting on the front end of the airframe 13 could be utilized. Preference for a two-stroke engine is discussed below with respect to module 10 being used to power a dual rotor configured VTOL aircraft. Auxiliary power for the module may be provided using one or more generators (not shown). It is preferred that a combination starter/generator is used to provide both auxiliary power and starter capability. Use of a combination starter/generator also provides benefis in terms of reduced weight.

Rotational power of the main drive shaft 34 is preferably transferred to the transmission power input shaft 21 by means of a pulley and belt drive arrangement 39. The pulley-belt drive arrangement 39 is one preferred embodiment as being light and effective. Gear trains and other well known power transfer apparatus may be utilized for power transmission. The main drive shaft 34 is also preferably adapted for detachable connection to an rotatable shaft of a VTOL augmentation auxiliary framework. This .9 can be accomplished using a splined coupling (not shown) to allow for quick 99 connection and disconnection to the transmission power input shaft 21 or other external rotatable shafts, A centrifugal clutch (not shown) may. be incorporated with the main drive shaft 34 for selectively connecting and disconnecting the main drive shaft 34 from the transmission power input shaft 21.

9999 The versatility of the above described module 10 for powering a variety of types of VTOL aircraft, particularly VTOL UAV aircraft (drone helicopters) is demonstrated in the following descriptive matter relating to the illustrations 99of Figures 2 and 3. Figure 2 illustrates the module of the invention powering a VTOL aircraft having a tail mounted torque compensating rotor. Referring now to Figure 2, a main drive shaft clutch assembly extension 60Ois detachably attached to the module component supporting airframe 13 by quick disconnect fasteners 22 or other attaching components. VTOL augmentation framework is connected to clutch assembly extension 60 using quick disconnect fasteners 22. The augmentation framework 45 contains a torque compensating rotor (counter torque rotor) 49. A counter torque rotor drive shaft 50 is preferably supported for rotation within the augmentation framework 45 and is operatively connected to rotate the counter torque rotor 49. Counter torque rotor drive shaft 50 is preferably also detachably. connected to the main power drive shaft 34. The counter torque rotor drive shaft 50 is preferably a floating thin-walled drive shaft. Augmentation framework 45 preferably comprises a tail boom section 45a detachably connected to a tail section 45b with quick disconnect fasteners 22.

An undercarriage 51 is preferably configured with a landing support 52 connected thereto using quick disconnect fasteners 22. The undercarriage 51 X0. is attached to the module 13 using the quick disconnect fasteners 22. The 6:6: undercarriage illustrated in Fig. 2 is one suitable for a VTOL UAV type aircraft. If the module 10 is of a size and power suitable for powering pilot *6 controlled aircraft, the undercarriage structure and configuration would conform more closely to a conventional VTOL fuselage.

In a preferred embodiment of the invention an exhaust boom support 0.structure is used to reduce the thermal heat signature and muffle the exhaust 6**sound signature. The augmentation framework 45 (and 59 discussed below) structure provides valuable space aboard the aircraft which can reduce noise pollution in commercial environments and increase survivability and stealth in war or near war environments. Accordingly, the augmentation framework is preferably used for exhaust baffling to reduce the sound signature.

A particularly useful VTOL configuration utilizing a pair of the modules of the invention for powering a twin rotor VTOL aircraft is illustrated in Figure 3. By interconnecting a pair of modules 10 of the invention in.' a backto-back arrangement, the payload is considerably more than can be carried by a single module configuration, the lifting rotor torque generated by one module being counteracted by the other module. This configuration is also preferable when one engine fails to operate, for whatever reason, as the other engine can still apply power to both rotor systems permitting safe recovery of the aircraft.

Referring to Figure 3, an augmentation framework 59 is configured for rapid detachable connection to the module component support airframe 13 via quick ~disconnect fasteners 22. A connecting drive shaft 61 is detachably connected to the transmission input shafts 21 of the respective modules Iar. The tandem rotor configuration of the VTOL aircraft of Figure 3 requires the lifting rotors 11 of the respective back-to-back arranged modules 10 rotate in opposite directions. the engine 30 of the left side module 10 rotates clockwise as viewed from the front side of the engine and the engine 30 of the right side module 10 rotates counterclockwise as viewed from the front side of the engine.

Two-stroke, engines are preferred since two-stroke engines have the characteristic of operating in either direction with no change to the timing or other operative components of the engine. A two-stroke engine operates in the same direction in which it is started. Hence, an operative configuration of the described tandem rotor VTOL aircraft of Figure 3 powered by a pair of modules of the invention connected back-to-back in the manner described is easily achieved by starting the respective engines of the pair of modules in *opposite directions. Four-stroke engines may be utilized, but require a different timing adjustment of each of the respective engines and other modifications.

It is preferred that engine timing is electromagnetically switched using a plurality of Hall effect sensors mounted on the rotating components of the engine, thereby eliminating the need for manual timing adjustments.

The embodiment shown in Figure 3 can be modified to include a third engine (not shown) mounted on or within augmentation framework 59 to provide additional payload capacity.- The third engine is preferably connected to the augmentation framework 59 using quick disconnect fasteners.

As previously indicated, the space provided on and around the module component support airframe 13 is available for installation of components involving operative control of the module lifting rotor assembly I11 and operative control of VTOL augmentation framework mounted flight control units. The present invention is adapted to powering VTOL UAV aircraft. The described VTOL embodiments of Figures 2 and 3 are of this unmanned type preferably include equipment which establishes remote control of the aircraft from the ground. An example of such equipment is disclosed in U.S. Patent 3,096,046 which is incorporated herein by reference.

Figures 4 and 5 illustrate two embodiments of the quick disconnect fasteners 22 which can be used to connect landing support 52 to undercarriage 1. Figure 6 shows an embodiment of quick disconnect fastener 22 which can be used to connect augmentation framework 45 to main drive shaft clutch assembly extension 60. Figure 7 shows an embodiment of the quick disconnect fastener 22 which can be used to connect transmission 12 to component support air frame 13. Figures 8 and 9 show an embodiment of quick disconnect fastener 22 which can be used to connect tail boom section 45a to main drive shaft clutch assembly extension 60. Figure 10 shows an embodiment of a .coupling which may be used to connect main drive shaft 34 to transmission !0 power input shaft 21 or counter torque rotor drive shaft It should be understood that the foregoing disclosure involves preferred embodiments of the invention and that numerous modifications or alterations therein may be made without departing from the spirit and scope of the invention as set forth in the appendant claims.

Claims

11. APR. 2006 17:34 FREEHILLS SYDNEY 3 +612 93224600 NO, 1888 P. 6 What is claimed: 1. A universal power drive and. lifting rotor system module for powering single and multiple rotor type VTOL aircraft comprising: an elongated maodule component support framework having a plurality of engine mounts aranged at one end for externally supporting an engine thereon and other end adapted for connecting to auxiliary VTOL augmentation framework, said engine being supported on said engine mounts, a main drive shaft supported for axial rotation within said component support framework to extend longitudinall y thereof between said component support framework respective ends, one end of said main drive shaft having coupling means for detachably connecting and disconnecting said main drive shaft and said engine, said main drive shaft other end being adapted for connection to a rotatable shaft, a lifting rotor assembly and underlying transmission mounted atop said component supportframnework, said rotor transmission having a power input shaft extending from within said 20 transmnission terminating in an outer end adjacent said component support framework other end wit said power input shaft outer end adapted for connection to said rotatable shaft, -power transfer means connected between said mnain drive shaft and said rotor 0....transmission power input shaft for transferring rotational power between said main drive and said rotor transmission input shafts and clutch means contained in said main drive shalt adjacent said power transfer means connection for selectively connecting and disconnecting said main drive shaft and said power 9- 9 transfer means. 2. The. module of claim 1 wherein said main drive shaft coupling means comprises flexible coupling means for axially de-linking said main drive shaft and said engine. COMS ID No: SBMI-03288028 Received by IP Australia: Time 17:32 Date 2006-04-11 11. APR. 2006 17:34 FREEHILLS SYDNEY 3 +612 93224000 NO. 1888 P. 7 3. The module of claim I wherein said power transfer means comprises main drive and rotor transmission power input shaft mounted pulleys interconnected by endless belting means. 4. The module of claim 2 wherein said power transfer means comprises main drive and rotor transmission power input shaft mounted pulleys interconnected by endless belting means. A VTOL aircraft compirising: the module of any one of claims 1-4, a first elongated VTOL augmentation framework having a counter torque rotor mounted at an outer end for rotation in an axially aligned vertical plane and having an inner end connected. to said component support framework other end of said module of any one of claims 1-4, a counter torque rotor'drive shaft supported for axial rotation within said first VTOL 0 augmentation framework with one end of said counter torque rotor drive shaft connected to said main drive shaft other end of said module of any one of claims 1-4 and said counter torque rotor 0. 0:drive shaft other end operatively connected to said counter torque rotor and .o 9 0: 20 an undercarriage with landing support attached to the underside of said component 0 9 support framework of said module of any one of claims 1-4. 6. A compound VTOL aircraft comprising: the module of any one of claims 1-4, a second elongated VTOL augmentation framework having a sbrouded propeller 25 mounted for rotation transversely of said second VTOL augmentation framework longitudinal axis forwardly of propeller slip stream deflecting means mounted at one end of said second 0.0. VTOL augmentation framework and of which said framework other end is connected to said component support f-rmework other end of said module of any one of claims 1-4, a shrouded propeller drive shaft supported for rotation within said second VTOL augmentation framework with one end of said shrouded propeller drive shaft connected to said main drive shaft other end of said module of any one of claims 1-4 and said shrouded propeller drive shaft other end operatively connected to said shrouded propeller, COMS ID No: SBMI-03288028 Received by IP Australia: Time 17.32 Date 2006-04-11 11. APR. 2006 17:35 FREEHILLS SYDNEY 3 +612 93224000 NO. 1886 P. 8 a pair of aerodynamic wing structures each having an inneor root end with said root end of each said wing structures affixed to respective opposite sides of said component support framework of said module of any one of claims 1-4 to extend laterally outwardly therefrom and an undercarriage with landing support attached to the underside of said component support framework of said module of any one of claims 1-4. 7. A VIOL dual rotor aircraft comprising: a pair of the module of any one of claims 1-4, a third elongated VTOL augmentation framework of which respective ends are attached to said component support framework other end of respective ones of said module pair of any one of claims 1-4, a connecting drive shaft supported for rotation by said third VTOL augmentation auxiliary framework to extend longitudinally thereof with respective ends of said connecting drive shaft operatively connected to said rotor transmission power input shaft outer ends of respective ones of said module pair of any one of claims 1-4 and an undercarriage with landing support attached to the underside of said component support framework of each said module pair of any one of claims 1-4. 8. A VTOL dual rotor aircraft comprising: a pair of the module of any one of claims 1-4, a third elongated VIOL augmentation framework of which respective ends are attached to said component support framework other end of respective ones of said module pair of any one of claimisl-4, a connecting drive shaft supported for rotation by said third VTOL augmentation fr-amework to extend longitudinally thereof with respective ends of said connecting drive shaft operatively connected to said main drive shaft other ends of respective ones of said module pair of any one of claims 1-4 and an undercarriage with landing support attached to the underside of said component support framework of each said module pair of any one of claims 1-4. 12 COMS ID Na:SBMI-03288028 Received by IP Australia: Tim e 17:32 Date 2006-04-11 11. APR. 2006 17:35 FREEHILLS SYDNEY 3 +612 93224000 NO. 1888 P. 9 9. A universal power drive and lifting rotor system module for single and multiple rotor type VTOL aircraft substantially as hereinbefore described with reference to the accompanying drawings. A VTOL aircraft substantially as hereinbefore described with reference to the accompanying drawings. 11. A VTOL dual rotor aircraft substantially as hereinbefore described with reference to the accompanying drawings. 99 9 9 99* 9 oooo 9999 9999 9999 oooo 9 *13 .3 COMS ID No: SBMI-03288 0 2 8 Received by IP Australia: Time 17:32 Date 2006-04-11