Method and system for manufacturing an aerostat with a rigid structure and an aerostat for carrying heavy loads manufactured in this way

Abstract

A method for assembling the structure of an aerostat (1) in successive horizontal sections starting from a top horizontal section, the method comprising the iteration of the following steps: starting from the current completed state of the aerostat structure, lifting the structure in its current state at a first lifting point by means of lifting means (20, 20', 50, 50') provided at the current lateral position; placing support equipment (30, 30') in alignment with a second lifting point for lifting the structure in its current state; transferring the structure in its current state from the lifting means to the support equipment; moving the lifting means to another lateral position; and fully assembling a horizontal section on the structure directly below the structure in its current state.

Description

Field of the Invention

[0001] The present invention relates to a method for manufacturing an airship having a rigid structure. The present invention also relates to a system for manufacturing an airship, and an airship carrying heavy loads manufactured by implementing the method.

[0002] The field of the present invention more particularly but not restrictively relates to airships having a rigid structure, in particular airships carrying heavy loads. Background Art

[0003] The present invention relates to a method for manufacturing an airship.

[0004] US Patent No. 1,559,807 is known, which proposes a method for manufacturing an airship, particularly a fully metal airship, in which the work becomes easier and very precise compared to the methods according to the prior art, since the airship is manufactured by appropriately adding parts gradually on the completed parts to complete the entire structure, thus avoiding the assembly of prefabricated sub-assemblies.

[0005] Furthermore, according to the method described in this prior art, the riveting of the longitudinal beams and the attachment of the airship skin are facilitated by the work of workers on the ground.

[0006] This method proposes to build the airship in successive horizontal sections starting from the upper horizontal section. The entire structure of this section (including the curved top of the transverse circular beams, the longitudinal beams, the skin, and all fittings) is manufactured on the floor of the hangar. Cables from the top of the hangar are fixed in the appropriate positions of the completed section, and then the completed section is lifted by a suitable winch that secures the cable. The upper horizontal section is raised to a height equal to the thickness of the section to be produced located below. This operation is repeated until the airship is manufactured.

[0007] Even though the solution proposed by the prior art is appreciable, it is not entirely satisfactory. In fact, it requires a hangar provided with rails that extend longitudinally with respect to the hangar and are in the longitudinal vertical plane of the airship when the airship is completed. The monorail must be equipped with multiple winches and cables starting from each winch.

[0008] Furthermore, the installation of this equipment has requirements for the structure of the building; this equipment is not easily movable in other hangars, for example, being used for another airship in other hangars. In addition, the parts being assembled are not mechanically maintained. Summary of the Invention

[0009] An object of the present invention is to significantly remedy all or part of the above defects.

[0010] According to a first aspect of the present invention, a method for assembling the structure of an aerostat by means of successive horizontal sections starting from an upper horizontal section is proposed, the method comprising the iteration of the following steps: starting from the current manufacturing state of the structure of the aerostat,

[0011] - lifting the structure in the current state at a first lifting point by means of lifting means arranged at the current lateral position,

[0012] - placing the supporting equipment in alignment with a second lifting point of the structure in the current state,

[0013] - transferring the structure in the current state from the lifting means to the supporting equipment,

[0014] - moving the lifting means to another lateral position, which is the current position of the lifting means in the state subsequent to the current state,

[0015] - completely assembling a horizontal section on the structure directly below the structure in the current state.

[0016] The step of transferring the structure in the current state to the supporting equipment by the lifting means can be carried out by lowering the structure in the current state by the lifting means and placing the structure in the current state in a resting state on the supporting equipment.

[0017] The step of lifting the structure in the current state can advantageously be carried out by means of jacks, but can also be carried out by means of a lifting winch arranged above the structure being assembled. These two devices can be used in combination. The lifting winch can advantageously be implemented in the so-called equatorial assembly phase corresponding to the maximum width of the structure being assembled.

[0018] According to other advantageous and non-limiting features of the present invention (either individually or in any technically feasible combination):

[0019] - the lifting means comprise jacks;

[0020] - the first lifting point is arranged at the lateral support end of the aerostat;

[0021] - the structure is lifted at the lateral ends of the structure.

[0022] The manufacturing method may further comprise the following steps:

[0023] - a step for arranging the cargo hold structure inside the structure being assembled;

[0024] - a step for arranging the cargo hold structure on a lifting platform.

[0025] - The iterative assembly steps include steps for assembling the cargo hold structure so as to mechanically couple the cargo hold structure to the horizontal section being assembled with the aid of beams.

[0026] The manufacturing method according to the present invention further includes multiple steps for connecting a defined point of the upper part of the already assembled structure to a defined point of the beam to mechanically couple the cargo hold structure to the structure.

[0027] According to a further aspect of the present invention, there is provided a system for assembling the structure of an airship by successive horizontal sections starting from an upper horizontal section, the system implementing the manufacturing method according to the present invention, the system comprising:

[0028] - A lifting device which is arranged in the current lateral position and which is provided for lifting the structure in its current state at a first lifting point;

[0029] - A device for placing the support equipment in alignment with a second lifting point of the structure in its current state;

[0030] - A device for transferring the structure in its current state from the lifting device onto the support equipment so as to lower the structure in its current state by means of the lifting device and to rest the structure in its current state on the support equipment;

[0031] - A device for moving the lifting device to another lateral position, which is the current position of the lifting device in the state subsequent to the current state;

[0032] - A device for positioning, beneath the structure in its current state in which the horizontal section is fully assembled, on the structure.

[0033] The assembly system according to the present invention may also advantageously include a device for arranging the cargo hold structure inside the structure being assembled.

[0034] The device for arranging the cargo hold structure may include a lifting platform on which the cargo hold structure is placed.

[0035] The assembly device may also be arranged to assemble the cargo hold structure so as to mechanically couple the cargo hold structure to the horizontal section being assembled with the aid of beams.

[0036] Then, the assembly system according to the present invention may include a device for connecting a defined point of the upper part of the already assembled structure to a defined point of the beam to mechanically couple the cargo hold structure to the structure.

[0037] According to another aspect of the present invention, there is provided an airship for carrying heavy loads, the airship being manufactured by implementing the assembly method according to the present invention.

[0038] Preferably, the aerostat has a structure including a rigid framework, which is covered with a flexible envelope and contains a lifting gas balloon. The framework is an assembly of beams arranged in transverse frames and longitudinal girders and reinforced by a system of tension elements. The lifting gas balloons are distributed along the length of the aerostat.

[0039] When the aerostat includes a cargo bay designed to accommodate a payload, the cargo bay includes a cargo bay structure, which is mechanically coupled to the structure of the aerostat in the following ways: on the one hand, by a set of beams arranged transversely on both sides of the cargo bay structure and mechanically connected to the sides of the structure, and on the other hand, by a set of cables stretched between a defined point of the coupled beams and a defined point of the upper part of the structure. This arrangement is suitable for separating the "main" framework of the lifting gas balloons.

[0040] The transverse beams may advantageously include grid beams made of composite tubes made of pultruded carbon, and the cables include solid-section composite rods made of pultruded carbon. Then, the aerostat includes articulated connectors of the cables to the coupled beams and to the upper part of the structure. These articulated connectors may include metal parts.

[0041] The beams between the cargo bay structure and the main body structure ensure the stability of the lower part. The cables stretched between these beams and the upper part of the main body structure transfer forces between the cargo bay supporting the payload and the upper part supporting the lifting force generated by the static pressure of helium.

[0042] The entire structure is self-supporting. It has resistance and stability, thus allowing the structure to support its own weight and the weight of various equipment in the absence of lifting gas. The self-supporting ability of the structure also applies to its intermediate state of assembly by continuous horizontal sections. This ability is achieved by arranging rigid beams and tension elements around the periphery of the main framework separating the lifting gas balloons.

[0043] According to another aspect of the present invention, there is provided a computer program product that can be downloaded from a communication network and / or stored on a computer-readable medium and / or can be executed by a microprocessor and can be loaded into the internal memory of a processing unit, characterized in that the computer program product includes instructions that, when executed by the processing unit, implement the steps of the method according to the first aspect of the present invention, or one or several steps of its improvements. Description of the Drawings

[0044] Other advantages and particularities of the present invention will become apparent by referring to the detailed description of the embodiments and implementations with reference to the drawings, which are in no way restrictive, wherein:

[0045] Figures 1 to 10Illustrated are a series of steps of a method according to the present invention and a device according to the present invention, the device being adapted to implement the method according to the present invention. Detailed Description

[0046] Since the embodiments described below are not restrictive in nature, variants of the present invention can be specifically considered, which variants include only a selection of the features described (as long as this selection of features is sufficient to confer a technical advantage or to distinguish the present invention from the prior art). This selection includes at least one preferred functional feature without structural details, or only a part of the structural details (if this part alone is sufficient to confer a technical advantage or to distinguish the present invention from the prior art).

[0047] In the drawings, elements that appear in more than one drawing retain the same reference numerals.

[0048] Reference Figure 1 , an initial stage of constructing the airship 1 by successive horizontal sections starting from an upper horizontal section is described.

[0049] Figures 1 to 10 Each of includes: a sub - figure a showing a front view of the current construction state of the airship 1, and a sub - figure b showing a longitudinal view (seen from the left) of the current construction state of the airship 1.

[0050] Shown is a manufacturing device 10 according to an embodiment of the present invention, the manufacturing device including two sets of a plurality of lifting columns 20 and 20' that rise from the surface of the assembly area.

[0051] As Figure 1 more particularly shown in b, a plurality of lifting columns 20' are arranged on the left side of the airship, while a plurality of lifting columns 20 are arranged on the right side of the airship.

[0052] In the transverse plane of the airship being constructed, each lifting column 20 corresponds to a lifting column 20'.

[0053] Each of the lifting columns has a lifting carriage, which is arranged to be slidably vertically mounted on the lifting column with a displacement of 10 meters and is controlled by a control handle in the form of a reinforcing shaft or a pedal.

[0054] A tripod 30 is arranged in the middle of these two sets of columns.

[0055] As Figure 1 more particularly shown in a, various cables and longitudinal beams for fixing connecting parts are implemented. Outer shell panels are also installed, as well as the positioning of the communication network and the helium cell.

[0056] As Figure 1As shown more particularly at b, this mounting is carried out not only on the transverse parts of the upper section but also all along the longitudinal extension of the upper section.

[0057] Furthermore, the entire structure of this section (including the curved upper part of the transverse circular beam, the longitudinal beams, the skin and all fittings) is manufactured on the floor of the hangar.

[0058] As Figure 1 shown at a, the weight of the airship is distributed laterally on the lifting columns 20 and 20' and on the intermediate tripod 30.

[0059] Reference Figure 2 is made to the steps which follow the steps described in reference Figure 1 As shown more particularly at a, the airship is raised to a height suitable for constructing the next horizontal section. Figure 2 In this state, at two support points, the weight of the airship is distributed laterally on the lifting columns 20 and 20', thus releasing the movable tripod 30.

[0060] This can be achieved by the vertical structural stability of the section reinforced by the cable support system 21 at the main frame separating the helium balloons.

[0061] Reference

[0062] is made to the steps which follow the steps described in reference Figure 3 As shown more particularly in a, the manufacturing equipment 10 includes an additional tripod 30'. Figure 2 Reference Figure 3 is made to the steps which follow the steps described in reference

[0063] The tripods 30 and 30' are placed in alignment with two load-bearing points of the airship 1, the two load-bearing points being arranged appropriately close to the ends supported by the two lifting columns 20 and 20'.

[0064] Thereafter, at each of the two load-bearing points of the airship, the airship is placed on the tripods.

[0065] In this state, the weight of the airship is distributed laterally on the two tripods 30 and 30', thus releasing the lifting columns 20 and 20'.

[0066] Reference Figure 4 is made to the steps which follow the steps described in reference Figure 3 As shown more particularly at a, the lifting columns 20 and 20' each move into a second transverse position.

[0067] As Figure 4 shown more particularly at a, the lifting columns 20 and 20' each move into a second transverse position.

[0068] As Figure 4More specifically, various cables and longitudinal beams for fixedly connecting parts are implemented. A housing panel is also installed, as well as the positioning of the communication network and the helium unit.

[0069] As Figure 4 Best shown in

[0070]

[0071] In addition, the entire structure of this section (including the curved upper part of the transverse circular beam, longitudinal beams, skin, and all fittings) is manufactured on the floor of the hangar. It has been observed that the presence of the operator on the work platform 40 (which is raised to a height of 3 meters) is necessary to perform certain operations. As Figure 4 can be seen from

[0072] a, the weight of the airship is laterally distributed on each of the lifting columns 20 and 20' and the tripods 30 and 30' at the load-bearing points. Figure 5 Reference Figure 4 describes the steps after the steps described in Figure 4 In order to be able to transition from the current construction state of the airship in Figure 5 to the current construction state of the airship in

[0073] - Lift the airship 1 to release each of the two tripods 30 and 30', and then the weight of the airship is only borne at the lifting columns 20 and 20', as in the steps described in Figure 2 the reference;

[0074] - Move the tripods 30 and 30' to align with two second load-bearing points, which are appropriately arranged near the ends supported by the two lifting columns 20 and 20', and place the airship on the tripods at each of the two second load-bearing points. Then the weight of the airship is only borne at the tripods 30 and 30', as in the steps described in Figure 3 the reference; and

[0075] - Move each of the lifting columns 20 and 20' to a third lateral position; install different cables and longitudinal beams to fixedly connect parts, as well as the positioning of the housing panel, communication network, and helium unit; the weight of the airship is laterally distributed on each of the lifting columns 20 and 20' and the tripods 30 and 30' at the second load-bearing points, as described in Figure 4 the reference. As Figure 5 Best shown in

[0076] It has been observed that the presence of the operator on the working platform 40 (which is raised to a height of 6 meters, which is its own lateral movement) is necessary to perform certain operations.

[0077] Reference Figure 6 , describes the steps after the steps described in reference Figure 5 described. Figure 6 Sub- Figure 6 a, which includes a front view showing the current construction state of the airship 1, and sub- Figure 6 b, which includes a longitudinal view showing the current construction state of the airship 1.

[0078] In order to be able to transition from the current construction state of the airship in Figure 5 to the current construction state of the airship in Figure 6 , the steps described with reference to the state transition from Figures 4 to 5 have been executed.

[0079] It has been observed that the presence of the operator on the working platform 40 (which is now raised to a height of approximately 10 meters, which is its own lateral movement) is necessary to perform certain operations.

[0080] In addition, this phase also includes the installation of the propulsion motor and the installation of the tail of the airship 1.

[0081] As Figure 6 more particularly shown in a, the manufacturing device 10 includes additional lifting columns 50 and 50'.

[0082] Each of the additional lifting columns has a lifting carriage that is arranged to be slidably vertically mounted on the lifting column according to a displacement of 25 meters and is controlled by a control handle in the form of a reinforcing shaft or a pedal.

[0083] In addition, each of the two tripods 30 and 30' is provided at its upper end with a vertical arm or mast or vertical rod, namely 32 and 32' respectively.

[0084] Reference Figure 7 , describes the steps after the steps described in reference Figure 6 described.

[0085] In order to be able to transition from the current construction state of the airship in Figure 5 to the current construction state of the airship in Figure 6 , the steps described below have been executed:

[0086] - Lift the airship to the full height of the lifting columns 20 and 20', so that the weight of the airship is borne only by the lifting columns 20 and 20';

[0087] - Move the tripods 30 and 30' to align with other load bearing points, which are appropriately arranged near the ends supported by the two lifting columns 20 and 20', and place the airship on the vertical poles of the tripods at each of the two load bearing points, then the weight of the airship is only borne at the tripods 30 and 30';

[0088] - Remove the lifting columns 20 and 20';

[0089] - Bear the other load bearing points by additional lifting columns 50 and 50'; and

[0090] - Remove the tripods 30, 30' and the working platform 40.

[0091] Reference Figure 8 describes the steps after the steps described in reference Figure 7 In step 8, the cargo hold 2 of the airship 1 is moved under the structure assembled to this point.

[0092] The manufacturing equipment 10 includes lifting platforms 60 and 60' on which the cargo hold 2 is placed.

[0093] Reference Figure 9 describes the steps after the steps described in reference Figure 8 The steps are described.

[0094] The additional lifting columns 50 and 50' raise the airship 1 so that the uppermost section of the lower part of the structure of the airship 1 can be fixed to the already assembled structure and to the cargo hold 2. For this purpose, each of the two tripods 30 and 30' is again placed such that the arm of the tripod is below the elevation point relative to the ground, and the end of the beam must be fixed to the arm.

[0095] In addition, two new tripods 30' and 30" are also placed below these elevation points relative to the ground.

[0096] As Figure 9 more particularly visible in a, various cables and girders for fixing connection parts are placed in the uppermost section of the lower part. The absence of the lifting gas is particularly beneficial for the installation of the connection cable 90, which limits the introduction of pre-tension. The outer shell panels are also installed, as well as the positioning of the communication network and the helium unit.

[0097] Reference Figure 10 describes the steps after the steps described in reference Figure 9 The structure of the airship 1 is completely completed, and the cargo hold 2 of the airship is attached to the structure of the airship. The structure of the airship includes several cross beams 80 and connection cables.

[0098] In addition, the airship 1 is placed on a transport device 70 of the transport platform type having a plurality of wheels. Static tests can then be carried out on the terminal, and the operation of a winch specific to the airship can also be tested. The winch can be loaded in the cargo hold for its operation and thus must be tested.

[0099] At this time, another embodiment of the method according to the present invention will be described, in which a lifting winch is also implemented in combination with the above-mentioned lifting columns during an assembly phase called "equator".

[0100] In the above-mentioned equator phase, the upper part of the airship has been assembled up to the widest part (equator) of the three-dimensional structure.

[0101] In this phase, the small columns ensure the geometric positioning, raising and lowering of the load, while the large columns are responsible for the geometric positioning performed by the small columns, the load bearing in the X, Y, and Z directions, and also contribute to the raising and lowering of the load.

[0102] The lifting winches (not shown) are arranged in the assembly unit on one or more mechanical structures suspended at the airship being assembled. These winches are attached to the small columns.

[0103] In the next phase of the assembly above the equator, the small columns ensure geometric positioning, load bearing in the X, Y, and Z directions, and the raising and lowering of the load, while the winches are responsible for the geometric positioning performed by the small columns, the load bearing in the Z direction above the equator, and contribute to the raising and lowering of the load.

[0104] In the next phase after the assembly is completed, the small columns ensure geometric positioning, load bearing in the X, Y, and Z directions, and the raising and lowering of the load, while the winches are responsible for the geometric positioning performed by the small columns, the load bearing in the Z direction above the equator, and contribute to the raising and lowering of the load.

[0105] As will be readily understood, the present invention is not limited to the examples just described, and various modifications can be made to these examples without departing from the scope of the present invention. In addition, the various features, forms, variations, and embodiments of the present invention can be combined together in various combinations as long as they are not incompatible or mutually exclusive.

Claims

1. A method for assembling the structure of an aerostat (1) by means of successive horizontal sections starting from an upper horizontal section, the method comprising the iteration of the following steps: starting from the current manufacturing state of the structure of the aerostat, - lifting the structure in its current state at a first lifting point by means of lifting devices (20, 20', 50, 50') arranged at the current lateral position; - placing the supporting devices (30, 30') in alignment with a second lifting point of the structure in its current state; - transferring the structure in its current state from the lifting devices to the supporting devices; - moving the lifting devices to another lateral position; - completely assembling a horizontal section on the structure directly below the structure in its current state.

2. The method according to claim 1, characterized in that the transfer comprises: lowering the structure in its current state by means of the lifting devices and resting the structure in its current state on the supporting devices.

3. The method according to claim 1 or 2, wherein the assembled structure is self-supporting in each current intermediate state of the method.

4. The method according to claim 1 or 2, wherein the step of lifting the structure in its current state uses a jack.

5. The method according to claim 1 or 2, wherein the step of lifting the structure in its current state implements a lifting winch arranged above the structure.

6. The method according to claim 5, characterized in that the lifting winch is implemented in a so-called equatorial assembly phase, in which the structure being assembled reaches the maximum width of the structure.

7. The method according to claim 1 or 2, wherein the first lifting point is arranged at the lateral support end of the aerostat.

8. The method according to claim 1 or 2, wherein the structure is lifted at the lateral ends of the structure.

9. The method according to claim 1 or 2, the method further comprising the step of arranging a cargo hold structure (2) inside the structure being assembled.

10. The method according to claim 9, wherein the cargo hold structure (2) is placed on a lifting platform (60, 60').

11. The method according to claim 9, wherein the iterative assembly step comprises a step of assembling the cargo hold structure (2) so as to mechanically couple the cargo hold structure to the horizontal section being assembled by means of a beam.

12. The method according to claim 11, characterized in that the method further comprises a plurality of steps of connecting a defined point of an upper part of the already assembled structure to a defined point of the beam to mechanically couple the cargo hold structure to the structure.

13. A system for assembling the structure of an aerostat (1) by means of successive horizontal sections starting from an upper horizontal section, the system implementing the method according to any one of the preceding claims, the system comprising: - Lifting devices (20, 20', 50, 50'), the lifting devices (20, 20', 50, 50') being arranged in the current lateral position and being arranged to lift the structure in the current state at a first lifting point; - Devices for placing the support equipment (30, 30') in alignment with a second lifting point of the structure in the current state; - Devices for transferring the structure in the current state from the lifting device to the support equipment so as to lower the structure in the current state by the lifting device and rest the structure in the current state on the support equipment; - Devices for moving the lifting device to another lateral position, the other lateral position being the current position of the lifting device in the state after the current state; - Assembly devices for fully assembling the horizontal section directly below the structure in the current state on the structure.

14. The system according to claim 13, the system further comprising devices for arranging the cargo hold structure inside the structure being assembled.

15. The system according to claim 14, wherein, the devices for arranging the cargo hold structure include a lifting platform on which the cargo hold structure is placed.

16. The system according to claim 14 or 15, wherein, the assembly devices are further arranged to assemble the cargo hold structure so as to mechanically couple the cargo hold structure to the horizontal section being assembled by means of beams.

17. The system according to claim 16, the system further comprises: Devices for connecting a defined point of the upper part of the structure that has been assembled to a defined point of the beam to mechanically couple the cargo hold structure to the structure.

18. The system according to any one of claims 13 to 15, characterized in that, the lifting device includes a jack.

19. The system according to any one of claims 13 to 15, characterized in that, the lifting device includes a winch arranged above the structure being assembled.

20. An airship (1) carrying heavy loads, the airship (1) being produced by implementing the method according to any one of claims 1 to 12.

21. The airship according to claim 20, the airship having a self-supporting rigid structure even in the absence of lifting gas.

22. The heavy-load-carrying airship according to claim 20 or 21, the airship including a cargo hold designed to accommodate a load, the cargo hold including a cargo hold structure, the cargo hold structure being mechanically coupled to the structure of the airship in the following manner: on the one hand by assembling beams arranged laterally on both sides of the cargo hold structure and mechanically connected to the sides of the structure, and on the other hand by assembling cables stretched between defined points of the beams and defined points of the upper parts of the structure.

23. The airship according to claim 22, wherein, the lateral beams include lattice beams made of pultruded carbon composite tubes.

24. The airship according to claim 22, wherein, The cable includes a composite solid cross-section rod made of pultruded carbon.

25. The aerostat according to claim 22, wherein, the aerostat further includes a hinged connection member that connects the cable to the beam and to the upper part of the structure.

26. The aerostat according to claim 25, wherein, the hinged connection member includes a metal part.

27. A computer program product that can be downloaded from a communication network and / or stored on a computer-readable medium and / or can be executed by a microprocessor and can be loaded into the internal memory of a processing unit, wherein, the computer program product includes instructions that, when the program is executed by the processing unit, cause the processing unit to perform the steps of the method according to any one of claims 1 to 12.

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