Unmanned aerial vehicle, kit therefor, and method for manufacturing an unmanned aerial vehicle

The drone's support structure with interconnected partial elements addresses the challenge of lightweight stability and assembly, ensuring efficient force transfer and reduced mechanical load.

WO2025210043A1PCT designated stage Publication Date: 2025-10-09BEAGLE SYSTEMS GMBH
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Patent Information

Application Number
PCT/EP2025/058896
Authority / Receiving Office
WO · WO
Patent Type
Applications
Current Assignee / Owner
Priority Date
2024-04-05
Filing Date
2025-04-02
Publication Date
2025-10-09

AI Technical Summary

Technical Problem

Existing small and micro drones face challenges in achieving a balance between lightweight construction and high stability, while also requiring simple assembly.

Method used

A drone design featuring a support structure with a support frame and elements extending from wing tips to a central frame, composed of interconnected partial support elements made from lightweight materials like carbon-fiber-reinforced polyamides, allowing for modular assembly and efficient force distribution.

Benefits of technology

The design achieves high stability with low weight and facilitates easy assembly, enabling efficient transfer of aerodynamic forces and reducing mechanical load on components.

✦ Generated by Eureka AI based on patent content.

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Abstract

In order to provide an unmanned aerial vehicle, in particular a drone, which has a low weight and high stability, an unmanned aerial vehicle (100), in particular a drone (10), comprising a fuselage (11) and wings (12) is proposed, also having a supporting structure (19) comprising a supporting frame (20) and supporting elements (21, 21a, 21b), wherein the supporting frame (20) is arranged at least partially in the fuselage (11), wherein the fuselage (11) is fastened to the supporting frame (20), wherein at least one supporting element (21, 21a, 21b) is arranged in each wing (12), wherein the supporting element (21, 21a, 21b) extends from a wing tip region (22) along a main axis (23) of the wing (12) through the wing (12), and is fastened to the supporting frame (20), wherein provision is made for each supporting element (21, 21a, 21b) to consist of separate supporting sub-elements (26, 26a, 26b) which are arranged one behind the other along the main axis (23) and are connected to one another.
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Description

[0001] UNMANNED AERIAL VEHICLE, KIT THEREFOR, AND METHOD FOR MANUFACTURING AN UNMANNED AERIAL VEHICLE

[0002] The present invention relates to an unmanned aerial vehicle, in particular a drone, comprising a fuselage and wings, further comprising a support structure comprising a support frame and support elements, wherein the support frame is arranged at least partially in the fuselage, wherein the fuselage is fastened to the support frame, wherein at least one support element is arranged in each wing, wherein the support element extends from a wing tip region along a main axis of the wing through the wing and is fastened to the support frame.

[0003] Furthermore, the present invention relates to a kit for an unmanned aerial vehicle and a method for producing an unmanned aerial vehicle.

[0004] Technological background

[0005] Unmanned aerial vehicles, also known as drones, are aircraft without a crew on board. Control and navigation are either remotely controlled, along a pre-programmed flight path, or completely autonomously. Small and micro drones are used commercially, for example, for surveying tasks. Such small and micro drones must be as lightweight as possible, while also being extremely stable. Furthermore, simple assembly of such small and micro drones is an advantage.

[0006] WO 2023 / 122145 A1 discloses an additively manufactured aircraft structure comprising a plurality of additively manufactured aircraft segments, wherein the aircraft segments can be connected to one another in an assembly direction. In an unassembled configuration, the aircraft segments are configured as separate aircraft segments. Reinforcing elements are provided to connect the aircraft segments; these reinforcing elements can be received in receiving portions of the plurality of aircraft segments and extend through the plurality of aircraft segments. An unmanned aircraft is known from IN 2018 410 367 38 A. The unmanned aircraft has a modular design with multiple subsegments.

[0007] An aircraft known from DE 10 2017 130 884 B4 has a primary structural element which extends along a main axis of the aircraft and at least one monolithic structural component which is manufactured by means of a three-dimensional printing process.

[0008] Description of the invention: task, solution, advantages

[0009] The present invention is based on the object of providing an unmanned aerial vehicle, in particular a drone, which has a low weight and a high stability.

[0010] To achieve the object underlying the invention, an unmanned aircraft, in particular a drone, comprising a fuselage and wings is proposed, further comprising a support structure comprising a support frame and support elements, wherein the support frame is at least partially arranged in the fuselage, wherein the fuselage is fastened to the support frame, wherein at least one support element is arranged in each wing, wherein the support element extends from a wing tip region along a main axis of the wing through the wing and is fastened to the support frame, wherein it is further provided that each support element consists of separate partial support elements arranged one behind the other along the main axis and connected to one another.

[0011] The supporting frame and the supporting elements together form the supporting structure of the unmanned aircraft. The wings are connected to the fuselage via the supporting elements connected to the supporting frame. Aerodynamic forces acting on the wings are transferred to the supporting frame via the supporting elements. Due to the supporting structure, the unmanned aircraft is very stable. Therefore, the fuselage and wings can be made of lightweight materials. The supporting elements extend from a wing tip area along a main axis of the respective wing through the wing and are attached to the supporting frame. The main axis of the wing corresponds to the main extension direction of the wing, starting from the wing root to the wing tip. The supporting elements can also extend into the wing tips.

[0012] According to the invention, each of the support elements consists of separate sub-support elements arranged one behind the other along the main axis of the wings and connected to one another. In other words, each support element consists of several sub-support elements that are independent and separate in the unassembled state and are connected to one another in the assembled state in the unmanned aircraft.

[0013] The design of the support elements in the form of several interconnected partial support elements has the advantage that the individual partial support elements can be adapted to the forces acting on them during operation of the unmanned aircraft and dimensioned accordingly.

[0014] The support element, in particular a partial support element of the support element, can be attached to the support frame with an end facing away from the wing tip region. Furthermore, it is possible for the support element to extend continuously from one wing tip region to the opposite wing tip region. In this case, the support element can be attached to the frame by passing the corresponding support element, in particular a partial support element of the support element, through a support element receptacle of the support frame. The support element receptacle can be designed in the form of a tube through which the support element or a partial support element of the support element is pushed.

[0015] Advantageously, it can be provided that at least two support elements are arranged in each wing.

[0016] The two support elements then run approximately along the main axis of the wing from the wing tip region to, preferably, the wing root and are, in particular, both attached to the support frame. The two support elements can be arranged within the respective wing approximately parallel or at an acute angle to each other. Particularly advantageously, at least one of the support elements is arranged in the region of the leading edge of the wing and another support element is arranged in the region of the trailing edge of the wing.

[0017] It is preferably provided that the support element arranged in the region of the leading edge extends continuously from one wing tip region to the opposite wing tip region, wherein the support element or a partial support element of the support element is particularly preferably guided through a support element receptacle of the support frame. Furthermore, it is preferably provided that the support element arranged in the region of the trailing edge is fastened to the support frame with an end facing away from the wing tip region.

[0018] It is preferably provided that each wing comprises a plurality of wing segments, that each wing segment comprises a profile body, and that at least one partial support element is arranged within each profile body.

[0019] The at least one partial supporting element is preferably assigned to the respective profile body.

[0020] In principle, it can also be provided that a partial load-bearing element is arranged within two or more profile bodies and is thus assigned to the two or more profile bodies.

[0021] If two support elements extend through a support surface, then two partial support elements are arranged in each of the profile bodies, wherein preferably one of the partial support elements is assigned to one of the support elements.

[0022] The wing segments can form separate units, enabling a modular assembly of the unmanned aircraft. In particular, the wing segments, which are separate in the unassembled state, can be combined to form wings by connecting the partial support elements. Advantageously, the support elements can be arranged centrally in the wings and / or the partial support elements can be arranged centrally in the profile bodies.

[0023] In other words, the supporting elements or partial supporting elements in a profile cross-section of the wings or profile bodies are not arranged on or in the wing skin.

[0024] It is preferably provided that the profile bodies are one-piece profile bodies.

[0025] The profile bodies of each wing segment are therefore not assembled profile bodies.

[0026] Therefore, it can preferably be provided that the profile bodies and / or the fuselage are 3D printed components.

[0027] The fuselage can be formed as a single, one-piece or one-piece 3D-printed component. Furthermore, all profile bodies of the wing segments are preferably formed as one-piece or one-piece 3D-printed components.

[0028] Polyamides, especially fiber-reinforced polyamides, can be used as the starting material for the 3D-printed components. The starting material is particularly preferably a carbon-fiber-reinforced polyamide, which can also be referred to as "nylon filament with carbon fibers." One example of this is the material available under the trade name PolyMide PA12-CF.

[0029] It can be further advantageously provided that the supporting elements, in particular the partial supporting elements, are bars or tubes with a preferably rectangular, in particular square, or round cross-section.

[0030] If the multiple partial load-bearing elements are rods or tubes, the load-bearing elements composed of these are also designed as rods or tubes. The rods or tubes of the partial load-bearing elements or the load-bearing elements can, in particular, be carbon fiber tubes or other fiber-reinforced tubes or rods.

[0031] It can be further advantageous to provide that the partial support elements are connected to one another by means of an adapter.

[0032] The partial load-bearing elements are preferably not welded or glued together.

[0033] It can preferably be provided that the adapter is a 3D printed component.

[0034] The adapter can be a substantially cylindrical or cuboid-shaped component. The adapter preferably has a central hole extending from one end face to a second end face. Alternatively, however, the adapter can also be provided without a hole extending from one end face to a second end face, but instead with a blind hole arranged in one of the end faces that does not extend to the other end face. The other, in particular the second, end face can be designed to be closed accordingly.

[0035] Furthermore, the adapter can have recesses in a component wall bordering the central hole. These recesses can serve to reduce the weight of the adapter. Furthermore, the recesses can provide flexibility to the adapter at designated locations.

[0036] Advantageously, the partial support element of a wing segment arranged further outward, in particular distally, with respect to the fuselage has a smaller diameter and / or a smaller cross-sectional area than the partial support element of an adjacent wing segment arranged further inward, in particular proximal. Therefore, the partial support element of a wing segment arranged further inward preferably has a larger diameter and / or a larger cross-sectional area than the partial support element of an adjacent partial wing segment arranged further outward with respect to the fuselage. Thus, the diameters and / or cross-sectional areas of the partial support elements decrease from the fuselage toward the wing tips. The adapter used to connect the partial support elements can therefore, in particular, be a size adapter.

[0037] It is further advantageous that the partial support element with the smaller diameter and / or the smaller cross-sectional area is inserted at the end into the partial support element with the larger diameter and / or the larger cross-sectional area.

[0038] The partial support elements, in particular the rods or tubes, are designed such that at least one end region of a partial support element, in particular a rod or tube, with a smaller diameter and / or a smaller cross-sectional area is inserted into a partial support element, in particular a rod or tube, with a larger diameter and / or a larger cross-sectional area. This creates a stable connection between the partial support elements, or the rods and tubes, so that the support element formed from them can absorb the forces acting on the wings during operation of the unmanned aircraft and transmit them to the support frame.

[0039] If a previously described adapter is provided, the adapter can be inserted into the partial support element, in particular the rod or tube, with the larger diameter and / or the larger cross-sectional area. The partial support element, in particular the rod or tube, with the smaller diameter and / or the smaller cross-sectional area is then preferably inserted into the central hole of the adapter at the end. Due to the flexibility of the adapter, a frictional connection can be established between the adapter and the partial support element with the larger diameter and / or the larger cross-sectional area, on the one hand, and between the adapter and the partial support element with the smaller diameter and / or the smaller cross-sectional area, on the other.Alternatively or additionally, the adapter, the partial support element with the larger diameter and / or the larger cross-sectional area, and the partial support element with the smaller diameter and / or the smaller cross-sectional area can be connected to one another by means of screws. The partial support elements are preferably rods or tubes with a square cross-section. The rods or tubes can have cross-sectional areas with dimensions of 5 mm x 5 mm to 50 mm x 50 mm. Particularly preferred dimensions are 10 mm x 10 mm, 15 mm x 15 mm, 20 mm x 20 mm, 25 mm x 25 mm, and / or 30 mm x 30 mm.

[0040] In the support elements, for example, a partial support element with a 10 mm x 10 mm cross-sectional area can be inserted, preferably using an adapter, into a partial support element with a 15 mm x 15 mm cross-sectional area. Accordingly, a partial support element with a 15 mm x 15 mm cross-sectional area can be inserted into a partial support element with a 20 mm x 20 mm cross-sectional area, and / or a partial support element with a 20 mm x 20 mm cross-sectional area can be inserted into a partial support element with a 25 mm x 25 mm cross-sectional area. Finally, a partial support element with a 25 mm x 25 mm cross-sectional area can be inserted into a partial support element with a 30 mm x 30 mm cross-sectional area.

[0041] In this case, it can be provided that the partial support elements of a support element are connected to one another, preferably clamped or screwed, by means of a clamping means, in particular a screw or a bolt, which is preferably arranged running through all the partial support elements.

[0042] The clamping device, in particular the screw or bolt, can extend from the wing tip through the supporting element formed from several partial supporting elements and reach all the way to the supporting frame. By tightening the clamping device, screw, or bolt, the wing segments are clamped together and thus stabilized. Adhesives or similar materials can also be used for the connection.

[0043] It is further advantageous that the profile body comprises a wing skin, wherein the wing skin has reinforcing structures.

[0044] Due to the reinforcement structures, the wing skin can be made very thin. For example, the wing skin can have a thickness of 0.3 mm to 1.2 mm, preferably 0.5 mm to 1.0 mm, and more preferably 0.6 mm to 0.8 mm.

[0045] It can be further advantageous for the reinforcing structures to be arranged on an inner side of the wing skin.

[0046] The reinforcing structures are therefore preferably not arranged at a distance from the wing skin in the interior of the profile body, so that the profile body is in particular largely hollow.

[0047] It can be further advantageously provided that the reinforcing structures are struts or ribs, preferably formed integrally with the profile body, wherein the struts or ribs preferably form a diamond-shaped arrangement.

[0048] The reinforcement structures, especially the struts or ribs, can thus be manufactured during the production of the profile bodies, particularly using a 3D printing process. Due to the one-piece or integral design of the reinforcement structures with the profile bodies, the wing skin can be made very thin while maintaining high structural stability.

[0049] The struts or ribs may also be designed in the form of triangular rib structures ("triangle web structures") or honeycomb structures. The reinforcing structures preferably extend along the length, i.e., the main axis of the wings, with no reinforcing structures possibly being provided in the wing tip end region.

[0050] The reinforcing structures, in particular the struts or ribs, can have a thickness of approximately 1.5 mm to 2.5 mm, preferably 1.8 mm to 2.2 mm, particularly preferably 2 mm.

[0051] It can further be advantageous for the profile bodies to be hollow and have end walls, with openings for the partial load-bearing elements of the load-bearing elements being provided within the end walls. The end walls run essentially at a right angle to the main axis of the wings. The end walls of adjacent wing segments are adjacent within the wings and arranged parallel to one another. The openings for the partial load-bearing elements of the load-bearing elements are arranged essentially centrally or midway in the end walls, so that the partial load-bearing elements are held at a distance from the wing skin inside and approximately centrally in the wings.

[0052] It can be further advantageously provided that the support frame has a support plate, wherein electronic or optical components are arranged on the support plate.

[0053] The support plate can be arranged, in particular, along the longitudinal extension of the fuselage. The electronic components can be systems of the unmanned aircraft itself, such as control systems, engines, etc. Furthermore, the electronic components can also include cameras, microphones, radar, or laser systems.

[0054] By attaching the electronic components to the support frame or to the support plate of the support frame, these often heavy components are not directly connected to the fuselage or the wings, thus reducing their mechanical load.

[0055] A further solution to the problem underlying the invention consists in providing a kit for producing a previously described unmanned aerial vehicle, comprising a fuselage, wing segments, a supporting frame, and partial supporting elements. At least one partial supporting element is arranged in each wing segment. The partial supporting elements can be connected to one another to form a supporting element such that the wing segments can be connected to form wings. All features and configurations explained in connection with the previously described unmanned aerial vehicle can be analogously transferred to the kit and applied therein.

[0056] In particular, the wing segments can be formed from one-piece profile bodies, wherein the profile bodies are more preferably produced using a 3D printing process.

[0057] The partial load-bearing elements can be bars or tubes.

[0058] Furthermore, adapters can preferably be provided by means of which the partial supporting elements of the wing segments can be connected to one another, so that the partial wing segments can be connected to form wings.

[0059] A further solution to the problem underlying the invention consists in a method for producing a previously described unmanned aerial vehicle, comprising the steps

[0060] Making a hull,

[0061] Attaching the fuselage to a supporting frame,

[0062] Manufacturing of profile bodies,

[0063] Provision of partial load-bearing elements,

[0064] Manufacturing wing segments by arranging the partial load-bearing elements in the profile bodies,

[0065] Connecting the wing segments to each other to form wings by connecting the partial supporting elements together,

[0066] Connecting the supporting elements to the supporting frame.

[0067] All features and configurations explained in connection with the previously described unmanned aerial vehicle can be analogously transferred to the method and applied therein. Thus, it can preferably be provided that the fuselage and / or the profile bodies are formed in one piece or in one piece and, more preferably, are manufactured using a 3D printing process.

[0068] Short description of the characters

[0069] The invention is explained in more detail below with reference to the accompanying figures. They show:

[0070] Fig. 1 an unmanned aerial vehicle,

[0071] Fig. 2 a wireframe model of the unmanned aerial vehicle from a first perspective,

[0072] Fig. 3 a wireframe model of the unmanned aerial vehicle from a second perspective,

[0073] Fig. 4 a wireframe model of the unmanned aerial vehicle from a third perspective,

[0074] Fig.5 a supporting structure of the unmanned aerial vehicle from a first perspective,

[0075] Fig. 6 the supporting structure of the unmanned aerial vehicle from a second perspective,

[0076] Fig. 7 the supporting structure of the unmanned aerial vehicle from a third perspective,

[0077] Fig. 8 a wing,

[0078] Fig. 9 a wing segment,

[0079] Fig. 10 the wing segment in a plan view and in a sectional view,

[0080] Fig. 11 is a flowchart for a method for manufacturing an unmanned aerial vehicle,

[0081] Fig. 12 is a longitudinal sectional view of an adapter, and

[0082] Fig. 13 the adapter in a connection of partial load-bearing elements.

[0083] Detailed description of the characters

[0084] Fig. 1 shows a perspective view of an unmanned aerial vehicle 100. The unmanned aerial vehicle 100 is designed as a drone 10 and comprises a fuselage 11 and wings 12. Furthermore, the drone 10 is equipped with four twin rotors 13 for controlling the flight attitude and a propeller 15 arranged at the rear 14 of the fuselage 11. The twin rotors 13 are attached to support rods 17 aligned in the direction of the longitudinal axis 16 of the drone 10. A tail unit 18 composed of several segments is arranged at the rear ends of the support rods 17.

[0085] Figs. 2 to 4 show wireframe models of the drone 10 from different perspectives. A support structure 19 is arranged within the drone 10. The support structure 19 is shown from different perspectives in Figs. 5 to 7.

[0086] The support structure 19 comprises a support frame 20 and support elements 21. The support frame 20 is arranged inside the fuselage 11, and the fuselage 11 is fastened to the support frame 20. The support elements 21 extend from a wing tip region 22 through the wings 12 along a main axis 23 of the wings 12 and are fastened to the support frame 20. Two support elements 21 are arranged in each wing 12, with a first support element 21a being arranged in the region of the leading edge 24 of the wing 12 and a second support element 21b being arranged in the region of the trailing edge 25 of the wing 12. The first support element 21a in the region of the leading edges 24 of the wings 12 is designed as a continuous support element 21a, which extends from the wing tip region 22 of one of the wings 12 to the wing tip region 22 of the other wing 12. The second support elements 21b in the region of the trailing edges 25 of the wings

[0087] 12 are not continuous and each extend from the respective wing tip region 22 to the supporting frame 20. The supporting elements 21 consist of partial supporting elements 26 arranged one behind the other along the main axis 23 and connected to one another. The partial supporting elements 26, and thus also the supporting elements 21 formed from them, are designed as rods or tubes TI with a rectangular cross-section. The rods and tubes TI are, in particular, carbon fiber tubes or other fiber-reinforced tubes.

[0088] The wings 12 are composed of several wing segments 28 (Figs. 1 to 4 and Figs. 8 to 10), which form separate, independent modules. Partial support elements 26 are arranged in each of the wing segments 28. By connecting the partial support elements 26 to one another, the wing segments 28 are assembled to form wings 12.

[0089] The partial support elements 26a of the wing segments 28 arranged further outward relative to the fuselage 11 have a smaller diameter than the partial support elements 26b of the adjacent wing segments 28 arranged further inward. To connect the partial support elements 26a, 26b, the partial support elements 26a with the smaller diameter are inserted at their ends into the partial support elements 26b with the larger diameter. To ensure a secure connection, an adapter 29, in particular a size adapter 29a, is also provided, by means of which the partial support elements 26a, 26b are interconnected. The partial support elements 26a, 26b of a support element 21, 21a, 21b are further clamped together by means of a screw 41 arranged continuously through all the partial support elements 26a, 26b.

[0090] The support frame 20 arranged in the fuselage 11 comprises a support plate 30 to which electronic components 31 such as control electronics 32 and cameras 33 are attached (Fig. 4).

[0091] Fig. 8 shows a wing 12. The wing 12 consists of several wing segments 28. One such wing segment 28 is shown in Figs. 9 and 10. The wing segment 28 comprises a profile body 34, which is designed as a 3D-printed component. The profile body 34 is largely hollow. At its ends, the profile body 34 has end walls 35, with openings 36 for the partial support elements 26 of the support elements 21 being provided within the end walls 35. On an inner side 37 of the wing skin 38, reinforcing structures 39 in the form of ribs 40 formed integrally with the profile body 34 are provided. The ribs 40 are approximately diamond-shaped or honeycomb-shaped.

[0092] Fig. 11 shows a flow diagram of a method 200 for producing an unmanned aerial vehicle 100. In a first method step 51, a fuselage 11 is produced, in particular using a 3D printing process. In a second method step 52, the fuselage 11 is attached to a support frame 20. In a third method step S3, profile bodies 34 are produced in one piece, in particular using a 3D printing process. In a fourth method step 54, partial support elements 26 are provided, which in a fifth method step S5 are arranged within the profile bodies 34, thereby providing wing segments 28. In a sixth method step S6, the wing segments 28 are connected to one another to form wings 12 by connecting the partial support elements 26 of the individual wing segments 28 to form support elements 21.Finally, in a seventh method step S7, the support elements 21 are connected to the support frame 20 and thus the wings 12 are joined to the fuselage 11.

[0093] Fig. 12 and 13 show an adapter 29, in particular a size adapter 29a, by means of which the partial support elements 26a, 26b are connected to one another. The adapter 29 is a substantially cuboid-shaped component 42. The adapter 29 has a central hole 45 extending from one end face 43 to a second end face 44. Furthermore, the adapter 29 has recesses 47 in the component wall 46 delimiting the central hole 45. As can be seen in Fig. 13, the adapter 29 is inserted into a partial support element 26b with a larger cross-sectional area. A partial support element 26a with a smaller cross-sectional area is inserted into the central hole 45 of the adapter 29. The adapter 29 also has openings 48. Screws can be inserted through the openings 48 with which the partial support elements 26a, 26b and the adapter 29 can be connected to one another.

[0094] In a variant of the adapter 29 not shown here, it does not have a hole 45 running from one end face 43 to a second end face 44, but instead a blind hole is arranged in only one of the end faces 43, 44.

[0095] List of reference symbols

[0096] 100 Unmanned Aerial Vehicle

[0097] 200 procedures

[0098] 10 drones

[0099] 11 Hull

[0100] 12 Wing

[0101] 13 double rotor

[0102] 14 Rear

[0103] 15 propellers

[0104] 16 Longitudinal axis

[0105] 17 Holding rod

[0106] 18 tail unit

[0107] 19 Supporting structure

[0108] 20 supporting frames

[0109] 21 Supporting element

[0110] 21a Supporting element

[0111] 21b Supporting element

[0112] 22 Wing tip area

[0113] 23 Main axis

[0114] 24 leading edge

[0115] 25 End bar

[0116] 26 partial load-bearing element

[0117] 26a Partial load-bearing element

[0118] 26b Partial load-bearing element

[0119] 27 pipe

[0120] 28 wing segment

[0121] 29 adapters

[0122] 29a size adapter

[0123] 30 supporting plate

[0124] 31 Component control electronics

[0125] camera

[0126] Profile body

[0127] End wall

[0128] opening

[0129] Inside wing skin reinforcement structure

[0130] rib

[0131] screw

[0132] Cuboid component

[0133] front side

[0134] front side

[0135] Hole

[0136] Component wall

[0137] recess

[0138] opening

[0139] Process step

[0140] Process step

[0141] Process step

[0142] Process step

[0143] Process step

[0144] Process step

[0145] Process step

Claims

Patent claims 1. Unmanned aerial vehicle (100), in particular a drone (10), comprising a fuselage (11) and wings (12), further comprising a support structure (19) comprising a support frame (20) and support elements (21, 21a, 21b), wherein the support frame (20) is arranged at least partially in the fuselage (11), wherein the fuselage (11) is fastened to the support frame (20), wherein at least one support element (21, 21a, 21b) is arranged in each wing (12), wherein the support element (21, 21a, 21b) extends from a wing tip region (22) along a main axis (23) of the wing (12) through the wing (12) and is fastened to the support frame (20), characterized in that each support element (21, 21a, 21b) is made up of separate, one behind the other along the main axis (23). arranged and interconnected partial supporting elements (26, 26a, 26b).

2. Unmanned aerial vehicle (100) according to claim 1, characterized in that at least two support elements (21, 21a, 21b) are arranged in each wing (12).

3. Unmanned aerial vehicle (100) according to claim 1 or 2, characterized in that the support element (21, 21a, 21b), in particular a partial support element (26, 26a, 26b) of the support element (21, 21a, 21b), is fastened to the support frame (20) with an end facing away from the wing tip region (22), or that the support element (21, 21a, 21b) extends continuously from the wing tip region (22) to an opposite wing tip region (22), wherein preferably the support element (21, 21a, 21b), in particular a partial support element (26, 26a, 26b) of the support element (21, 21a, 21b), is guided through a support element receptacle of the support frame (20).

4. Unmanned aerial vehicle (100) according to one of the preceding claims, characterized in that each wing (12) comprises a plurality of wing segments (28), that each wing segment (28) comprises a profile body (34), and that at least one partial support element (26, 26a, 26b) is arranged within each profile body (34).

5. Unmanned aerial vehicle (100) according to one of the preceding claims, characterized in that the support elements (21, 21a, 21b) are arranged centrally in the wings (12), and / or that the partial support elements (26, 26a, 26b) are arranged centrally in the profile bodies (34).

6. Unmanned aerial vehicle (100) according to claim 4 or 5, characterized in that the profile bodies (34) are one-piece profile bodies (34), wherein the profile bodies (34) and / or the fuselage (11) are preferably 3D-printed components.

7. Unmanned aerial vehicle (100) according to one of the preceding claims, characterized in that the support elements (21, 21a, 21b), in particular the partial support elements (26, 26a, 26b), are rods or tubes (27) with a preferably rectangular, in particular square, or round cross-section.

8. Unmanned aerial vehicle (100) according to one of the preceding claims, characterized in that the partial support elements (26, 26a, 26b) are connected to one another by means of an adapter (29), wherein the adapter (29) is preferably a 3D-printed component.

9. Unmanned aerial vehicle (100) according to one of claims 4 to 8, characterized in that the partial support element (26, 26a) of a wing segment (28) arranged further outwards with respect to the fuselage (11) has a smaller diameter and / or a smaller cross-sectional area than the partial support element (26, 26b) of an adjacent wing segment (28) arranged further inwards, wherein the partial support element (26, 26a) with the smaller diameter and / or the smaller cross-sectional area is preferably inserted at the end into the partial support element (26, 26b) with the larger diameter and / or the larger cross-sectional area.

10. Unmanned aerial vehicle (100) according to one of the preceding claims, characterized in that the partial support elements (26, 26a, 26b) of a support element (21, 21a, 21b) are arranged by means of a tensioning means, in particular a screw (41) or a bolt, are connected to one another, preferably clamped or screwed.

11. Unmanned aerial vehicle (100) according to one of claims 4 to 10, characterized in that the profile body (34) comprises a wing skin (38), wherein the wing skin (38) has reinforcing structures (39), wherein the reinforcing structures (39) are preferably arranged on an inner side (37) of the wing skin (38).

12. Unmanned aerial vehicle (100) according to claim 11, characterized in that the reinforcing structures (39) are struts or ribs (40), preferably formed integrally with the profile body (34), wherein the struts or ribs (40) particularly preferably form a diamond-shaped arrangement.

13. Unmanned aerial vehicle (100) according to one of claims 4 to 12, characterized in that the profile bodies (34) are hollow and have end walls (35) at their ends, wherein openings for the partial support elements (26, 26a, 26b) of the support elements (21, 21a, 21b) are provided within the end walls (35).

14. Unmanned aerial vehicle (100) according to one of the preceding claims, characterized in that the support frame (20) has a support plate (30), wherein electronic or optical components (31) are arranged on the support plate (30).

15. Kit for producing an unmanned aerial vehicle (100) according to one of the preceding claims, comprising a fuselage (11), wing segments (28), a supporting frame (20) and partial supporting elements (26, 26a, 26b), wherein at least one partial supporting element (26, 26a, 26b) is arranged in each wing segment (28), wherein the partial supporting elements (26, 26a, 26b) can be connected to one another to form a supporting element (21, 21a, 21b) in such a way that the wing segments (28) can be connected to form wings (12).

6. A method (200) for producing an unmanned aerial vehicle (100) according to any one of claims 1 to 14, comprising the steps Making a hull (11), Attaching the fuselage (11) to a supporting frame (20), Manufacturing of profile bodies (34), Providing partial load-bearing elements (26, 26a, 26b), Producing wing segments (28) by arranging the partial supporting elements (26, 26a, 26b) in the profile bodies (34), Connecting the wing segments (28) to one another to form wings (12) by connecting the partial support elements (26, 26a, 26b) to one another, connecting the support elements (21, 21a, 21b) to the support frame (20).

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