Leading rope laying by drone with active-payload and tension-keeping-device

Abstract

An active payload and tension keeping device to be attached to a drone to lay a leading rope over electrical masts or towers. The active payload adding side thrust to the drone and the tension keeping device acting a brake on pulleys attached to the masts. The tension keeping device configured to be connected to a drone or active payload and to be disconnected. When positioned on the pulley, the tension keeping device allows the drone or active payload to disconnect and land for fuel, battery replacement of maintenance while allowing the laid leading rope to remain in tension. The drone can then return and continue laying leading ropes over the masts.

Description

[0001] LEADING ROPE LAYING BY DRONE WITH ACTIVE-PAYLOAD AND TENSION-KEEPING-DEVICE

[0002] RELATED APPLICATIONS

[0003] This application claims the benefit of priority of Israel Patent Application No. 317819 filed on 18 December 2024, the contents of which are incorporated herein by reference in their entirety.

[0004] FIELD AND BACKGROUND OF THE INVENTION

[0005] The present invention, in some embodiments thereof, relates to power line installation and, more particularly, but not exclusively, to installation by drone. The present invention provides additional thrust and a method and device to maintain tension in the leading rope.

[0006] US20240332925A1 has guide arm that directs a line on to a pulley and has a spring loaded gate to maintain the line on the pulley without maintaining tension.

[0007] SUMMARY OF THE INVENTION

[0008] The invention is directed towards the laying leading rope on masts by a drone allowing the drone to lift and position the leading rope on pulleys attached to the masts, maintain tension to the leading rope, and allow the leading rope to remain in tension if the drone needs to land.

[0009] According to a first aspect of some embodiments of the present invention An active payload system for powerline installation, comprising: a towing vehicle for lifting, positioning and applying tension to a leading rope an elongated rod pivotably attached to the rear of the towing vehicle at a first end via a pivot mechanism; the rod is configured to pivot by one or more of pitch, yaw, and roll, a thrust generator mounted on the rod and configured to generate thrust along the longitudinal axis of the rod, a connector at a second end of the rod configured to attach to a leading rope; wherein, the pulled leading rope under tension aligns the rod with the leading rope, aiming the thrust generator to provide thrust in addition the drone, assisting the drone to carry the leading rope, maintain predetermined rope tension of the leading rope so that the leading rope lowest point between masts sags above a predetermine elevation from the ground.

[0010] According to some embodiments of the first aspect of the invention the towing vehicle is a drone.

[0011] According to some embodiments of the of the first aspect invention, wherein the active payload the thrust generator has at least two propellers or jets, that rotate in opposite directions to produce thrust with a reduced parasitic rolling torque. According to some embodiments of the first aspect of the invention and including the first embodiment of the active payload of wherein the thrust generator propellers are ducted, to enhance the efficiency or to protect the propellers.

[0012] According to some embodiments of the first aspect of the invention the active payload and including the previous embodiments of the invention, wherein the thrust generator is controlled by an integrated controller or by the drone's controller.

[0013] According to some embodiments of the first aspect of the invention, the active payload, wherein sensors are attached to the rod, wherein the sensors are one or more of camera, three dimensional (“3D”) sensors, tension meters, inertia measurement unit (“IMU”), navigation measures, and tilt sensors, coupled to the controller.

[0014] According to some embodiments of the first aspect of the invention, the active payload, wherein the controller controls communications with a remote-control station and / or a power supply for the thruster.

[0015] According to some embodiments of the first aspect of the invention, the active payload, wherein the connector is configured to connect and release at least one of a leading rope, a tension keeping device, or another device.

[0016] According to some embodiments of the first aspect of the invention, wherein the active payload is connected to the leading rope, pulling it through a plurality of masts, positioning the leading rope onto a pulley, the pulley having a wheel, and the pulley is attached to each mast, the pulley has a pivoted lock that is normally closed, wherein, the drone approaches the side of each pulley lock, positioning the rope under tension to rotate the lock into an open position, positioning the leading rope on the pulley wheel, allowing the lock to relock the rope on the pulley wheel.

[0017] According to some embodiments of the first aspect of the invention, configured to adjust the thrust generator so that as the drone operates to install the leading rope, the drone hovers, moves toward and parallel to the pulley lock and pulley, moves away from the pulley and pulley lock to open the lock, hovers to position the leading rope on the pulley, moves away from the pulley and pulley lock to place the leading rope into tension, and moving away from the pulley lock, all of these operations having different thrust requirements.

[0018] According to a second aspect of some embodiments of the present invention there is provided A tension keeping device (“TKD”) pulling the rope, positioning the rope onto a pulley having a pulley wheel, enabling the drone to land during leading rope pulling, while maintaining the leading rope tension to maintain a predetermined sag, comprising, a pivoted pulley lock that is normally closed by gravity or by spring, a main member, a connector to connect the leading rope to the main member, a connector sized to pass through the pulley lock; and wherein the member has a cone-like structure that at the structure base that sized to that it cannot pass between the pulley and the pulley lock, and cone-like smaller diameter pointing to the leading rope, wherein the member is connected to one of the drone and an active payload by a controlled connector that is built to enable quick-releasing and aerial-reconnecting, wherein the pulling drone approaches the side of the pulley lock, positioning the rope under tension or the rear part of the main member, rotating the lock pivot into an open position, approaching the pulley wheel, allowing the lock to relock the rope or the main member on the pulley wheel, and wherein, immediately after the leading rope or the rear part of the member passes through the pulley lock, the drone reduces the pulling tension, allowing the leading rope to pull back the member until the cone-like structure to snugly tighten between the lock and the pulley, providing a brake that prevents the leading rope from breaching a predetermined maximal allowed sag, wherein after the cone-like stopper is snugly tightened, the connector between the tension keeping device and the drone or the active payload is released and the drone can land; and wherein the drone can refuel or have its battery replaced, or for maintenance, and then takeoff to reconnect to the tension keeping device and continue the leading rope pulling.

[0019] According to some embodiments of the second aspect of the invention, wherein the pulley is configured to receive a stopper shaped as a curved hook, the curvature corresponds to the pulley curvature, and the stopper is snugly tightened onto the wheel of the pulley.

[0020] According to some embodiments of the second aspect of the invention, wherein the tension keeping device is pivotally connected to the drone.

[0021] According to some embodiments of the second aspect of the invention, wherein the tension keeping device, wherein one or more tension meters and / or one or more sensors are attached to the main member.

[0022] According to some embodiments of the second aspect of the invention, wherein the tension keeping device, wherein a controller with a communication system, is attached to the main member and controls the communication system and is connected to the sensors and one or more tension meters.

[0023] According to some embodiments of the second aspect of the invention, wherein a system for a drone laying leading rope on pulleys attached to plurality of masts comprising, at least one or more of: a drone active payload and tension keeping device.

[0024] According to some embodiments of the second aspect of the invention, wherein the system, wherein, further comprising a remote-controlled rope releasing machine for the rope releasing and tension balancing at the beginning of the line laying section, the machine is configured to perform the following commands: to stop or releasing the rope under required tension. According to some embodiments of the second aspect of the invention, wherein the rope releasing machine is capable of rewinding the rope.

[0025] According to some embodiments of the aspect of the invention, wherein further comprising a ground based remote-controlled rope releasing machine for the rope releasing and tension balancing; the machine positioned at the beginning of a section of line laying over masts, the machine is configured to stop or release the rope under required tension under the remote control command.

[0026] According to some embodiments of the aspect of the invention, wherein the rope releasing machine is configured to rewind the rope.

[0027] According to some embodiments of the second aspect of the invention wherein the drone flight route, exact flight operation plan are preplanned based on an accurate 3D mapping of a specific power line section the drone flight route, exact flight operation plan are preplanned based on an accurate 3D mapping of a specific power line section and sensors, wherein the sensors are one or more of camera, three dimensional (“3D”) sensors, tension meters, inertia measurement unit (“IMU”), navigation measures, and tilt sensors, coupled to a controller; and wherein the system is configured for flight operation beyond line of sight..

[0028] According to a third aspect of some embodiments of the present invention there is provided a system for a drone laying leading rope on pulleys attached to plurality of masts comprising at least one or more of: a drone active pay load as described in the first aspect, the drone active pay load and second aspect of the invention, the tension keeping device.

[0029] According to some embodiments of the aspect of the invention, wherein further comprising a ground based remote-controlled rope releasing machine for the rope releasing and tension balancing; the machine positioned at the beginning of a section of line laying over masts, the machine is configured to stop or release the rope under required tension under the remote control command.

[0030] According to some embodiments of the aspect of the invention, wherein the rope releasing machine is configured to rewind the rope.

[0031] According to some embodiments of the second aspect of the invention wherein the drone flight route, exact flight operation plan are preplanned based on an accurate 3D mapping of a specific power line section the drone flight route, exact flight operation plan are preplanned based on an accurate 3D mapping of a specific power line section and sensors; wherein the sensors are one or more of camera, three dimensional (“3D”) sensors, tension meters, inertia measurement unit (“IMU”), navigation measures, and tilt sensors, coupled to a controller; and wherein the system is configured for flight operation beyond line of sight.

[0032] According to an aspect of some embodiments of the present invention there is provided A system for a drone laying leading rope on pulleys attached to plurality of masts comprising at least one or more of the first aspect of the invention, the drone active payload, a second aspect of the device, and third aspect of the device and their embodiments and a rope releasing machine as described in previous embodiments.

[0033] According to some embodiments of the aspect of the invention, wherein the drone flight route, exact flight operation plan are preplanned based on an accurate 3D mapping of a specific power line section.

[0034] Another aspect of the invention is method for a powerline on a high voltage masts by a drone comprising: attaching an active payload to a drone with a lift capacity of up to 150 kg., the active payload having a thruster; attaching TKD or leading rope to the active payload, the TKD having a pulley brake; flying the drone assisted by the thrust generator to position the leading rope onto a pulley attached to the mast; and maintaining a predetermine tension on the leading rope configured for a predetermined sage of the leading rope between masts.

[0035] According to some embodiments of the third aspect of the invention wherein the TKD has the additional step of opening a pulley lock before the step of positioning the rope onto the pulley and after positioning the rope on the pulley permitting the pulley lock to close.

[0036] According to some embodiments of the third aspect of the invention comprising the additional step of the drone positioning the TKD to apply the pulley brake and is connecting the TKD.

[0037] According to some embodiments of the second aspect of the invention the drone has a lift capacity of up to 150 kg.

[0038] According to an aspect of the invention an active payload system for near horizontal pulling of aerial, ground or maritime objects, comprising: a drone for lifting, positioning and applying tension to a pulling rope; an elongated rod pivotably attached by one of a rope or a pivot mechanism to the towing drone at a first end, the rod is configured to pivot by one or more of pitch, yaw, and roll; a thrust generator mounted on the rod and configured to generate thrust along the longitudinal axis of the rod, a connector at a second end of the rod configured to attach to a pulling rope that is pulling the object; wherein, the pulled rope under tension aligns the rod with the rope, aiming the thrust generator to provide thrust in addition to the drone, assisting the drone to pull the object horizontally at the required towing forth, while preserving its maneuverability and maintaining itself inside predefined orientation limits.

[0039] According to some embodiments of the previous aspect of the invention power to the thrust generator of the active payload or the drone is supplied from the towed object.

[0040] Unless otherwise defined, all technical and / or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the invention, exemplary methods and / or materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.

[0041] Implementation of the method and / or system of embodiments of the invention can involve performing or completing selected tasks manually, automatically, or a combination thereof. Moreover, according to actual instrumentation and equipment of embodiments of the method and / or system of the invention, several selected tasks could be implemented by hardware, by software or by firmware or by a combination thereof using an operating system.

[0042] For example, hardware for performing selected tasks according to embodiments of the invention could be implemented as a chip or a circuit. As software, selected tasks according to embodiments of the invention could be implemented as a plurality of software instructions being executed by a computer using any suitable operating system. In an exemplary embodiment of the invention, one or more tasks according to exemplary embodiments of method and / or system as described herein are performed by a data processor, such as a computing platform for executing a plurality of instructions. Optionally, the data processor includes a volatile memory for storing instructions and / or data and / or a non-volatile storage, for example, a magnetic hard-disk and / or removable media, for storing instructions and / or data. Optionally, a network connection is provided as well. A display and / or a user input device such as a keyboard or mouse are optionally provided as well.

[0043] BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0044] Some embodiments of the invention are herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced.

[0045] In the drawings:

[0046] FIG. 1 is an illustration of the invention with drone pulling rope with an active payload. FIG. 2 is an illustration of an active payload with its thrust generator;

[0047] FIG. 3 is an illustration of a pulley with a pulley lock

[0048] FIG. 4 is an illustration of the TKD with a curved pulley brake; and

[0049] FIG. 5 is an illustration of the TKD with a cone-like pulley brake;

[0050] FIG. 6 is an illustration of the invention with drone pulling a leading rope with an active payload and a tension keeping device. DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTION

[0051] The present invention, in some embodiments thereof, relates to power line installation and, more particularly, but not exclusively, to installation by drone.

[0052] The present invention uses an active payload in combination with TKD a drone to elevate a leading rope for installation of a powerline on electrical power masts. Leading rope as used in this application is flexible stout cord of strands of fibers or filaments, natural or synthetic, twisted or braided together, or an extended slender strip. As used in this application, mast is interchangeable with tower, specifically a power line tower. The technical problem that is addressed is the lifting of a leading power with a drone is that the drone lacks the thrust to lift a leading rope and operate within normal operational limits. As used in this application rope refers to the leading rope. (For most drones, the pitch limit is 30°)

[0053] A typical heavy lift drones can lift up to 150 kg. under ideal conditions. However, in operation, heavy lift drones cannot operate at maximum capacity as explained elsewhere in this application. Normal operational limits of such a drone are for sustained flight at less than 30° pitch. Without additional supplemental thrust from a thruster, the drone cannot provide intensive side force while operate within normal limits.

[0054] A drone as used in this application includes an unmanned aerial vehicle or any device that can hover.

[0055] While the use described in this application is to install power lines on masts by pulling leading ropes over pulleys that are installed on masts, there are other applications.

[0056] The active payload supplies additional thrust to a drone. The drone in combination with the active payload is used to pull a leading rope. In the installation of the leading rope on the mast pulleys, the leading rope is attached to a power line. The active payload in combination with the TKD allows the drone to disconnect while maintaining tension on the leading rope. The drone can then land and return, aerially reconnect and resume installation.

[0057] However, the active payload can also be used to pull a rope to tow a glider or ground vehicle. The use with a ground vehicle can be used to pull a vehicle that is immobilized in mud, rocks, or snow where the active payload is used to add horizontal thrust to a drone, enabling it to provide the required towing forth while preserving its maneuverability and maintaining itself inside its orientation limits.

[0058] Hover as used in this application as any vehicle that can hold its position, to place a leading rope as further detailed in this application. A leading rope includes a line that can be woven, filament, or twisted line whether is a natural fiber or synthetic. The leading rope is light weight as compared to a metal cable. However, a similar lightweight cable whether metal or nonmetal could be used. Synthetic materials include: polypropylene, nylon, polyesters (e.g. PET, LCP, and Vectran®), polyethylene (e.g., Dyneema® and Spectra®), aramids (e.g. Twaron®, Technora® and Kevlar®), and acrylics (e.g. Dralon®).

[0059] The drone also has the constrain of limited flight time and is required to periodically land for a new or charged batteries and for maintenance. This constraint is addressed in the technical problem of using a leading rope in the installation of power lines.

[0060] The technical solution is a system that has a pulley brake so that where the tension applied to the leading rope can be maintained by applying a pulley brake at the elevation of a pulley attached to a mast. The application of the brake allows the drone to release the leading rope to be disconnected from the drone while maintaining the required tension. Maintaining the tension can be used interchangeably with keeping installed tension. The drone can then land for a charged batteries or maintenance with the leading rope remaining in tension. This allows the now resupplied drone can reattach, connecting to the leading rope and continue pulling the leading rope.

[0061] Lifting the leading rope includes positioning the leading rope, pulling the leading rope across a plurality of pulleys. The current commercial drone lift are rated at a lift capacity of up to 150 kg. However, this is rating is under ideal manufacturers conditions. However, conditions such as wind and the elements reduce this capacity. The claimed invention has an active payload with additional thrust and a tension making device. Therefore, the invention however, is not limited to 150 kg.

[0062] The active payload is also referred to as a leading rope laying active payload (“LRLAP”). It is pivotally attached to the drone and has at least a thrust generator to provide additional thrust to the drone so that the leading rope can be safely lifted, and positioned on a pulley attached to a powerline mast by the drone operating within normal limits.

[0063] The tension required for leading rope laying in high-voltage (“HV”) powerline installation is a critical factor that varies significantly based on multiple parameters. Typically, this tension can range from approximately 20-30 kilograms for shorter spans in favorable conditions to well over 150 kilograms for longer spans or in challenging environments. The primary factors influencing this tension include:

[0064] 1. Span length: Longer spans require higher tension to maintain proper sag and clearance. 2. Terrain: Uneven or mountainous terrain necessitates increased tension to account for elevation changes.

[0065] 3. Weather conditions: Strong winds and heavy rain can dramatically increase the required tension due to additional forces acting on the rope.

[0066] 4. Rope specific weight: Heavier rope demand higher tension for proper installation.

[0067] Modern heavy-lift drones, typically used in industrial applications, have payload capacities ranging from 100 to 150 kg. However drones and certainly other towing vehicles are not limited to 150 kg. While this may seem sufficient for the task, it's important to note that this payload capacity is usually measured under ideal conditions with the drone in a stable, horizontal position.

[0068] When tasked with lifting or pulling a rope to the side while maintaining its elevation, the drone must counteract the horizontal force exerted by the rope's tension. This requires the drone to tilt its body, either by adjusting its pitch (forward / backward tilt) or roll (side-to-side tilt) angles. The degree of tilt necessary is directly proportional to the tension force and can easily exceed 30 degrees for tensions in the higher end of the typical range.

[0069] This extreme tilt angle poses several significant challenges:

[0070] 1. Stability: Most drones are designed to operate optimally when level or at slight angles. Prolonged operation at steep angles can compromise the drone's stability and control systems.

[0071] 2. Motor stress: The motors must work harder to maintain altitude and position when tilted, leading to increased power consumption and potential overheating.

[0072] 3. Reduced lift: As the drone tilts, the effective lift generated by its propellers decreases, further limiting its ability to maintain altitude and position.

[0073] 4. Safety concerns: Operating at such extreme angles leaves little margin for error. Sudden gusts of wind or minor control inputs could easily lead to loss of control or collisions.

[0074] 5. Regulatory compliance: Many aviation authorities have strict regulations regarding the maximum tilt angles allowed for drone operations, often limiting them to much less than 30 degrees.

[0075] 6. Battery life: The increased power demand significantly reduces flight time, limiting the drone's ability to cover long spans or perform extended operations.

[0076] Given these limitations, heavy lift drones current capabilities make them unsuitable for tasks involving high side tension forces over extended periods or distances. Therefore, a thrust generator to provide additional thrust in addition to the thrust of the drone allows the drone to lift the leading rope and position it. The invention of this application provides a thrust generator attached to the active payload.

[0077] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not necessarily limited in its application to the details of construction and the arrangement of the components and / or methods set forth in the following description and / or illustrated in the drawings and / or the Examples

[0078] The two devices introduced in this invention work together to create a more efficient, safer, and repeatable method for laying leading ropes along power line sections, typically spanning around three kilometers.

[0079] The first device: Active Payload for even a lightweight drones. The Active Payload works by generating a lateral thrust, which assists the drone in pulling the rope. The second device: The TKD addresses a critical need for interruptions in the powerline installation process. The TKD performs three essential functions:

[0080] 1. Locking: When the drone needs to pause its flight, the TKD automatically secures the rope to the last intermediate pulley it has passed. This action maintains tension in the rope, preventing slack and potential tangling or damage;

[0081] 2. Disconnection: The TKD allows the drone to detach from the rope's end, enabling it to land safely without compromising the rope's position or tension.

[0082] 3. Reconnection: After the drone has addressed the reason for its landing and is ready to resume operations. The TKD facilitates easy aerial reconnection of the Active Pay load to the rope. This feature ensures a smooth continuation of the rope-pulling process without the need for complex manual interventions.

[0083] The combination of these two devices represents a significant advancement in power line leading rope laying technology. By enabling the use of lighter drones and providing a reliable method for handling necessary interruptions, this invention offers a technical advancement of improved efficiency and speed in completing leading rope laying projects.

[0084] The active payload has a rod with a controlled thrust generator installed on the rod. The rod can be a straight or curved rod. One end of the rod is connected to the drone's ventral side by a connector that allows the rod to pivot such as by a hinge pivot and other end is connected to the TKD or directly to the rope by a release and connect mechanism. The pivotable connection allows the thrust generator of the active payload to align with the rope without intervention by a controller or user. The tension of the rope provides the alignment. The rod will be connected to the drone in a mechanical interface only and it will be easy to Disassemble and assemble it from the drone.

[0085] The rod provides four functions:

[0086] 1) It enables the active payload to push the drone while pulling the rope.

[0087] 2) It distances the thrust generator out of the downwash airflow under the drone propellers.

[0088] 3) A rod with a curve upwards can elevate the thrust generator above relative to the drone's rotors plane for a better separation between the thrust generator and the airflow of the drone's rotors.

[0089] 4) It prevents the rope and other part of the system from touching the drone's propellers. The thrust generator can be based on propellers can be driven by electrical motors or jets motors or any other thrust source. The thrust generator propellers can be open or ducted. The thrust generator can operate parallel to the rod. The rod aligned along the axis of the connected rope. Parallel in this context means ±10° along the direction of the longitudinal axis of the rod. The thrust generator can be configured to operate on a vertical transverse axis to the rod longitudinal axis at a negative angle to add vertical thrust. The negative angle may be from 0 degrees to -45°, preferably up to 30° to add additional vertical thrust while maintaining the leading rope in tension.

[0090] Also attached may be optionally, a controller, sensors, and a communication system.

[0091] The active payload may have a controller attached the rod or other component of the active payload. The controller is controls power for the thrust generator motors (or fuel to the Jets) and to the sensors, communicates with the remote-control station, and is coupled or connected to the sensors. In another optional configuration, the active payload may be controlled and powered directly by the drone's controller and its power system.

[0092] If the thrust generator consists of a single propeller, it might exert a parasitic torque on the roll axis of the drone, causing waste of energy and controllability. To reduce this torque and to enlarge the disc load of the thruster, a two propellers with opposite rotation clockwise and counter-clockwise can be used. The propellers can be coaxial. Similarly, the jet or jets exhaust can be configured to have opposite rotation to counteract torque.

[0093] A camera or 3D sensors e.g. Time Of Flight (“TOF”) or Light Detection and Ranging (“LiDAR”), or inertial measurement unit (“IMU”) can be installed on the active payload either on the rod towards the end opposite the drone or on the thrust generator or other component. These sensor will help to perform the leading rope laying task. This permits control Beyond Vision Line of Sight (“BVLOS”) from a remote control room and also will serve the remote pilot.

[0094] The installation of a powerline requires multiple operations of the drone as detailed in this application and therefore has multiple thrust requirements. The sensors allow the drone operator to approach a pulley at elevation attached to a mast, open a pulley lock, position the leading rope on a pulley, allow the pulley lock to close, and to move away from the mast putting the leading rope into a predetermined tension.

[0095] The sensors allow the drone pilot to properly position the drone and the tension meters allow the pilot to control the thrust through a controller that controls the thrust attachment of the leading rope, and communicates the sensor data to the remote pilot.

[0096] The sensors onboard the active payload allow a remote pilot to control the installation BVLOS because the position, the position of the mast and pulley, a pulley lock, and the tension of the leading rope is communicated to the remote pilot.

[0097] The TKD is configured to place a pulley brake on a pulley attached to a mast. The brake is attached at elevation of the mast and where the leading rope is under tension. The drone places the leading rope under sufficient tension so that the lowest point of the leading rope that sags between masts is at a predetermined elevation above the ground. The predetermine elevation is such that the leading rope will not touch the ground or be a hazard. The maximum predetermined sag is at an elevation to allow for the leading rope to be efficiently deployed in the installation process.

[0098] The pulley brake is snugly positioned against the pulley wheel. Snugly as used in this application means that the brake one placed against the pulley wheel will not allow the wheel to rotate until the brake is disengage. The brake is meant to be placed as a lock temporarily so that the drone can disconnect and land while leaving the brake in place and the leading rope under a predetermined tension.

[0099] The TKD connected to the leading rope and when the pulley brake is placed on the pulley, it can be disconnected from the drone or active payload to allow the drone to land.

[0100] The drone can then reconnect and continue installation of the powerline with the leading rope under its predetermined tension and sag. The connection may be a quick connection meaning that it requires only one operation or movement to connect or reconnect as opposed to a multi-step process.

[0101] The basic structure of the TKD is a preferably several meters long main member is a rod with a curved pulley brake that generally matches the curvature of the pulley and resembles a hook that fits the diameter and width of the powerline laying pulleys. The TKD description and operation are described in the following paragraphs:

[0102] One end TKD is connected to the drone or to the active payload by a ring or magnet or any other device that enable the drone to easily aim the connector as a quick release mechanism of the active payload to re-connect to the TKD after a process of pulling, pausing, the process of a pulling pause for the TKD to tighten the pulley brake to the mast pulley, releasing the active payload or drone. This permits the drone to land, replace batteries takeoff and re-connect to the TKD.

[0103] The powerline laying pulley is a pulley that is hanging on the mast or pole arm. The invention solves the technical problem maintaining tension on a leading rope during aerial powerline installation while using equipment in use for power line masts. The technical solution is to use a pulley lock to maintain the leading rope tension on the pulley wheel. The lock has a diagonal bar that has a pendulum pivotally attached to the pulley with a weight that holds the lock in a closed position.

[0104] The drone or other aircraft that pulls the leading cable or rope, passes on the side of the pulley and afterwards moves the stretched cable to the side and down, above the diagonal bar. This leads it to push and open the lock in order for the leading rope to fall on the wheel of the pulley. After the cable passes through the pendulum lock, the pendulum closes, and the cable is locked on the pulley's rail. When the cable is locked on the pulley, the pulling process continues towards the next electric pole. In this application, the cable is a leading rope.

[0105] In one embodiment the TKD has a curved pulley brake in another embodiment the TKD has a cone like brake. The active payload and TKD can each be used separately as towed by a drone or preferably together.

[0106] Another embodiment modifies the thrust generator of the active payload described in the first embodiment. It incorporates at least two propellers that rotate in opposite directions - one clockwise (“CW”) and one counterclockwise (“CCW”). This configuration can help balance torque and improve stability during operation.

[0107] A further embodiment has the active payload of the first embodiment with ducted thruster. Improving the efficiency of the thrust generator and protecting the propellers during landing and takeoff.

[0108] Another embodiment, the rod of the active-payload is not necessarily straight. It can be curved or shaped in various ways to suit specific operational requirements.

[0109] An embodiment at least one optical or 3D sensor connected to its control system, to enable an exact control of the position of the pulled rope. These sensors enable more precise control of the pulled rope's position by providing real-time spatial data to the control system.

[0110] An embodiment of at least one tension meter to either the front or rear of the rod. The tension meter is connected to the control system, allowing for real-time monitoring and adjustment and balancing of the rope tension, the active payload thrust and the drone pulling tension during operation.

[0111] A further embodiment of a TKD for tensioning rope through a series of poles with pulleys, A rigid or rigid member; a connect and release ring or magnet or other easy to connect device at the rod front side; stopper device at the rear side of the rod that cannot pass between the leading rope pulley and its locking pendulum; a ring or other device to connect the rope to the rear side of the rod and can pass between the pulley and the locking pendulum, So that when the tension of the rope is pulling the device backwards towards the pulley, the stopper tightens on the pulley or between the pulley and its locking pendulum and holds the rod in horizontal position, to enable the releasing of the device while maintaining the cable's tension and easily aerially reconnect to it while the drone is flying.

[0112] Another embodiment is a system wherein the active payload for cable pulling by a drone as connected to the drone and the TKD connected between the active payload and the pulled cable.

[0113] A further embodiment is further having an optional tension balancing machine of powerlines laying is capable to release or stop the rope by controlling the friction of its brakes. When laying a light leading rope instead of a metal cable, a much lower tension is required. Hence, the magnitude of the required forces to pull the leading rope can be achieved by means of a small, motorized friction drum that can balance the tension on the rope while the rope is pulled forward by the drone or stop it by a small brakes. This tension balancing machine can also be motorized to pull the rope and the drone backwards while maintaining the necessary tension in the rope, thereby enable to attach the TKD to the pulley of the previous electric pole. The further embodiment comprising a remote-controlled machine for the rope releasing and tension balancing at the beginning of the line laying section. This machine is capable of performing the following commands: stop and release of the rope pulling, tension control of the released rope and rope rewinding.

[0114] Another embodiment is piloted and operated automatically or manually from a controller beyond visual line of sight the drone flight route, exact flight operation plan are preplanned based on an accurate 3D mapping of a specific power line section and sensors. The sensors are one or more of camera, three dimensional (“3D”) sensors, tension meters, inertia measurement unit (“IMU”), navigation measures, and tilt sensors, coupled to a controller. Another embodiment wherein the flight route and its exact flight and operation plan are preplanned based on an accurate 3D mapping of the specific powerline section of operation alone or in combination with beyond line of sight flight operations.

[0115] Another embodiment is to use two tension meters for better control over the system. One meter between the drone and the active payload and the second between the active payload and the TKD or the rope, to directly and separately measure the thrust of the active payload and to measure the cumulative tension on the rope.

[0116] A further embodiment of an active payload system is for near horizontal pulling of aerial, ground or maritime objects. It has a drone for lifting, positioning and applying tension to a pulling rope, an elongated rod pivotably attached by one of a rope or a pivot mechanism to the towing drone at a first end, the rod is configured to pivot by one or more of pitch, yaw, and roll, a thrust generator mounted on the rod and configured to generate thrust along the longitudinal axis of the rod, and a connector at a second end of the rod configured to attach to a pulling rope that is pulling the object.

[0117] The pulled rope, under tension, aligns the rod with the rope thus aiming the thrust generator to provide thrust in addition to the drone. This assists the drone to pull the aerial, ground or maritime object horizontally for the required towing forth of the object, while preserving drone maneuverability and maintaining the drone within predefined orientation limits. Orientation meaning pitch, roll, and yaw.

[0118] Another embodiment supplies power to operate the thrust generator of the active payload or the drone propellers from the connected towed object.

[0119] Referring now to the drawings, Figure 1 illustrates the invention with the active payload. This is embodiment provides extra thrust to a drone to lift and position a leading rope (100).

[0120] The active payload (100) is referred to as LRLAP. The ducted thrust generator (101) is installed on the rod (108). The camera, sensor, (106) is installed on the thruster, but could optionally be installed on any of the components. Also installed is the rope tension meters 104 and 105. The rope tension meter (104) measures the rope tension. The drone tension meter (105) is installed on the rod (108) the difference between the rope tension meter (104) and the drone tension meter (105) is the thrust provided by the thruster. A connector (103) is positioned at the other end of the rod. The active payload can be used in combination with the TKD (200).

[0121] The drone tension meter and the rope tension meter are sensors that are connected to a controller. The controller takes this sensor data. The difference between these sensors is the thrust and the controller can then control the thrust generator on the active payload.

[0122] Fig. 2 illustrates the thrust generator in isolation with the counter rotating coaxial propellers in the clock wise (CW) and counter clockwise (CCW) rotation. The counter rotation reduces parasitic torque.

[0123] Fig. 3 illustrates the pulley lock with pulley (6), the lock having a diagonal bar (5) that is aiming the tensed rope towards the locking pendulum (4). The cable locking pendulum (4) has a weight and when released closes the lock onto the rope that is positioned on the pulley wheel.

[0124] Fig. 4 is the TKD (200) with the circular hook like brake (202) tightened against the pulley (6) that is on pole or mast (2). The rope (7) is on the pulley (6) and held in position by rope locking pendulum (4). The drone has positioned the TKD (200) so that the leading rope (7) remains under tension. The other end of the member (204) has a ring (201) to be attached and detached from the active payload. The active payload and drone are not shown in this view. The preferred embodiment is the active payload along with the TKD (200), but it is possible to use the TKD (200) alone.

[0125] Fig. 5 is an illustration of the TKD (200) in an embodiment wherein the pulley brake (203) is a cone-like shape attached to main member (204) that fits between the pulley (6) and the pendulum lock (4) holding the main member (204) in a generally horizontal position. The pulley (6) is attached to the mast or pole (2). The TKD also in this embodiment has a ring (201) at the other end of main member (204) that can be attached to the drone and active payload (not shown). An advantage of this embodiment is that the main member (204) is held in generally horizontal position to allow an easier re-connection.

[0126] Fig. 6 is an embodiment with both the active payload (100) and the TKD (200). The drone (1) has the active pay load (100) pivotally attached with the TKD (200) releasably connected to the active payload (100) at ring (201). In this illustration the circular brake (202) is not positioned on the pulley (6). The rope (7) is locked on to the pulley (6) wheel. When used in combination this embodiment allows the drone to lift and position the rope (7) while operating in normal flight limits because of the thrust generator attached to the active payload (100).

[0127] It is expected that during the life of a patent maturing from this application many relevant brakes for the pulleys and thrust generator for the active payload will be developed and the scope of the term brake and thrust generator is intended to include all such new technologies a priori. The terms "comprises", "comprising", "includes", "including", “having” and their conjugates mean "including but not limited to".

[0128] The term “consisting of’ means “including and limited to”.

[0129] The term "consisting essentially of" means that the composition, method or structure may include additional ingredients, steps and / or parts, but only if the additional ingredients, steps and / or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.

[0130] As used herein, the singular form "a", "an" and "the" include plural references unless the context clearly dictates otherwise.

[0131] “And / or” has used herein means singularly or one or more in combination.

[0132] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination or as suitable in any other described embodiment of the invention. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments, unless the embodiment is inoperative without those elements.

[0133] Various embodiments and aspects of the present invention as delineated hereinabove and as claimed in the claims section below find support in the following examples.

[0134] EXAMPLES

[0135] Reference is now made to the following examples, which together with the above descriptions illustrate some embodiments of the invention in a non limiting fashion.

[0136] The sag of a rope stretched between two poles with 350 m distance between them (L), is calculated as follows:

[0137] The values of the rope parameters are for 10mm Dyneema® rope with specific mass (w) of 0.065 k / m. This rope is strong enough to be used as a leading rope.

[0138]

[0139] Where:

[0140] a = Catenary constant that depends on the boundary conditions.

[0141] a depends on the cable weight, the maximal sink ymaxand

[0142] the gap between the poles, a is calculated numerically.

[0143] x = distance from the minimum point.

[0144] x is the middle point if the masts are equal and levelled

[0145] θ = The angle of the slope of the rope at the connection to the pole.

[0146] The following table presents the results of the calculations for the parameters of the example above, for sag values of 10, 15 & 20 m:

[0147] Sag [m] a [m] Tension [N] 0 [deg] Rope Length [m] Rope Weight Wrope[N]

[0148] 10 1532.9 983.8 6.5 350.8 111.8

[0149] 15 1023.3 662 9.8 351.7 112.1

[0150] 20 768.9 502.8 12.9 353 112.5

[0151]

[0152] Calculation of the forces on the drone that is pulling the above mentioned Dyneema® rope when it is at the end stage of the pulling:

[0153] Let's assume that a 100kg (=l,000N) drone (without the assisting of the active payload) is required to maintain the rope tension always above the tensions for the three listed sags in the table above, with 25% margin for wind and maneuvering. We define this minimal required tension as To.

[0154] The cumulative force vectors on the hovering drone while it maintaining the rope required tension are presented in the following equation (Ly, Lx - Vertical and horizontal dimensions of required lift, y is the angle of the rope towed by the drone and 0 is the pitch angle of the drone):

[0155]

[0156] The results for l,000N pulling drone (Without the Active pay load) are listed in the following table: Sag a [m] Rope 6 [deg] Rope Weight l,000N drone's pitch

[0157] [m] Tension + [N] without LRLAP [deg]

[0158] 25% margin

[0159] [N]

[0160] 10 1532.9 1230 6.5 111.8 45.0

[0161] 15 1023.3 828 9.8 112.1 33.7

[0162] 20 768.9 629 12.9 112.5 26.6

[0163]

[0164] Adding the thrust of the active payload to the calculation, defining it as Ti and its total selfweight as Wi (Wi includes the entire additional weight as in the self-contained configuration of the LRLAP of the active pay load).

[0165] The new cumulative force vectors on the drone with LRLAP are presented in the following equation.

[0166] (L\—^drane + I 2 J ^rope + Po—^1) 9 +

[0167] Lx= (To— TJcosffl)

[0168] ., ' _ L* _ _ (TD-7j)cos(6l) _ tan(y ) „.

[0169] 7^drone + I 7 IX wrope + (Ta - Ti) Sin 0 + WLRLAp

[0170] L \

[0171] ( 2 / ^rape "t"

[0172]

[0173] / (To- L) sin 9 +

[0174] The results for l,000N pulling drone with 20kg LRLAP (-200N) that provides 400N lift with the same 25% margin, are listed in the following table:

[0175] Sag [m] a [m] Rope e Rope drone pitch with active

[0176] Tension + [degrees] Weight payload [deg]

[0177] 25% margin [N]

[0178] [N]

[0179] 10 1532.9 1230 6.5 111.8 27.8

[0180] 15 1023.3 828 9.8 112.1 13.4

[0181] 20 768.9 629 12.9 112.5 5.4

[0182]

[0183] A comparison of the required drone's pitch and total lift, between a 100 kg drone that is pulling the leading rope without active payload (Total system weight of 1,000N) and the same pulling drone with active pay load that provides 400N lift and weight 20kg (Total system weight of l,200N) is summarized in the following table:

[0184] Sag Rope Tension + 25% margin Drone's pitch [deg] Drone's total lift [N]

[0185] [m] [N] With Without With Without

[0186] LRLAP LRLAP LRLAP LRLAP

[0187] 10 1230 27.8 45.0 1630 1749

[0188] 15 828 13.4 33.7 1448 1495

[0189] 20 629 5.4 26.6 1382 1395

[0190]

[0191] The conclusion from this table is that although the active payload is adding some weight, it enables the drone to perform the leading rope laying task with much smaller pitch and smaller total lift. Because the weight of the active payload includes its power supply for the entire mission, it is possible to conclude that the assistance of the active payload will provide significantly better controllability (smaller required pitch) and longer flight time (lower required lift).

[0192] In the above calculations the weight of the TKD is ignored because the TKD is required in both cases, with or without the use of an active payload.

[0193] Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.

[0194] It is the intent of the Applicant(s) that all publications, patents and patent applications referred to in this specification are to be incorporated in their entirety by reference into the specification, as if each individual publication, patent or patent application was specifically and individually noted when referenced that it is to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention. To the extent that section headings are used, they should not be construed as necessarily limiting. In addition, any priority document(s) of this application is / are hereby incorporated herein by reference in its / their entirety.

Claims

WHAT IS CLAIMED IS:

1. An active payload system for leading rope installation, comprising:a drone for lifting, positioning and applying tension to a leading ropean elongated rod pivotably attached by one of a rope or a pivot mechanism to the towing drone at a first end, the rod is configured to pivot by one or more of pitch, yaw, and roll;a thrust generator mounted on the rod and configured to generate thrust along the longitudinal axis of the rod,a connector at a second end of the rod configured to attach to a leading rope;wherein, the pulled leading rope under tension aligns the rod with the rope, aiming the thrust generator to provide thrust in addition the drone, assisting the drone to lift and pull the rope, maintain predetermined rope tension of the leading rope so that the leading rope lowest point between masts sags less than a predetermine limit.

2. The active pay load of claim 1, wherein the thrust generator has at least two propellers or turbines that rotate in opposite directions to produce thrust with a reduced parasitic rolling torque.

3. The active pay load of one of claims 1 and 2 wherein the thrust generator propellers are ducted, to enhance the efficiency or to protect the propellers.

4. The active pay load of one of claims 1 - 3, wherein the active pay load further comprises a controller, the controller is connected to and controls the thrust generator, wherein the controller can be positioned on the rod of the active payload or the drone.

5. The active payload of claim 4, wherein sensors are attached to the rod, wherein the sensors are one or more of camera, three dimensional (“3D”) sensors, tension meters, IMU, navigation measures, and tilt sensors, coupled to the controller.

6. The active pay load of claim 4, wherein the controller is connected to and controls: - communications with a remote-control station, and / or- a power supply for the thruster, the power supply is configured to be installed on one of the elongated rod or the towing drone.

7. The active payload controller of claim 6 is configured to adjust the thrust generator so that as the drone operates to install the leading rope, the drone hovers, moves toward and parallel to the pulley lock and pulley, moves across to the pulley and pulley lock to open the lock and position the leading rope on the pulley, and moving away from the pulley lock.

8. The active payload of one of claims 1 - 3, wherein the connector is configured to connect and release at least one of:- a leading rope,- a tension keeping device, or- another device.

9. An active payload of one of claims 1-8 wherein the active payload is connected to the leading rope, pulling it through a plurality of masts, positioning the leading rope onto a pulley, the pulley having a wheel, and the pulley is attached to each mast;the pulley has a pivoted lock that is normally closed;wherein, the drone approaches the side of each pulley lock, positioning the rope under tension to rotate the lock into an open position, positioning the leading rope on the pulley wheel, allowing the lock to relock the rope on the pulley wheel.

10. A tension keeping device pulling the rope, positioning the rope onto a pulley having a pulley wheel, enabling the drone to land during leading rope pulling, while maintaining the leading rope tension to maintain a predetermined sag, comprising:a pivoted pulley lock that is normally closed by gravity or by spring;a main member;a connector to connect the leading rope to the main member, a connector sized to pass through the pulley lock; andwherein the member has a cone-like structure that at the structure base that sized to that it cannot pass between the pulley and the pulley lock, and cone-like smaller diameter pointing to the leading rope, andwherein the member is connected to one of the drone and a active payload by a controlled connector that is built to enable quick-releasing and aerial-reconnecting, andwherein the pulling drone approaches the side of the pulley lock, positioning the rope under tension or the rear part of the main member, rotating the lock pivot into an open position, approaching the pulley wheel, allowing the lock to relock the rope or the main member on the pulley wheel, and wherein, immediately after the leading rope or the rear part of the member passes through the pulley lock, the drone reduces the pulling tension, allowing the leading rope to pull back the member until the cone-like structure to snugly tighten between the lock and the pulley, providing a brake that prevents the leading rope from breaching a predetermined maximal allowed sag and holds the TKD main member in horizontal position to enable the drone or the active payload to perform aerial releasing and reconnecting away from the powerline mast.wherein after the cone-like stopper is snugly tightened, the connector between the tension keeping device and the drone or the active payload is released and the drone can land; andwherein leading rope maintains tension and the drone can land, for any reson, and then have the drone takeoff and the TKD is positioned horizontally to aerially reconnect to the leading rope and continue pulling the leading rope.

11. A tension keeping device of claim 10, wherein the pulley lock is configured to receive a stopper shaped as a curved hook, the curvature corresponds to the pulley curvature, and the stopper is snugly tightened onto the wheel of the pulley.

12. The tension keeping device of one of claims 10 to 11, wherein the tension keeping device is pivotally connected to the drone.

13. The tension keeping device of one of claims 10 to 12, wherein one or more tension meters and / or one or more sensors are attached to the main member, wherein the sensors are one or more of camera, three dimensional (“3D”) sensors, tension meters, inertia measurement unit (“IMU”), navigation measures, and tilt sensors, coupled to the controller.

14. The tension keeping device of one of claims 10-13, wherein a controller with a communication system, is attached to the main member and controls the communication system and is connected to the sensors and one or more tension meters.

15. A system for a laying leading rope by a drone, the rope laid on pulleys attached to each of a plurality of masts comprising one or more of:-a drone active pay load as described in one of claims 1-9; and-a tension keeping device as described in one of claims 10-14.

16. The system of claim 15, further comprising a ground based remote-controlled rope releasing machine for the rope releasing and tension balancing; the machine positioned at the beginning of a section of line laying over masts, the machine is configured to stop or release the rope under required tension under the remote control command.

17. The system of claim 15 wherein the rope releasing machine is configured to rewind the rope.

18. The system of claim 15 wherein the drone flight route, exact flight operation plan are preplanned based on an accurate 3D mapping of a specific power line section and sensors, wherein the sensors are one or more of camera, three dimensional (“3D”) sensors, tension meters, inertia measurement unit (“IMU”), navigation measures, and tilt sensors, coupled to a controller; andwherein the system is configured for flight operation beyond line of sight.

19. The system of claim 18, where in there are two tension meters, a drone tension meter on elongated rod and a rope tension meter on the leading rope; wherein the drone tension meter and the rope tension meter are connected to the controller controlling the thrust generator; the differencebetween the drone tension meter measurement and the rope tension meter is the thrust from the thrust generator.

20. The system of claim 19 wherein the thrust from the generator is transmitted by the controller to a ground station.

21. A method for a powerline on a masts by a drone, comprising:attaching an active payload to a heavy lift drone, the active payload having a thrust source; attaching TKD or leading rope to the active payload, the TKD having a pulley brake; flying the drone assisted by the pulling thrust generator to position the leading rope onto a pulley attached to the mast; andmaintaining a predetermined tension on the leading rope configured for a predetermined sage of the leading rope between masts.

22. A method of claim 21, wherein the drone has a lift capacity of up to 150 kg.

23. An active pay load system for near horizontal pulling of aerial, ground or maritime objects, comprising:a drone for lifting, positioning and applying tension to a pulling ropean elongated rod pivotably attached by one of a rope or a pivot mechanism to the towing drone at a first end, the rod is configured to pivot by one or more of pitch, yaw, and roll;a thrust generator mounted on the rod and configured to generate thrust along the longitudinal axis of the rod,a connector at a second end of the rod configured to attach to a pulling rope that is pulling the object;wherein, the pulled rope under tension aligns the rod with the rope, aiming the thrust generator to provide thrust in addition to the drone, assisting the drone to pull the object horizontally at the required towing forth, while preserving its maneuverability and maintaining itself inside predefined orientation limits.

24. The active payload system of claim 23 wherein power to the thrust generator of the active payload or the drone is supplied from the towed object.

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