Aerostat Tether Quick-Disconnect Spool for Rapid Replacement
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Solution Overview
Problem
Tethered aerostats face challenges in maintaining uninterrupted service due to the inability to quickly repair, remove, and replace tethers, leading to extended downtime and reduced operational time on station.
Innovation Solution
A novel tether system with a quick connection design and a tether spool system that enables rapid installation and removal of tethers, utilizing a Removable Sealable Top End (RSTE) at both ends, allowing for near-instantaneous replacement and maintenance, ensuring continuous operational capability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If traditional tether installation and replacement methods are used, then structural integrity and reliability are maintained, but the time required for tether replacement and maintenance is excessive
Solution Approach 1:
The tether system is divided into modular components including quick-connect couplings at each end of the tether, allowing the tether to be segmented and replaced in sections rather than as a single unit. The couplings include separate sealing mechanisms and connection elements that can be independently assembled and disconnected.
Solution Approach 2:
Replacement tethers are pre-prepped and staged in advance with pre-attached quick-connect couplings and pre-installed sealing elements. The couplings are pre-assembled with O-rings and sealing surfaces prepared before the actual tether replacement operation, enabling rapid exchange without time-consuming on-site assembly.
2Productivity
If quick connection designs are implemented to reduce tether replacement time, then operational continuity is improved, but the reliability and sealing integrity may be compromised
Solution Approach 1:
The quick-connect coupling replaces traditional mechanical threading or bolting systems with a simplified insertion and locking mechanism. The coupling uses a bayonet-style or push-button release system that maintains full sealing integrity through precision-machined mating surfaces and elastomeric O-rings, eliminating complex mechanical fasteners while enabling rapid connection and disconnection.
Solution Approach 2:
The coupling design incorporates changeable parameters such as adjustable sealing pressure, modular O-ring cross-sections, and temperature-compensated sealing surfaces that adapt to different operational conditions. The sealing mechanism can transition between different pressure states to ensure reliable sealing during both connection and disconnection phases.
3Reliability
If comprehensive maintenance procedures are performed to ensure aerostat reliability, then service quality is maintained, but the ground service time increases
Solution Approach 1:
Maintenance activities are performed in advance while the aerostat is still operational or during scheduled downtime. Tethers are pre-inspected, pre-repaired, or pre-replaced in a staged manner, allowing comprehensive maintenance to be completed before the aerostat needs to be redeployed, minimizing the actual ground service time required.
Solution Approach 2:
The system incorporates self-diagnostic capabilities and automated monitoring that identify tether wear, damage, or performance degradation before critical failure occurs. Sensors and monitoring systems provide real-time data on tether health, allowing maintenance to be scheduled proactively rather than reactively, reducing unplanned ground time.
Data Source
AI summary
An aerostat tether, anchorage, and tether spool system which extends the “On Station” uninterrupted intervals of service for which a “Lighter Than Air” (LTA) aerostat may stay aloft at its designated altitude without requiring retrieval for ground service. Anchoring vessels are provided at both the aerostat and ground control ends of the tethered system which enables remote control of varying choices for bi-directional gas flow patterns within the tether which better facilitate continuous lift gas maintenance and emergency control. The gas routing is selectively controlled per best practice toward the constant filtering and scrubbing of the lift gas within both the aerostat and the tether restraining the aerostat. The system uniquely provides for a very rapid switch-out of tethers by having a full “replacement tether spool” on the ground at the ready which is pre-wound, pre-filled, and sealed with fresh lift gas where it is available at all times for rapid changeout. Quick tether replacement is accomplished by interchangeable quick disconnect fittings at both ends of a hollow tether with a hollow piston valve stem to provide a simple process of unplugging the tether at both the aerostat to close the valves and ground terminal ends and then plugging in the replacement tether to open the valves and reinstituting deployment facilitated by the unique tether spool and anchoring system. The system also enables the effective prevention and dissipation of damage due to torque forces being applied to the tether by a weathervaning aerostat. This is accomplished through counter rotation being applied to the tether at the most advantageous and effective source of tether/aerostat union, at its point of attachment at the aerostat end since the tether attachment point (TAP) is where damage to the tether is most likely to occur. Also favorable to the longevity of service, the aerostat system provides improvements of electrical strike/static build-up dissipation as well as superior tether terminal end preparation, interconnection speed, and short turnaround repair times. The entire aerostat system is designed for plug and play usage and versatility.