Quad-rotor Torque Management via Synchronized Gearing

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Solution Overview

Problem

Conventional rotorcraft face challenges such as torque imbalance, complex pitch adjustments, and high maintenance requirements due to the need for swashplates, which make them difficult to fly, inefficient, and prone to vibration.

Innovation Solution

A quad-rotor aircraft design with intersecting rotors synchronized by beveled gears and torque sensors, eliminating the need for swashplates and allowing for adjustable rotor pitch, ensuring balanced torque and efficient operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a conventional helicopter configuration with a single lift rotor and tail rotor is used, then the aircraft can achieve forward flight and hover, but the tail rotor is required to cancel main rotor torque which creates additional complexity and maintenance requirements

Engineering Contradiction:

Improveflight controlVSAvoidrotor configuration

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The single rotor system is segmented into four separate rotors arranged in pairs, with each rotor independently controllable. This segmentation eliminates the need for a tail rotor to cancel torque, as the opposing rotors naturally balance each other's torque effects.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Opposing rotors are configured to rotate in opposite directions, creating counterbalancing torque effects that eliminate the need for a separate tail rotor. The anti-rotor serves as a built-in counterweight system that naturally balances the main rotors.

Inventive Principle:

Principle #8Anti-weight (Counterweight)

2Adaptability or versatility

If a swashplate mechanism is used to adjust blade pitch during rotor rotation, then forward flight and maneuvering are enabled, but the mechanism experiences severe wear and tear and creates vibration

Engineering Contradiction:

Improvepitch adjustmentVSAvoidmechanism durability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The swashplate mechanism is completely removed from the system. Instead of using a complex mechanical swashplate to adjust pitch, the invention uses independent electronic control of each rotor's pitch angle, eliminating the wear and vibration problems associated with traditional swashplate mechanisms.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical swashplate system is replaced with an electronic control system that independently adjusts the pitch angle of each rotor blade. This substitution eliminates mechanical wear and tear while maintaining the ability to perform pitch adjustments for forward flight and maneuvering.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If four intersecting rotors are used with adjacent rotors rotating in opposed directions, then torque is canceled and swashplate is eliminated, but synchronization mechanisms experience wear and rotor collision risk remains

Engineering Contradiction:

Improverotor synchronizationVSAvoidrotor collision prevention

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Synchronization sensors detect the rotational position and speed of each rotor, providing real-time feedback to the control system. The control system uses this feedback to continuously adjust motor commands, ensuring precise synchronization and preventing rotor collision while minimizing wear on synchronization mechanisms.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The synchronization system dynamically adjusts rotor speed and phase based on real-time operational conditions. Rather than using fixed mechanical synchronization gears, the system uses dynamic electronic control to maintain proper rotor spacing and prevent collision, adapting to changing flight conditions.

Inventive Principle:

Principle #15Dynamics

4Use of energy by moving object

If longer rotor blades rotating at lower speeds are used, then energy efficiency is improved, but the rotors require larger size and may intersect more significantly

Engineering Contradiction:

Improveenergy efficiencyVSAvoidrotor blade length

Core Design Contradiction:

Use of energy by moving objectVSLength of moving object

Solution Approach 1:

The rotors are arranged in a three-dimensional configuration with vertical separation between opposing rotor pairs. This spatial arrangement in another dimension allows longer blades to rotate without collision, enabling lower operating speeds and improved energy efficiency while maintaining a compact overall aircraft structure.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS10343770B2Torque and pitch managed quad-rotor aircraft

Publication Date: 2019.07.09 MULLINS JOE H

AI summary

A torque and pitch managed four rotor aircraft includes intersecting blades connected by synchronizing gears. The power for the rotors is provided by individual motors, one for each rotor, the motors preferably electric. Each rotor-motor assembly includes a torque management system including a set of torque sensors mounted on the drive shaft of the rotor-motor, the torque management system configured to balance the load torque presented by the rotors against the torque supplied by the motors. An additional overriding feedback system regulates rotational speed of the rotors. Direction of the aircraft is effected by adjusting the pitch of the individual rotors, and power is supplied through a battery and/or a motor-generator system located in the aircraft.