IP Library Granted Patent US 12,649,569
Granted Patent B2
US 12,649,569 · App. 18/930,078 · Granted Jun 9, 2026

Autorotating payload delivery device

Inventors: Joel Ifill (Los Angeles, CA); Zach Taylor (Redondo Beach, CA); Jason Litzinger (Canyon Lake, CA); Philip Stahlhuth (Pasadena, CA); Marc Berte (Leesburg, VA)
Assignee: AeroVironment, Inc.
B64C27/028B64C27/02G05D1/105G05D1/461B64D19/02
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Quick Facts
Patent No.
US 12,649,569
App. No.
18/930,078
Granted
Jun 9, 2026
Kind
B2
Abstract

A payload delivery device configured to deliver an aircraft deployed payload along a flight path to a predetermined landing destination includes a support member configured to be removably attached to the payload, a flight control and navigation system module configured to control orientation of the plurality of control surfaces while the payload is travelling along the flight path to the predetermined landing destination, a control surface assembly module including a plurality of control surfaces, a rotor assembly including a plurality of rotor blades having a central axis of rotation, and a collective control assembly module including at least one collective servomotor configured to control a plurality of control linkages connected to the plurality of rotor blades.

Claims (55)

1 . A payload delivery device configured to deliver an aircraft deployed payload along a flight path to a predetermined landing destination, the payload delivery device comprising:

a flight stabilizer assembly mounted on a containerized payload assembly configured to enclose the payload;

a rotor assembly attached to the flight stabilizer assembly, the rotor assembly including:

a first plurality of rotor blades configured to rotate about a central axis of rotation and rotate within a first plane of rotation, wherein the first plurality of rotor blades are passively powered to rotate only by air impinging upon the rotor assembly as the payload delivery device descends along the flight path, and wherein each rotor blade of the first plurality of rotor blades comprises a folding joint for each rotor blade to be stowed in an initial pre-deployment configuration before being deployed into an autorotating configuration, and

at least one rotor blade angular actuator configured to control rotation of a leading edge of at least one of the first plurality of rotor blades with respect to the first plane of rotation, wherein the at least one rotor blade angular actuator is further configured to control rotation of the leading edge of the at least one of the first plurality of rotor blades to a first downward angle orthogonal to the first plane of rotation, wherein the at least one rotor blade angular actuator provides co-planar control of the first plurality of rotor blades such that the at least one rotor blade actuator is disposed in the first plane of rotation;

a gimbal assembly attached to the flight stabilizer assembly, the gimbal assembly including:

a gimbal spherical surface, wherein the rotor assembly is mounted on the gimbal spherical surface via a rotor assembly rotational bearing; and

at least two gimbal servomotors configured to move the rotor assembly in a gimbal angular range of motion to control an X direction and a Y direction in a horizontal plane orthogonal to a rotational central axis of the rotor assembly; and

at least one flight control surface attached to the flight stabilizer assembly, each flight control surface rotatable about a respective flight control surface rotational axis, wherein the at least one flight control surface provides additional control along the flight path in conjunction with the rotor assembly.

2 . The payload delivery device of claim 1 , wherein the rotor assembly further comprises a plurality of rotor blade angular actuators, wherein each of the plurality of rotor blade angular actuators being coupled respectively to each of the first plurality of rotor blades to control rotation of the leading edge of each of the first plurality of rotor blades.

3 . The payload delivery device of claim 2 , wherein the plurality of rotor blade angular actuators are configured to simultaneously control rotation of the leading edge of each of the respective first plurality of rotor blades to the first downward angle orthogonal to the first plane of rotation to cause the payload delivery device to enter a maximum descent speed state of flight along the flight path.

4 . The payload delivery device of claim 2 , wherein the plurality of rotor blade angular actuators are configured to independently control rotation of the leading edge of each of the respective first plurality of rotor blades to varying negative and positive angles with respect to the first plane of rotation to cause the rotor assembly to be controlled under at least one of collective input control and cyclic input control along the flight path.

5 . The payload delivery device of claim 2 , the rotor assembly further comprising a second plurality of rotor blades configured to rotate about the central axis of rotation and rotate within a second plane of rotation,

wherein the second plurality of rotor blades are passively powered to rotate only by air impinging upon the rotor assembly as the payload delivery device descends along the flight path,

wherein the second plurality of rotor blades being configured to rotate in an opposite rotational direction of a rotational direction of the first plurality of rotor blades.

6 . The payload delivery device of claim 1 , wherein the rotor assembly further comprises a plurality of rotor blade angular actuators, wherein each of the plurality of rotor blade angular actuators being coupled to at least two of the plurality of rotor blades to control rotation of both leading edges of the coupled to at least two of the plurality of rotor blades.

7 . The payload delivery device of claim 6 , wherein the plurality of rotor blade angular actuators are configured to simultaneously control rotation of the both leading edges of each of the coupled to at least two of the plurality of rotor blades to the first downward angle orthogonal to the first plane of rotation to cause the payload delivery device to enter a maximum descent speed state of flight along the flight path.

8 . The payload delivery device of claim 6 , wherein the plurality of rotor blade angular actuators are configured to control rotation of both leading edges of each of the coupled to at least two of the plurality of rotor blades between (i) a neutral angle in which the leading edge is coincident with a rotor blade rotation plane; (ii) a 90-degree negative angle in which the payload delivery device travels at a maximum vertical descent speed with minimal resistance from the rotor blades; (iii) a negative angle in which the rotor assembly is configured to achieve an autorotating motion and provide downward thrust while providing collective and cyclic pitch control to navigate toward the predetermined landing destination; and (iv) a positive angle in which the rotor assembly is configured to generate an increased downward thrust force, relative to the autorotating state, by using rotational inertia built up during autorotation to slow the payload delivery device prior to landing.

9 . The payload delivery device of claim 6 , the rotor assembly further comprising a second plurality of rotor blades configured to rotate about the central axis of rotation and rotate within a second plane of rotation,

wherein the second plurality of rotor blades are passively powered to rotate only by air impinging upon the rotor assembly as the payload delivery device descends along the flight path,

wherein the second plurality of rotor blades being configured to rotate in an opposite rotational direction of a rotational direction of the first plurality of rotor blades.

10 . The payload delivery device of claim 1 , wherein the at least one rotor blade angular actuator being configured to control rotation of the leading edge of the at least one of the plurality of rotor blades to a second downward angle less than an angle orthogonal to the first plane of rotation,

wherein the rotor assembly is configured to enter an autorotation state of flight along the flight path while the at least one rotor blade angular actuator holds the leading edge of the at least one of the plurality of rotor blades at the second downward angle.

11 . The payload delivery device of claim 1 , wherein the at least one rotor blade angular actuator being configured to control rotation of the leading edge of the at least one of the plurality of rotor blades to a third upward angle relative to the first plane of rotation,

wherein the rotor assembly is configured to enter a deceleration state of flight along the flight path while the at least one rotor blade angular actuator holds the leading edge of the at least one of the plurality of rotor blades at the third upward angle.

12 . The payload delivery device of claim 1 , wherein the at least one rotor blade angular actuator comprises a servomotor located in a rotating reference frame of the rotor assembly and independent of a fixed reference frame of the flight stabilizer assembly attached to the payload.

13 . A payload delivery device configured to deliver an aircraft deployed payload along a flight path to a predetermined landing destination, the payload delivery device comprising:

a flight stabilizer assembly mounted on a containerized payload assembly configured to enclose the payload; and

a rotor assembly attached to the flight stabilizer assembly, the rotor assembly including

a plurality of rotor blades configured to rotate about a central axis of rotation and rotate within a first plane of rotation, wherein the rotor assembly is passively powered to rotate only by air impinging upon the rotor assembly as the payload delivery device descends along the flight path, and wherein each rotor blade of the plurality of rotor blades comprises a folding joint for each rotor blade to be stowed in an initial pre-deployment configuration before being deployed into an autorotating configuration, and

a plurality of rotor blade angular actuators configured to control rotation of a corresponding leading edge of the plurality of rotor blades with respect to the first plane of rotation, wherein the plurality of rotor blade angular actuators are further configured to control rotation of the corresponding leading edge of the plurality of rotor blades to a first downward angle orthogonal to the first plane of rotation, wherein the plurality of rotor blade angular actuators provides co-planar control of the plurality of rotor blades such that the plurality of rotor blade actuators are disposed in the first plane of rotation;

a gimbal assembly attached to the flight stabilizer assembly, the gimbal assembly including:

a gimbal spherical surface, wherein the rotor assembly is mounted on the gimbal spherical surface via a rotor assembly rotational bearing; and

at least two gimbal servomotors configured to move the rotor assembly in a gimbal angular range of motion to control an X direction and a Y direction in a horizontal plane orthogonal to a rotational central axis of the rotor assembly; and

at least one flight control surface attached to the flight stabilizer assembly, each flight control surface rotatable about a respective flight control surface rotational axis, wherein the at least one flight control surface provides additional control along the flight path in conjunction with the rotor assembly.

14 . The payload delivery device of claim 13 , wherein the plurality of rotor blade angular actuators are configured to control rotation of both leading edges of each of the coupled to at least two of the plurality of rotor blades between (i) a neutral angle in which the leading edge is coincident with a rotor blade rotation plane; (ii) a 90-degree negative angle in which the payload delivery device travels at a maximum vertical descent speed with minimal resistance from the rotor blades; (iii) a negative angle in which the rotor assembly is configured to achieve an autorotating motion and provide downward thrust while providing collective and cyclic pitch control to navigate toward the predetermined landing destination; and (iv) a positive angle in which the rotor assembly is configured to generate an increased downward thrust force, relative to the autorotating state, by using rotational inertia built up during autorotation to slow the payload delivery device prior to landing.

15 . The payload delivery device of claim 13 , wherein the plurality of rotor blade angular actuators being configured to control rotation of the corresponding leading edges of the plurality of rotor blades to a second downward angle less than an angle orthogonal to the first plane of rotation,

wherein the rotor assembly is configured to enter an autorotation state of flight along the flight path while the plurality of rotor blade angular actuators maintain the corresponding leading edges of the plurality of rotor blades at the second downward angle.

16 . The payload delivery device of claim 13 , wherein the plurality of rotor blade angular actuators being configured to control rotation of the corresponding leading edge of the plurality of rotor blades to a third upward angle relative to the first plane of rotation,

wherein the rotor assembly is configured to enter a deceleration state of flight along the flight path while the plurality of rotor blade angular actuators maintains the corresponding leading edges of the plurality of rotor blades at the third upward angle.

17 . A payload delivery device configured to deliver an aircraft deployed payload along a flight path to a predetermined landing destination, the payload delivery device comprising:

a flight stabilizer assembly mounted on a containerized payload assembly configured to enclose the payload;

a rotor assembly attached to the flight stabilizer assembly, the rotor assembly including

a plurality of rotor blades configured to rotate about a central axis of rotation and rotate within a first plane of rotation, wherein the rotor assembly is passively powered to rotate only by air impinging upon the rotor assembly as the payload delivery device descends along the flight path, and wherein each rotor blade of the plurality of rotor blades comprises a folding joint for each rotor blade to be stowed in an initial pre-deployment configuration before being deployed into an autorotating configuration, and

a plurality of rotor blade angular actuators configured to control rotation of a corresponding leading edge of the plurality of rotor blades with respect to the first plane of rotation, wherein the plurality of rotor blade angular actuators are further configured to control rotation of the corresponding leading edge of the plurality of rotor blades to a first downward angle orthogonal to the first plane of rotation, wherein the plurality of rotor blade angular actuators provides co-planar control of the plurality of rotor blades such that the plurality of rotor blade actuators are disposed in the first plane of rotation;

a flight control and navigation system configured to control the plurality of rotor blade angular actuators to enable the payload delivery device to maintain travel along the flight path to the predetermined landing destination;

a gimbal assembly attached to the flight stabilizer assembly, the gimbal assembly including:

a gimbal spherical surface, wherein the rotor assembly is mounted on the gimbal spherical surface via a rotor assembly rotational bearing; and

at least two gimbal servomotors configured to move the rotor assembly in a gimbal angular range of motion to control an X direction and a Y direction in a horizontal plane orthogonal to a rotational central axis of the rotor assembly; and

at least one flight control surface attached to the flight stabilizer assembly, each flight control surface rotatable about a respective flight control surface rotational axis, wherein the at least one flight control surface provides additional control along the flight path in conjunction with the rotor assembly.

18 . The payload delivery device of claim 17 , wherein the flight control and navigation system is configured to control rotation of both leading edges of each of the coupled to at least two of the plurality of rotor blades between (i) a neutral angle in which the leading edge is coincident with a rotor blade rotation plane; (ii) a 90-degree negative angle in which the payload delivery device travels at a maximum vertical descent speed with minimal resistance from the rotor blades; (iii) a negative angle in which the rotor assembly is configured to achieve an autorotating motion and provide downward thrust while providing collective and cyclic pitch control to navigate toward the predetermined landing destination; and (iv) a positive angle in which the rotor assembly is configured to generate an increased downward thrust force, relative to the autorotating state, by using rotational inertia built up during autorotation to slow the payload delivery device prior to landing.

19 . The payload delivery device of claim 17 , wherein the flight control and navigation system is configured to instruct the plurality of rotor blade angular actuators to independently rotate each of the leading edges of the plurality of rotor blades to cause the payload delivery device to enter an autorotation descent flight phase,

wherein the leading edges of the plurality of rotor blades are rotated to a second downward angle less than the first downward angle relative to the first plane of rotation.

20 . The payload delivery device of claim 17 , wherein the flight control and navigation system is configured to instruct the plurality of rotor blade angular actuators to independently rotate each of the leading edges of the plurality of rotor blades to cause the payload delivery device to enter a flair thrust flight phase,

wherein the leading edges of the plurality of rotor blades are rotated to a third upward angle relative to the first plane of rotation configured to generate an upward thrust force on the payload delivery device.

Assignments (3)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 30, 2025
From: IFILL, JOEL; TAYLOR, ZACH; LITZINGER, JASON; STAHLHUTH, PHILIP; BERTE, MARC
To: FARCAST, INC.
Reel/Frame 071272/0327 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 30, 2025
From: FARCAST, INC.
To: AEROVIRONMENT, INC.
Reel/Frame 071272/0435 →
SECURITY INTEREST Recorded May 5, 2025
From: AEROVIRONMENT, INC.
To: BANK OF AMERICA, N.A., AS THE ADMINISTRATIVE AGENT
Reel/Frame 071024/0525 →
Continuity (3)
Division 17644653 · Dec 16, 2021
Provisional Application 63126345 · Dec 16, 2020
Related Publication 20250051007A1 · Feb 13, 2025
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