Encapsulated Underwater Vehicle Modules

Abstract

An encapsulated module (14) for an unmanned underwater vehicle (UUV) (V) is formed with an operational component (16) and encapsulating material (60). The encapsulant (60) forms a rigid capsule surrounding the operational component (16). The capsule (14) has a least one exterior surface (18) that assists in forming the exterior surface (26) of the UUV (V) when the capsule (14) is combined into the UUV (V).

Description

BACKGROUND OF THE INVENTION

1. Technical Field

The invention relates to the field of Unmanned Underwater Vehicles (UUVs) and more particularly to forms of such UUVs that are adaptable to multiple mission profiles.

2. Background Art

Unmanned Underwater Vehicles (UUVs) are a well known tool used in military and non-military operations. UUVs are currently designated for a single mission. Additionally, the high cost of development hinders their application for other purposes. UUVs are typically designed as a metallic pressure vessel with cables running from its extremities to the central processor. This results in an architecture that does not lend itself to be easily reconfigured for other purposed.

Exemplary UUVs are disclosed in U.S. Pat. Nos. 5,578,751; 5,786,545; 6,058,874; 6,536,365; and 7,000,560.

Polyurethane potting has been used in conjunction with UUVs for sealing holes and individual cables against water intrusion as disclosed in U.S. Pat. No. 5,578,751; however, it is not known that a potting mixture has been used to form part or all of the UUV itself.

The present invention enhances the functionality of the above cited patents by utilizing a modular system to rapidly combine single or multiple purpose or use modules into a fully functional UUV particular to the specific mission profile.

While the above cited references introduce and disclose a number of noteworthy advances and technological improvements within the art, none completely fulfills the specific objectives achieved by this invention.

DISCUSSION OF INVENTION

In accordance with the present invention, an unmanned underwater vehicle (UUV) includes a steering unit for directional control of the UUV having an exterior surface and at least one interchangeable module component for housing a desired operational unit appropriate for a chosen mission profile. The interchangeable module has an exterior surface preferably impervious to the undesirable intrusion of water or other fluids. A frontal portion may have an exterior surface that is adapted for flow through a fluid. The exterior surfaces of the steering unit, the interchangeable module component and the frontal portion form a substantially smooth surface envelope when the interchangeable module is attached to the steering unit and frontal portion for controlled movement through a fluid.

The modules of the UUV V or the complete UUV V itself, as desired, may be formed from an encapsulating material protecting the operational mechanical and electrical components. The encapsulating material provides protection for the electronic and other operating components from water intrusion, crushing due to pressures on the module at a depth below the water surface, and other factors affecting the operability of the electronic components.

The present invention is a design for standardized UUV modules that can be combined in any way to make an unmanned underwater vehicle. This standardization allows the same technology to be used in multiple configurations. The reuse of technology significantly lowers the cost of development of a UUV. Therefore, a module only needs to be designed once, but can be reused in many vehicles with different purposes. The present invention discloses standardized modules than can be combined any way a user needs to make vehicles appropriate for a desired mission profile.

These and other objects, advantages and preferred features of this invention will be apparent from the following description taken with reference to the accompanying drawings, wherein is shown the preferred embodiments of the invention.

BRIEF DESCRIPTION OF DRAWINGS

A more particular description of the invention briefly summarized above is available from the exemplary embodiments illustrated in the drawing and discussed in further detail below. Through this reference, it can be seen how the above cited features, as well as others that will become apparent, are obtained and can be understood in detail. The drawings nevertheless illustrate only typical, preferred embodiments of the invention and are not to be considered limiting of its scope as the invention may admit to other equally effective embodiments.

FIGS. 1A and 1B are isomeric views of the modular UUV of the present invention.

FIG. 2 is a functional diagram of one form for a typical modular UUV of the present invention.

FIG. 3 is a perspective view of a rail system for assembly of the modules forming the competed modular UUV.

FIG. 4 is a perspective view of a truss assembly that may be used to join the modules.

FIG. 5 illustrates a tethered modular UUV of the present invention deployed from a control ship on the surface of a body of water.

FIG. 6 is a top view of a mold that may be used to form an encapsulated modular component of the UUV of the present invention.

MODES FOR CARRYING OUT THE INVENTION

So that the manner in which the above recited features, advantages and objects of the present invention are attained can be understood in detail, more particular description of the invention, briefly summarized above, may be had by reference to the embodiment thereof that is illustrated in the appended drawings. In all the drawings, identical numbers represent the same elements.

The present invention relates to co-pending patent application entitled “Self Contained Underwater Vehicle Modules,” the disclosure of which is incorporated by reference herein as if fully set forth.

An unmanned underwater vehicle (UUV) V includes a steering unit or segment 10 with an exterior surface 12 and at least one interchangeable operational module component 14. The steering unit 10 functions to provide for or assist in directional control or stability of the UUV V. The interchangeable module or modules 14 house one or more desired operational units 16 appropriate for a chosen mission profile of the impervious to the undesirable intrusion of water or other fluids 20. A frontal or nose cone portion 22 may by formed having an exterior surface 24 that is adapted for flow through the fluid 20. The exterior surfaces 12, 18, and 24 of the steering unit 10, the interchangeable module component(s) 14 and the frontal portion 24, respectively, form a substantially smooth surface envelope or body 26 resembling a torpedo shape when the interchangeable module(s) 14 is attached to the steering unit 10 and frontal portion or nose cone segment 22 for controlled movement through the fluid 20.

Each module is designed and built to have a unique, single function (i.e. thrust, control, navigation, etc.). A vehicle V can be constructed of only the modules needed for a given mission profile. Additional modules 14 can be added or unnecessary modules 14 removed from the vehicle V with no impact. If a mission requires a particular attribute to be optimized or changed, that particular module 14 or sub-system can be changed without redesigning the entire vehicle V. This independence allows each function of the vehicle V to be added, removed, or upgraded by only replacing one section and establishing communications with other operational modules 14 as necessary. Different vehicles V can be constructed of modules 14 with varying performance and cost based on mission requirements. FIG. 2 illustrates how each module 14 is self-sufficient and provides a single or multiple functions as desired.

The modules 14 of the present invention are self-contained and self-supporting, and vehicles V can be assembled from any number of compatible modules 14, in any order desired, to provide any length desired. Each module 14 may provide a single function and may be fully complete for its desired information gathering or defensive functions. Preferably, a single interchangeable module 14 would include all necessary electrical or mechanical components or arrays such as sensors 28, processing 30. recording 32, communications 34, energy 36 or others by way of example within each section or module 14 in order to improve reliability if one module 14 were to fail during a mission.

There is no minimum or maximum number of modules 14 required and each can operate independently or collectively. Each module 14 may be self-powered with its won energy component 36 and therefore not be dependent upon a common power bus subject to failure. Every module 14 may have the same mechanical attachment in order that it can be positioned in any sequence in the vehicle V as assembled.

Communication, either two-way or one-way, may be achieved over a standard or known protocol and architecture. Typically, communications may be exchanged between individual interchangeable modules 14 or the steering or propulsion unit 10 to exchange mission profile information and information or intelligence that has been collected by the sensor 28 or other operational components or arrays. Communication may be achieved with the steering or propulsion segment 10 for independent directional and stability control of the UUV V. Further, communications may be exchanged between the UUV V and a surface ship or supporting station 44 either through a wireless connection using an antenna 38 or over a tethered communication cable 40 extending between the support station 44 and an attachment point 42 on the UUV V.

Also, while a typical vehicle V may have an internal wired communications connection or bus 46, such as a known Ethernet form of electronic communication used for computing machinery, another vehicle V may communicate wirelessly through a known commercial Wi-Fi or radio frequency technology, for example, with an appropriate internal (not shown) or external antenna 38 for data interchange between modules 14 or the support station 44. Testing has been done to prove the viability of the wireless form of communication either between the modules 14 or from one or more modules to the information collection point 44.

Each module 14 may be designed to be neutrally buoyant so the addition and subtraction of modules has no effect on the overall vehicle buoyancy at the desired mission profile operating depth.

Alternatively, one interchangeable module 14 may be formed to include the nose cone or frontal portion 22 as is depicted in FIG. 2. A typical sensor that may be mounted with the nose cone segment 22 is a camera to provide visual assistance in guiding the craft V from the support station 44.

While the nose cone portion 22 is normally tapered or otherwise shaped to improve the movement of the UUV V through the water, the nose cone may even be a blunt surface. However, such blunt surface would not improve the movement characteristics through water or other medium and likely is not recommended to be used.

The steering or propulsion segment 10 generally includes a means of propulsion suitable for moving the UUV V through the water or other fluid medium. A known propeller 48 or other known means for propulsion may be selected. The cowling or exterior surface 12 of the propulsion unit 10 may have a tapered area or section 50 as necessary. Fins (not shown) or other means for steering the UUV V may be mounted with the steering unit 10 or any other segment 14 to provide directional control and stabilizing control to the assembled UUV V.

Alternatively, if the UUV V is tethered as shown in FIG. 5, a separate propulsion unit may not be needed and the section 14 that includes the attachment point 42 substitutes for or acts as the propulsion unit 10 and directional control of the UUV V is predominately achieved through movement of the surface ship 44 that is towing the UUV V while it is submerged. In such an alternative arrangement the UUV V can be solely assembled from one or more interchangeable modules 14.

Each module 14, although scalable up or down, may be a 12″ diameter 52 encapsulated segment, for example. Further, an optional outer covering or surface 26 may be applied or used to encompass all the modules or sections for further streamlining of the modular UUV V in relation to the fluid's characteristics during the mission. Such a covering could be a simple spray on material that is selected for radar reflection, sound absorption or the like.

Each interchangeable module 14, propulsion or steering unit 10, and the nose cone 22 may have a cast U-channel 54 with pins 56 that enable the modules to slide onto a mechanical backbone 58 to form the completed modular UUV V. Referring particularly to FIG. 3, a U-channel or rail 54 is shown with pins 56 that slid onto the extrusion 58 to secure the individual components or segments 10, 14, or 22 into the completed UUV V.

Alternatively, the modular vehicle V may have a truss system 60 as shown in FIG. 4 for each module or other component such as the propulsion unit 10 or nose cone 22 that is connected with V-band clamps (not shown) or the like at rings or edges 62 to join the individual selected modules or sections 10, 14, or 22 into the completed modular UUV V.

In addition to mechanical standardization, all electrical connections and connectors on the module are standardized as well. With standardized of design, components, and processes there are reductions in cost through quantity production of standard modules. Such a design yields a reduction in cost that enables the first expendable UUV V.

Formation of an Encapsulated UUV Module

An encapsulated module 14 for an unmanned underwater vehicle (UUV) V is formed with an operational component 16 and encapsulating material 60. The encapsulant 60 forms a rigid capsule or module surrounding the operational component 16. The capsule 14 has at least one exterior surface 18 that assists in forming the exterior surface 26 of the UUV V when the capsule 14 is combined into the UUV V.

The modules of the UUV V or even the complete UUV V itself, as desired, may be formed from an encapsulating material protecting the operational mechanical and electrical components. The encapsulating material provides protection for the electronic and other operating components from water intrusion, crushing due to pressures on the module at a depth below the water surface, and other factors affecting the operability of the electronic components.

The encapsulant, by way of example, may be a three part mixture 60, which is initially moldable and flowable, comprising a polyurethane 62 (EN-9 from the manufacturer Conap may be used by way of example), glass microspheres 64 (K20 from 3M may be used for this component), and a wetting agent 66 (Dow Corning 29, as example).

The mixture ratio of glass microspheres 64 and the types of glass microspheres may be altered as required to achieve the necessary density appropriate for the cruising depth and pressure of the vehicle for the particular mission profile. This three part mixture 60 is then used to encapsulate electronic components such as batteries 36 or other operational components 16, with seemingly few or no unfavorable effects. Typically, the encapsulant material 60 begins as a flowable liquid. The operating or desired components are placed in a mold 68 appropriate for the desired outline of the UUV module. The encapsulating material 60 is then poured into the mold 68 about the selected operating components suitable for the module being crafted. The encapsulant material 60 is then left to dry or cure, which hardens the encapsulant material 60.

The mold 68 may be formed from paper or other materials compatible with the encapsulant mixture 60 with provisions or cut-outs 70 excluding the flowable encapsulant material 60 from encroaching into the space for the rail system 54 as shown in FIG. 3.

Additionally, the truss system 60 can be molded into the encapsulated module to provide substantial strength and exceedingly rigidity when combining the various modules into the UUV.

The suggested encapsulant has been used to create a sample vehicle V with an embedded single board computer and batteries. The sample unmanned underwater vehicle V was pressure tested and this encapsulant was found to protect the operational single board computer to 1050′ and the batteries to 6750′ ft.

The formation of a module formed without undesired voids and from an essentially solid encapsulant eliminates or substantially reduces the chances of a crushing of the UUV module from the pressure about the UUV module resulting from the water/fluid column pressure above the UUV V.

The density of the encapsulated UUV module may be adjusted to provide neutral buoyancy for the UUV V at the selected operating depth when considering other factors such as temperature and salinity at the operating depth. Weighted spheres or other objects 72 may be added to make the overall density of the encapsulated UUV module appropriate. Such weighted objects 72 can be formed from materials having a higher or lower density than the surround encapsulant material 60 to adjust the overall density of the encapsulated UUV module to the desired value for the assigned mission. Preferably the weighted objects 72 are rigidly formed so as to not degrade the crush resistance of the encapsulated UUV module.

Depending on the type of encapsulating material used, it may be possible to add a “dissolving” material to return the hardened encapsulated module into a liquefied state thereby permitting the removal or retrieval of the operating component separate from the encapsulant material 60.

The present invention is truly novel because of the design and manufacturing techniques used. It advances the state of the art for UUV systems and provides an architecture that could be used industry wide. The techniques described yield functionality, performance, and reliability that is unique for a typical unmanned underwater vehicle. The present invention produces a UUV that is less expensive to manufacture than current systems.

Advantages of the present invention as compared to known devices include improved crush resistance for the UUV; a non-proprietary design, easily reconfigured and upgraded, lower cost due to standardized components making the UUV; and, increased reliability due to a connectorless design and the resistance to the degrading impacts of water and pressure.

The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction may be made without departing from the spirit of the invention.

Claims

1. An encapsulated module for an unmanned underwater vehicle (UUV) comprising:

an operational component;

encapsulating material forming a rigid capsule surrounding the operational component; the capsule having at least one exterior surface assisting in forming the exterior surface of the UUV when the capsule is combined into the UUV; and

the encapsulating material further including weighted objects for adjusting desired buoyancy of the UUV.

2. The invention of claim 1 wherein the completed UUV is formed comprising a single module.

3. The invention of claim 1 further including means for joining the encapsulated module with other encapsulated modules to form the UUV.

4. The invention of claim 1 further including means for conveying information out of the capsule to other capsules or a support station.

5. The invention of claim 1 wherein the encapsulating material is formed from a mixture of a polyurethane component and a wetting agent component.

6. The invention of claim 5 wherein the weighted objects comprise beaded material.

7. A method for preparing an encapsulated module for an unmanned underwater vehicle (UUV) comprising:

positioning an operational component into a mold;

introducing an encapsulating material into the mold forming a rigid capsule surrounding the operational component; the capsule having at least one exterior surface assisting in forming the exterior surface of the UUV when the capsule is combined into the UUV; and,

introducing into the encapsulating material weighted objects for adjusting desired buoyancy of the UUV.

8. The method of claim 7 wherein the completed UUV is formed comprising a single module.

9. The method of claim 7 further including means for joining the encapsulated module with other encapsulated modules to form the UUV.

10. The method of claim 7 further including means for conveying information out of the capsule to other capsules or a support station.

11. The method of claim 7 wherein the encapsulating material is formed from a mixture of a polyurethane component and a wetting agent component.

12. The method of claim 11 wherein the weighted obiects comprise beaded material.