Abstract:
A multi-axial telescoping support structure positioning system includes a frame having first and second opposed vertical sections. An axle is rotatably coupled to the first vertical section of the frame. A first rotary actuator has a first end mounted to the second vertical section of the frame and a second end rotatable with respect to the first end attached to the axle to rotate the axle. A telescoping support structure has a plurality of telescoping sections extendable from a base section along a longitudinal axis. A second rotary actuator is attached to the base section of the telescoping support structure at an intermediate position along the length of the base section and to the axle at a position between the first and second vertical sections of the frame to tilt the telescoping support structure about a tilt axis aligned perpendicular to the longitudinal axis of the telescoping support structure.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application is a continuation of U.S. patent application Ser. No. 15/054,263, filed on Feb. 26, 2016 which is a continuation of U.S. patent application Ser. No. 14/682,296, filed on Apr. 9, 2015, now U.S. Pat. No. 9,309,686, issued Apr. 12, 2016 which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/977,949, filed on Apr. 10, 2014, the contents of which are incorporated in this disclosure by reference in their entirety. 
     
    
     BACKGROUND 
       [0002]    Prior art does exist for an extendable mast connected to a skid via a linkage that allows pivoting of the mast with respect to the skid. A typical prior-art mast positioning system is taught by U.S. Pat. No. 7,997,388. This design is inherently limited in the orientation of the mast that it is able to achieve because of the type of actuators used, the positioning of the actuators relative to each other, the existence of a pivot point at the far end of the mast and by the linkage that is used to orient the mast. Due to all of these limitations, the system is only capable of orienting the mast in a substantially vertical position on a maximum slope of up to about 8 degrees. 
         [0003]    Therefore, there is a need for an improved multi-axial mast positioning system that does not suffer from these limitations. 
       SUMMARY 
       [0004]    According to one embodiment of the invention, A multi-axial mast positioning system includes frame having two opposed vertical support sections, an axle coupled to the frame and rotatable around a first axis passing through the opposed vertical sections of the frame, and a mast coupled to the axle and rotatable about a second axis aligned with and perpendicular to the first axis. 
     
    
     
       DRAWINGS 
         [0005]    These and other features, aspects and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where: 
           [0006]      FIG. 1  is a diagram showing an illustrative embodiment of the present invention mounted on the bed of a pickup truck. 
           [0007]      FIG. 2  is a diagram showing a view of an illustrative embodiment of the present invention in a common stowed position. 
           [0008]      FIG. 3  is a diagram showing another isometric view of an illustrative embodiment of the present invention in a common stowed position. 
           [0009]      FIG. 4  is a diagram showing a side view of an illustrative embodiment of the present invention in a common stowed position. 
           [0010]      FIG. 5  is a diagram showing an isometric view of an illustrative embodiment of the present invention in a common at the ready position. 
           [0011]      FIG. 6  is a diagram showing an isometric view of an illustrative embodiment of the present invention in a common at the ready position with portions of enclosure covers cut away to show inclinometers. 
           [0012]      FIG. 7  is a diagram showing a front view of an illustrative embodiment of the present invention in a common at the ready position. 
           [0013]      FIG. 8  is a diagram showing an isometric view of an illustrative embodiment of the present invention in a side-to-side tilted at-the-ready position. 
           [0014]      FIG. 9  is a diagram showing a front view of an illustrative embodiment of the present invention in a side-to-side tilted at-the-ready position. 
           [0015]      FIG. 10  is a diagram showing a side view of an illustrative embodiment of the present invention in a front-to-rear tilted at-the-ready position. 
           [0016]      FIG. 11  is a diagram showing an isometric view of an alternate illustrative embodiment of the present invention in a common stowed position. 
           [0017]      FIG. 12  is a diagram showing an isometric view of the alternate illustrative embodiment of the present invention of  FIG. 10  in a common at-the-ready position. 
           [0018]      FIG. 13  is a diagram showing an illustrative rotary actuator that can be used in the present invention. 
           [0019]      FIG. 14  is a block diagram showing exemplary control logic that may be used in the present invention. 
           [0020]      FIG. 15  is a block diagram showing an exemplary control configuration that may be used in the present invention. 
           [0021]      FIG. 16  is a flow diagram showing an illustrative sequence for operating the multi-axial mast positioning system of the present invention. 
       
    
    
     DESCRIPTION 
       [0022]    According to one embodiment of the present invention, a multi-axial mast leveling system according to the present invention is capable of positioning a mast at any desired orientation independent of the pallet (or other support structure) by which it is supported. This capability is achieved by use of at least two continuous rotation actuators oriented in two planes that are orthogonal relative to each other. 
         [0023]    The multi-axial mast leveling system  10  of the present invention is particularly useful for deploying masts mounted on mobile platforms, such as the bed of a pickup truck  12  as illustrated in  FIG. 1 . The mast  14  depicted in the system of  FIG. 1  includes a radar dome  16 , a daylight camera  18 , and a night vision camera  20 , although persons of ordinary skill in the art will appreciate that the payload shown in  FIG. 1  is merely illustrative and non-limiting, and that the payload placed on the mast  14  in any particular application will depend solely on the application. 
         [0024]    One illustrative embodiment of the multi-axial mast leveling system  10  of the present invention is shown in  FIGS. 1-10 . 
         [0025]    According to one embodiment of the invention, the multi-axial mast positioning system of the present invention includes frame  22  having two opposed vertical support sections  24 , an axle  26  coupled to the frame and rotatable by a rotary actuator  28  around a first axis passing through the opposed vertical sections of the frame. The mast  14  is coupled to the axle  26  and is also rotatable by a rotary actuator  30  about a second axis aligned with and perpendicular to the first axis. One type of actuator that can be used in the present invention is identified as model number ZKE9C-61MHA-1205RC-DB215 slewing drives manufactured by Kinematics Mfg. of Phoenix, Ariz. However any rotational output gearbox or actuator (whether electrical, mechanical or hydraulic) can be used. These rotary actuators are particularly useful, among other reasons, due to their high gear ratio (61:1) which prevents back-drive of the rotary actuators and because of their high backward holding torque capabilities. The rotary actuators are able to rotate the mast 360° about two orthogonal axes, which allows the mast to be oriented to any desired orientation. This can be an operational orientation or an orientation that facilitates easy access to the payload atop the mast in order to make adjustments, perform maintenance, installation or removal. This arrangement of the rotary actuators  28  and  30  relative to each other also allows for each rotary actuator to act on the mast independent of all other actuators and without being limited by the mechanical limitations of its own range of movement, the range of movement of the other rotary positioners, or the physical limitation imposed by the structure of the mast or the pallet (or other supporting structure). 
         [0026]    The mast  14  is preferably a telescoping mast and may be extended and retracted using a motor drive unit  32  as is known in the art. One example of such a mast is disclosed in U.S. Pat. No. 8,413,390. 
         [0027]    Attachment of the mast  14  to the frame  22  (pallet or other support structure) occurs with at least one rotary positioner ( 28 ) being affixed to the mast at an intermediate position along the length of the mast and then that same rotary positioner being attached to the support structure. By at least one rotary actuator ( 28 ) acting on the mast at an intermediate position along the length of the mast, the mast requires a smaller linear displacement in which to achieve the same angular displacement compared to a system that would use either end of the mast as the pivot point. 
         [0028]    The use of rotary actuators  28  and  30  allows each actuator to act in a motion concentric with the axis of rotation normal to the plane to which they are affixed. This feature eliminates the need for any multi-member linkage to act on the mast  14  to cause it to pivot about an offset pivot point. Elimination of a multi-member linkage improves the rigidity of the system while eliminating potential failure points of the system that would exist at all of the pivotal connections inherent in a multi-member linkage. 
         [0029]    The embodiment depicted in  FIGS. 2 through 10  uses a first rotary actuator  28  to drive axle  26 . A second rotary actuator  30  is affixed to axle  26 . An alternate embodiment of the multi-axial mast positioning system of the present invention as shown in  FIGS. 11 and 12  utilizes a first rotary actuator  28  to rotate the mast  14  around a first axis passing through the opposed vertical sections of the frame as in the embodiment depicted in  FIGS. 2 through 10 . The frame  22  is mounted to a second rotary actuator  38  that is used to rotate the entire frame  22 . Together, actuators  28  and  38  can level mast  14  in both X and Y directions. This embodiment does not use rotary actuator  30 . 
         [0030]      FIG. 13  depicts an illustrative rotary actuator that can be used with the present invention. The actuator includes a motor  42  driving a worm gear disposed inside of worm gear enclosure  44 . The worm gear drives a planetary gear inside of planetary gear enclosure  46 . 
         [0031]    The system is controlled by utilization of an integrated controller  50  to drive rotary actuators  52  and  54  as shown in  FIG. 14 . When the mast  14  is ready to be deployed, the controller  50  receives input from either an array of sensors or a single sensor (reference numeral  56 ) that is affixed to the pallet (or other support structure). In one embodiment of the invention, sensors  32   x  and  32   y  attached to the frame (shown in a cutout portion of an enclosure  34  in  FIG. 6 ) report the inclination of the frame to the control system. Sensors  58  (sensors  34   x  and  34   y  shown in a cutout portion of an enclosure  36  in  FIG. 6 ) attached to the mast  14  reports the inclination of the mast to the control system. 
         [0032]    Next, it receives input from either a human or non-human operator (reference numeral  58 ) indicating what the desired orientation is relative to the orientation of the pallet (or other support structure). Once the desired orientation has been sent to the controller  50 , the controller  50  then actuates the rotary actuators  52  and  54  to begin orienting the mast. As the mast is being oriented, the controller receives real-time input from either an array of sensors or a single sensor (reference numeral  58 ) affixed to the mast  14 . It continually compares this input from the sensor(s) on the mast  14  to the desired orientation. Once all inputs have reached the predetermined position as determined by the controller based on the human or non-human input, the mast is ready to be extended. 
         [0033]      FIG. 15  is a block diagram showing an exemplary control system  60  that may be used in the present invention. The controller system  60  can operate from a fixed voltage supply, such as 24V, shown at reference numeral  62 . Persons of ordinary skill in the art will appreciate that the control system  60  depicted in  FIG. 15  is merely illustrative and that other additional functions or fewer functions could be provided in other embodiments. 
         [0034]    The control system  60  shown in  FIG. 15  can employ a pendant or other control panel  64  connected to the other components in the control system  60  wirelessly or by a suitable cable. Provision may also be made to provide an Internet interface  66  to allow the control functions to be implemented remotely. Internet interfaces are well known in the art. 
         [0035]    The control module  68  can employ a suitable microcontroller to implement all of the functions described. Implementation of such a control module  68  and microcontroller is well within the level of ordinary skill in the art. 
         [0036]    The Extend/Retract functions used to extend and retract the mast  14  can be momentary functions enabled by a momentary switch  70 . When Extend is selected, the X-slew motor  72  is rotated in the CW direction until the switch  70  is released. When Retract is selected, the Y-slew motor  74  is rotated in the CCW direction until the switch  70  is released. 0V on both X-slew Motor+ and X-slew Motor− lines stop the X-slew motor and 0V on both Y-slew Motor+ and Y-slew Motor− lines stop the Y-slew motor. If the mast  14  reaches the extend limit as sensed by the height indicator  76 , further extension of the mast  14  will be inhibited. Likewise if the mast  14  reaches the retract limit as sensed by the height indicator, further retraction of the mast  14  will be inhibited. Both Extend and Retract functions will only operate when the MAINTENANCE switch is in NORMAL mode of operation. 
         [0037]    The Extend Indicator  78  may be an LED that shows the status of the mast  14  when the mast is being extended. During the extend operation the Extend Indicator LED may be caused to flash, e.g., at a rate of approximately 1 Hz when the mast is being extended. If the extend limit is reached the Extend Indicator  78  LED may be caused to remain ON, and the mast  14  will no longer extend. When the extend function is not selected the Extend Indicator  78  LED will remain OFF. 
         [0038]    The Retract Indicator  80  may be an LED that shows the status of the mast when the mast is being retracted. During the retract operation the Retract Indicator  80  LED can be caused to flash, e.g., at a rate of approximately 1 Hz when the mast is being retracted. If the retract limit is reached the Retract Indicator  80  LED can be caused to remain ON, and the mast will no longer retract. When the retract function is not selected the Retract Indicator  80  LED will remain OFF. 
         [0039]    The Auto Level function is momentary function used to level the mast that may be enabled by a momentary switch  82 . The mast  14  will not Auto Level unless the mast  14  is fully retracted. When Auto Level is selected the mast is automatically leveled. The signal must remain true until Level is reached, if it is not the function will terminate. Auto Level is achieved when the Auto Level Indicator is on. The Auto Level function will only operate when the MAINTENANCE switch is in the NORMAL mode of operation, Maintenance Indicator HIGH. 
         [0040]    The Auto Level Indicator  84  may be an LED which shows the status of the Auto Level operation. When the Auto Level mode is selected by switch  82  the Auto Level Indicator  84  can be caused to begin flashing, e.g., at a rate of approximately 1 Hz, and continue flashing until the operation is complete, then it will remain illuminated, indicating that the operation is complete. The Auto Level Indicator  84  will remain ON, 1 as long as the mast  14  is level. When the mast  14  is not level the Auto Level Indicator will be OFF. The Auto Level function cannot be selected unless the mast is fully retracted and the Retract Indicator  80  is ON. 
         [0041]    The Auto Stow function is a momentary function selected by switch  82  used to stow the mast  14 . The mast will not Auto Stow unless the mast  14  is fully retracted. When Auto Stow is selected by switch  82  the mast  14  is automatically stowed. The signal must remain true until Stow is reached, if it is not the function will terminate. Auto Stow is achieved when the Auto Stow Indicator  86  is on. The Auto Stow function will only operate when the MAINTENANCE switch  88  is in the NORMAL mode of operation. 
         [0042]    The Auto Stow Indicator  86  may be an LED which shows the status of the Auto Stow operation. When the Auto Stow mode is selected the Auto Stow Indicator  86  can be caused to begin flashing, e.g., at a rate of approximately 1 Hz, and continue flashing until the operation is complete, then it will remain illuminated, indicating that the operation is complete. The Auto Stow Indicator  86  will remain ON, as long as the mast  14  is stowed. When the mast is not stowed the Auto Stow Indicator  86  will be OFF The Auto Stow function cannot be selected unless the mast is fully retracted and the Retract Indicator  80  is ON. 
         [0043]    The Excessive Slope Indicator  90  may be an LED which will turn ON if the system has exceeded a predetermined leveling range of the mast in either the X or Y axis. If the Excessive Slope Indicator  90  is on Extend, Retract, Auto Level, and Auto Stow will not operate until the system is re-orientated within the limits of the system. 
         [0044]    The Low Voltage Indicator  92  is a LED which will turn ON if the voltage to the system is at such a level that it could prevent the system from preforming normal operations. This voltage level is dependent on the particular system and is typically set at the factory. 
         [0045]    The Maintenance Indicator  94  may be an LED which will turn ON when the system is in the Maintenance mode of operation due to operation of switch  88 . In one embodiment of the invention, to place the system in Maintenance mode the control box front panel must be opened and the Maintenance switch  88  placed in Maintenance position. The only functions the system can perform are the ones provided on the maintenance panel, i.e. Limited Extend, Retract, and full travel in the X-axis. The Limited Extend and Retract functions are usually programmed at the factory. 
         [0046]    The System Indicator  96  can be configured to work on flash codes. 
         [0047]    The Switched Power function at switch  98  turns power onto the system. 
         [0048]    The On/Off Indicator  100  will indicate if the system power is ON. 
         [0049]    Manual control of the x and y actuators may be implemented by switches  102  and  104 , respectively. Whether working in an automatic mode or a manual mode, inputs from x and y level sensors  106  on the frame  22  are provided to the control module, as are then outputs of the X position sensor  108  and Y position sensor  110  associated with the actuators. 
         [0050]    The system is capable of acting on a mast and pallet combination that is static or one that is in a dynamic environment such as a moving vehicle. In the case of the moving vehicle, the system would remain active at all times and continually orient the mast to the desired orientation as the slope of the ground changed due to movement of the vehicle. 
         [0051]    The second depicted embodiment of the design shown in  FIGS. 10 and 11  separates the positioning of the rotary actuators allowing for a more compact pallet (or other support structure) to be utilized by the system while still achieving the same performance as the previously depicted embodiment. In this embodiment, at least two rotary positioners are used and at least one is positioned at an intermediate position along the length of the mast and acts directly on the mast at that position. The other rotary positioner has been moved to the outside of the pallet (or other support structure) and acts on the mast by indirectly by rotating the pallet (or other support structure) to which the mast is affixed. This embodiment provides the benefit of a smaller pallet being required in order to achieve the same range of motion afforded by the previous embodiment. 
         [0052]    Referring now to  FIG. 16 , a flow diagram shows an illustrative sequence  120  for operating the multi-axial mast positioning system of the present invention. The sequence starts at reference numeral  122 . 
         [0053]    At reference numeral  124  the mast is tilted from the stow position. Next, at reference numeral  126  the frame inclination is measured in both the x and y directions using the inclinometers on the frame. At reference numeral  128  it is determined whether the frame inclination angle is too great to ensure the stability of the extended mast and its payload. The actual maximum angle in any given embodiment will depend on engineering considerations particular to that embodiment and will be easily determinable by persons of ordinary skill in the art. 
         [0054]    If the angle is too great, at reference numeral  130  an error is reported and at reference numeral  132  the sequence ends. It can be reinitiated after the vehicle has been repositioned to correct the problem. 
         [0055]    If, at reference numeral  128  the angle was within the acceptable range, the sequence proceeds to reference numeral  134  where the mast is pre-positioned to a nominal plumb position based on the measurements that had previously been made at reference numeral  126 . At reference numeral  136 , an x-orientation reading is taken from the sensors on the mast. If the mast is not plumb in the x direction, the method proceeds to reference numeral  138  where the x-rotation of the mast is corrected. If the mast is plumb in the x direction, the sequence proceeds to reference numeral  140  where a y-orientation reading is taken from the sensors on the mast. If the mast is not plumb in the y direction, the method proceeds to reference numeral  142  where the y-rotation of the mast is corrected. If the mast is plumb in the y direction, the sequence proceeds to reference numeral  144  where the sequence at reference numerals  136 ,  138 ,  140 , and  142  is repeated to perform a fine adjustment. If the fine adjustment has already been made, the sequence proceeds to reference numeral  146 , where the mast extend function is enabled. 
         [0056]    At reference numeral  148 , the mast extension motor is started to extend the mast. This may be a manual operation or an automatic operation in some embodiments of the invention. At reference numeral  150  the process continues to extend the mast until it has reached its maximum height. The sequence then proceeds to reference numeral  152  where the motor is stopped. The sequence ends at reference numeral  132 . 
         [0057]    Although the present invention has been discussed in considerable detail with reference to certain preferred embodiments, other embodiments are possible. Therefore, the scope of the appended claims should not be limited to the description of preferred embodiments contained in this disclosure.