Patent Publication Number: US-2013240057-A1

Title: Pre conditioned air duct storage and deployment reel apparatus

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     None. 
     FIELD OF THE INVENTION 
     This invention relates to a powered reel apparatus for storage and deployment of duct for the supply of pre conditioned air for the heating and cooling of the interior of an aircraft while parked at an airport. 
     BACKGROUND OF THE INVENTION 
     Commercial aircraft are equipped with an auxiliary power unit, or APU, to supply electrical power while the aircraft is parked on the ground and the engines are not running. A function of the APU is to power the aircraft on-board air conditioning system, however, the APU is a source of both high noise and also high carbon emissions. Recently most airports have come under the directive of regulations targeting a reduction in noise and also a reduction of the carbon pollution, and as a result, it is now required to shut down the aircraft engines and the APU and to supply pre conditioned air from an external source to aircraft parked at a terminal during the unloading and loading interval. 
     These pre conditioned air sources can be portable units mounted to a trailer or integrated to a vehicle platform, or stationary mounted units attached to the jet-bridge or terminal building. If the unit is portable it is simply driven to close proximity of the aircraft and a short duct is coupled between the portable air source and the aircraft inlet to convey the pre conditioned air. If the unit is stationary, however, then the problem of conveying the pre conditioned air to the aircraft is not so easily solved. 
     In U.S. patent to Anderson et al, U.S. Pat. No. 3,399,545, there is disclosed a longitudinally expandable duct system that is mounted to the underside of a telescoping passenger loading bridge. The position of two points of the duct is fixed relative to two moveable sections, preferably the end sections, of the bridge. Thus the bridge and the duct are integrated in a single unit, both expanding together for use, and contracting together for storage. A supporting cable extends through the interior of the duct along the top surface thereof between the two relatively fixed points. Preferably the cable is fastened on one end, and the other end is wound on a reel maintaining a substantially constant tension on the supporting cable. 
     In U.S. patent to Krzak, U.S. Pat. No. 4,357,860, there is disclosed a telescoping conduit for directing air at moderate pressures to a waiting aircraft along a telescoping bridge. The telescoping conduit includes a number of telescoping tubes suspended beneath the segments of a telescoping bridge. The tubes are coaxially supported below the bridge walkway by adjustable brackets, and one tube is mounted to each bridge segment. This means of suspension allows the tubes to telescopically extend and retract, or nest, to a maximum degree while providing support for the tubes at each end. The tubes are sealed typically with an O-ring at one end of each tube. The sealing portion of the tube, around which the O-rings are seated, is made of a somewhat flexible material which acts as a bearing and accommodates slight misalignment. A roller cage acts to center the nesting tubes so that a wiper seal between the tubes does not become permanently deformed. 
     The aforementioned two patents disclose an apparatus meant to convey the pre conditioned air duct to the end of the passenger bridge, however, the air inlet connector on the aircraft may be a distance of up to 100 feet away. And a means of deploying and storage of the duct is not yet solved. 
     As can be expected pre conditioned air duct can be rather large to accommodate the necessary airflow to control the internal environment of a large aircraft. For example, these hoses can have an inner diameter on the order of 8 inches to 14 inches. It can be appreciated that these ducts, due to their diameter and their length, can be quite heavy, and weigh in excess of 75 pounds. Operators must move these heavy ducts across the surface of the airport tarmac and wind them up to store them between aircraft. 
     Referring to U.S. patents to Bombardi et al, U.S. Pat. No. 6,776,705, U.S. Pat. No. 6,821,201, and U.S. Pat. No. 6,834,668, there is disclosed an apparatus for supplying conditioned air for heating and cooling to an aircraft. The apparatus has a container having a length defined by a first end and a second end. A flexible hose is provided within the container and a retractor may engage the hose and pull the hose from the container. The container may deliver the hose to the aircraft via the retractor. In addition, the retractor may also retract the hose into the container when the hose is not needed. The retractor may be released from the hose and the container, allowing the hose to be pulled manually from the container. 
     The Bombardi patents disclose pre conditioned air systems that are mounted to the passenger bridge and deploys the amount of hose required to suit the length of a particular aircraft, however, the system is technically complex with many moving parts and drive belts that can wear and break. Additionally, these types of systems are relatively expensive. 
     Other commercial devices are available to provide storage to the pre conditioned air duct between the departure of one aircraft and the arrival of the next. These types of electrically driven storage and deployment devices consist of chain driven spools that utilize bicycle type chain, sprocket gears, and pinion gears connected to a motor for the drive system. End of travel limit switches are provided to stop the drive system when the duct is fully deployed or fully retracted and these limit switches are mechanically actuated via additional chains, sprockets, and an acme screw device. While comparatively less expensive than the Bombardi style systems, these types of systems are maintenance intensive and care has to be taken to grease the chain and drive systems regularly and adjust the chain tension due to chain stretching over time. 
     A need, therefore, exists over the prior art, for a relatively inexpensive, low maintenance, and easily configurable storage and deployment system for duct used in the supply of pre conditioned air for the heating and/or cooling of the interior of commercial aircraft while parked at the airport terminal. 
     SUMMARY OF THE INVENTION 
     The pre conditioned air duct reel apparatus includes a mounting frame rotatably supporting a plenum reel assembly comprising a first side frame mounting an electric reversible gear drive assembly, the plenum reel assembly first end drivenly connected to the gear drive shaft. The axially opposite, second side frame mounts a rotary air swivel mechanism having a rotary inner portion fixedly connected to the plenum reel assembly second end about an opening corresponding to the internal diameter of the rotary air swivel rotary inner portion, the rotary air swivel mechanism having a stationary outer portion that rotatably mounts the plenum reel second end to the second side frame about an air inlet opening corresponding to the internal diameter of the air inlet swivel mechanism. Adjustable rotary limit switch cams are provided to control limit switches to de-energize the reversible drive motor at the limit of travel for the duct deployment or retraction to prevent over winding or under winding of the duct. 
     Additional features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with references to the accompanying drawings in which like characters represent like parts throughout the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a perspective view of an aircraft connected via a duct to a pre conditioned air storage and deployment reel apparatus according to an embodiment of the present invention; 
         FIG. 2  illustrates a perspective view of the front gear drive side of an embodiment of the reel apparatus shown in  FIG. 1 ; 
         FIG. 3  illustrates a perspective view of the front air inlet side thereof; 
         FIG. 4  illustrates a front elevation view thereof; 
         FIG. 5  illustrates a rear elevation view thereof, 
         FIG. 6  illustrates a right side elevation view thereof; 
         FIG. 7  illustrates a left side elevation view thereof; 
         FIG. 8  illustrates a top plan view thereof; 
         FIG. 9  illustrates a bottom plan view thereof; 
         FIG. 10  illustrates a cross-sectional view of an embodiment of the present invention taken along line  10 - 10  of  FIG. 7 ; and 
         FIG. 11  illustrates a cross sectional view of an embodiment of the present invention taken along line  11 - 11  of  FIG. 8 . 
     
    
    
     DRAWINGS 
     Reference Numerals 
     
         
           1  Aircraft 
           3  Duct Reel Apparatus 
           5  Pre Conditioned Air Ducting 
           7  Aircraft Inlet 
           9  Duct Clamp 
           10  Frame Assembly 
           11  Upper Frame 
           11 A Side Frame 
           11 B Side Frame 
           12  Plenum Reel Assembly 
           13 A Side Flange 
           13 B Side Flange 
           14  Air Duct Outlet Adaptor 
           16  Air Duct Inlet Adaptor 
           18  Plenum Reel Outlet Flange 
           20  Plenum Reel Wrapper 
           21  Gear Drive Assembly 
           22  Gear Drive Bearing 
           24  Gear Drive Housing 
           26  Drive Shaft 
           28  Gear Drive Hollow Shaft 
           30  Drive Shaft Key 
           32  Drive Motor 
           34  Limit Switch Cover 
           36  Gear Drive Mount Bracket 
           38  Limit Switch Rotary Shaft 
           40  Limit Switch Cam 
           42  Limit Switch 
           44  Limit Switch Mount 
           46  Drive Shaft Hub 
           48  Air Inlet Rotary Swivel Assembly 
           50  Outer Race 
           52  Inner Race 
           54  Swivel Spacer Mount 
           56  Air Inlet Bearing 
           58  Inner Race Bolt 
           60  Inner Race Nut 
           62  Outer Race Bolt 
           64  Outer Race Nut 
           66  Hub Bolt 
           68  Mount Bolt 
           70  Worm Gear 
           72  Motor Shaft 
       
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring generally to  FIG. 1 , an aircraft designated by the reference numeral  1 , is illustrated in its parked position while the pre conditioned air ducting  5  is connected at a second end to aircraft inlet  7 , the first end being connected to duct reel apparatus  3  by duct clamp  9 . While  FIG. 1  illustrates pre conditioned air ducting  5  in the context of supplying conditioned air to an aircraft  1 , it should be appreciated by one skilled in the art that pre conditioned air ducting  5  may be used in various other settings, such as mining, or construction. 
     It should be appreciated by one skilled in the art that pre conditioned air ducting  5  is generally constructed of a heavy duty fabric material and will be flat when not being pressurized by the pre conditioned air to be supplied to aircraft  1 . Pre conditioned air ducting  5  may be configured in any length required in order to reach air conditioning inlet  7 , and duct reel apparatus  3  sized accordingly to store this required length. Duct reel apparatus  3  is configured to connect to a pre conditioned air delivery system and may be attached to a passenger bridge or to a fixed location, such as a terminal building, or mounted to a mobile cart, or vehicle. Pre conditioned duct assembly  5  must be disconnected at air inlet  7  from aircraft  1  and retracted and stored on duct reel apparatus  3  when aircraft  1  is in motion, such as when it taxis to and from a terminal. When aircraft  1  is parked, pre conditioned air ducting  5  is deployed from the duct reel apparatus  3  and connected to the aircraft  1  at aircraft inlet  7  to alleviate the need for the use of the air conditioning system of aircraft  1  itself. 
     Referring now to the drawings, and particularly to  FIGS. 2-11 , there is shown a duct reel apparatus generally designated  3  including a generally U shaped mounting frame assembly  10  having an upper frame  11  and axially spaced, first and second, generally parallel side frames  11 A,  11 B, supporting a plenum reel assembly  12  and gear drive assembly  21 . Plenum reel assembly  12  includes axially spaced, annular side flanges,  13 A,  13 B fixedly joined to axial opposite ends of plenum reel outlet flange  18  and plenum reel wrapper  20 , and having a longitudinal axis defining an axis of rotation about the centerline of drive shaft  26  and air inlet rotary swivel assembly  48 . Plenum reel outlet flange  18  having air duct outlet adaptor  14  for the connecting of the pre conditioned air duct  5  allowing for an air outlet means of the plenum reel assembly  12 . Side flange  13 A having a drive shaft hub  46  fixedly mounted about the flange center axis by a plurality of hub bolts  66  supporting a first end of drive shaft  26 , a second end of drive shaft  26  being supported by gear drive hollow shaft  28 , the first and second ends of drive shaft  26  being rotatably fixed by drive shaft key  30 . 
     A reversible electric gear drive assembly  21  is fixedly attached to side frame  11 A and gear drive mount bracket  36  by mount bolts  68  attached to gear drive housing  24 . As electrical power is applied to drive motor  32 , motor shaft  72  fixedly connected to worm gear  70  rotate gear drive hollow shaft  28  rotatably mounted within gear drive bearings  22  and fixedly attached to drive shaft  26 . The axis of rotation of drive shaft  26  is coextensive with the axis of rotation of plenum reel assembly  12 . A first and second limit switch cam  40  is rotatably adjustable about the center of limit switch rotary shaft  38  to actuate a corresponding first and second limit switch  42  fixedly attached to limit switch mount  44 , mounted internal to limit switch cover  34 . Limit switch rotary shaft  38  drivenly connected to the axis of rotation of plenum reel assembly  12  at a fixed ratio allowing the plenum reel assembly  12  to rotate the number of times to retract or deploy the length of pre conditioned air ducting  5  before limit switch rotary shaft  38  revolves one time causing limit switch cam  40  to actuate limit switch  42  and de-energizes the motor. Limit switches  42  being electrically connected to an external control means (not shown), a first limit switch cam  40  is adjusted to actuate a first limit switch  42  for controlling the number of revolutions of plenum reel assembly  12  in a first direction, a second limit switch cam  40  is adjusted to actuate a second limit switch  42  for controlling the number of revolutions of plenum reel assembly  12  in an opposite direction to prevent over winding or unwinding of the pre conditioned air ducting  5  as the duct is retracted or deployed to aircraft  1 . As the motor is energized to rotate the plenum reel assembly  12  in a retracting or winding direction the duct is pulled across the ground or airport tarmac and is collapsed to a flat state as it is wound about the reel until the length is fully retracted and limit switch  42  de-energizes the motor. If the motor is energized to rotate the plenum reel assembly  12  in the opposite angular direction, the duct is deployed or unwound from the reel until the corresponding limit switch  42  de-energizes the motor. 
     Air inlet rotary swivel assembly  48  has an outer race  50  disposed radially around inner race  52  axially connected by air inlet bearing  56  being mounted in grooves formed on the inward radial face of outer race  50  and corresponding grooves on the outer radial face of inner race  52 . Inlet bearing  56  consisting of an engineered polymer such as a grease impregnated nylon material to minimize friction and allow the outer race to rotate freely and coextensively about the inner race. Inner race  52  is fixedly mounted to swivel spacer mount  54  and side flange  13 B by a number of inner race bolts  58  and inner race nuts  60 , side flange  13 B having an opening corresponding to inner race  52  internal diameter to allow pre conditioned air to flow freely into plenum reel assembly  12 . Outer race  50  is fixedly mounted to side frame  11 B and air duct inlet adaptor  16  with a number of outer race bolts  66  and outer race nuts  64 , side frame  11 B and air duct inlet adaptor  16  having an opening corresponding to the outer race  50  internal diameter to allow pre conditioned air to flow freely into the plenum reel assembly  12  from an external air conditioning apparatus (not shown) connected to air duct inlet adaptor  16 . Due to the provision of the air inlet rotary swivel assembly  48  the air inlet at the air inlet duct adaptor is not rotated while remaining in pressurized communication with the plenum reel assembly  12  as it is rotated in a deploying or retracting direction. Plenum reel assembly  12  comprising an internal air chamber directing air flow from a fixed air duct inlet adaptor  16  to a rotatable air duct outlet adaptor  14 , and an external surface for the winding and storage of pre conditioned air ducting  5  when not required for providing pre conditioned air to waiting aircraft  1 . 
     While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.