Abstract:
A collapsible component lift for removal and replacement of, for example, a helicopter engine or transmission in a remote location. The lift includes a mast, boom, adjustable support arm and winch. The mast is supported substantially vertical and stands next to the failed helicopter. The boom extends outwardly, over the helicopter during removal and replacement of the component (e.g. engine, transmission) and swivels away from the helicopter to access the component. A strap and winch provide lifting force. An adjustment arm connects between the mast and the boom, forming a triangle with the mast and boom. The collapsible component lift disassembles into component sections that are short enough to be transported in a maintenance helicopter that is flown to the site of the failed helicopter. Preferably, a carrying case is provided for the transportation of the individual components.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application is claiming the benefit of provisional application No. 61/447,873, filed Mar. 1, 2011, the disclosure of which is hereby incorporated by reference. 
     
    
     FIELD 
       [0002]    This invention relates to the field of helicopter maintenance and more particularly to a system for removing and replacing an engine or transmission of a helicopter or other device at the failure location in the field. 
       BACKGROUND 
       [0003]    It is well known that mechanical failures often occur at the worst possible time and location. For many types of vehicles, the disabled vehicle is towed to a repair facility where the failure is diagnosed and fixed. The repair facility has staff, tools, diagnostic machines, etc. for facilitating the repair. With this class of vehicles, towing is performed by pulling the vehicle (e.g. car, boat) using a tow vehicle (e.g. tow truck, tow boat) or, for wheeled vehicles, the vehicle is winched up onto a flat-bed truck and moved to the repair facility. 
         [0004]    These procedures are not available for vehicles that are designed to reach places that are not accessible to such tow vehicles. When such a vehicle is disabled due to mechanical failure, it cannot be towed to the repair facility. Instead, the repair needs to be performed at the location of failure. In particular, helicopters are used to access locations where there are no roads, rivers, or other means for transporting a disabled helicopter back to a service facility. When a helicopter fails in a remote location, such as in a jungle or on a mountain top, it is almost impossible to return the helicopter to a repair facility. Therefore, the repair must be done in the field. 
         [0005]    Minor helicopter repairs such as replacing a fuel pump or battery are routinely performed in the field, but often engine failure is mechanical in nature. Due to the location and weight of the helicopter engine, it is very difficult to perform repairs in the field. Since the helicopter cannot be returned to the repair facility and, often there is no reasonable way to reach the failed helicopter by means other than by a second, functioning helicopter, repair staff are limited to using replacement components that readily fit within the working helicopter to carry the replacement components to the site of the failed helicopter. It is well known that a replacement engine and/or transmission for a helicopter will fit within the cargo hull of a similar helicopter, but replacing the failed component (engine, transmission, etc.) of the failed helicopter in the field is a challenge due to the weight, size and location of the engine. A component hoist is needed to lift the failed component (e.g. engine) out of the inoperable helicopter and substitute the replacement component for the failed component. Unfortunately, existing hoists do not fit within the cargo hull of most helicopters. 
         [0006]    What is needed is a system, apparatus and method for removing and replacing a failed component in the field. 
       SUMMARY 
       [0007]    A system, method and apparatus for removal and replacement of, for example, a helicopter engine or transmission in a remote location includes a mast, boom, adjustable support arm and winch. The mast is held in a substantially vertical orientation by a plurality of legs and leg supports. The boom extends outwardly, over the helicopter during removal and replacement of the component (e.g. engine) and swivels away from the helicopter to access and lower/loft the component (e.g. engine). A strap and winch provide lifting force. The strap passes over/through rollers and over the component and the winch winds or unwinds the strap to lift the component out for the failed helicopter and to set down the replacement or repaired component back into the failed helicopter. In some embodiments, an adjustment arm connects to the mast and the boom forming an adjustable triangle with the mast and boom, providing for height adjustment of the boom to compensate for different sizes of failed helicopters. In some embodiments, the strap passes over a movable trolley and the trolley moves along the boom to adjustably positions the strap. 
         [0008]    The apparatus disassembles into component sections that are short enough to be transported in a maintenance helicopter that is flown to the sight of the failed helicopter. Preferably, a carrying case is provided for the transportation of the individual components of the lift. 
         [0009]    In one embodiment, a helicopter component hoist is disclosed including a mast that has at least two detachable sections including an upper mast section and a lower mast section. The helicopter component hoist has legs, a first end of each leg being affixed to a bottom end of the lower mast section. Collapsible support arms hold the lower mast section in a substantially vertical orientation; a first end of each collapsible support arm is affixed to the lower mast section and a distal second end of each collapsible support arm is attached to a corresponding leg. A boom extends from the upper mast. A first end of the boom is pivotally connected to a top end of the upper mast section An arm has a first end removably connected to the upper mast section and a second end removably connected to an attach point on the boom. A strap is interfaced and slideably held by the boom and also interfaced and slideably held by an upper end of the upper mast section. A first end of the strap extends downward from the boom for engagement with a component of a failed helicopter and a second end of the strap is affixed to a winch which is affixed to the upper mast. The winch is operated to take in or let out the strap, thereby raising or lowering the component. 
         [0010]    In another embodiment, a helicopter component hoist is disclosed including a mast that has at least two detachable sections including an upper mast section and a lower mast section. The helicopter component hoist has legs, a first end of each leg being affixed to a bottom end of the lower mast section. Collapsible support arms hold the lower mast section in a substantially vertical orientation; a first end of each collapsible support arm is affixed to the lower mast section and a distal second end of each collapsible support arm is attached to a corresponding leg. A first end of a boom is pivotally connected to a top end of the upper mast section. A first strap interface is positioned at a second, distal end of the boom and a second strap interface is positioned at the first end of the boom. An arm has a first end that is removably connected to the upper mast section and a second end that is removably connected to any of multiple attachment points on the boom. A strap is slideably held by the first strap interface and slideably held by the second strap interface. A first end of the strap extends downward from the boom for engagement with a component of a failed helicopter and a second end of the strap is affixed to a winch which is affixed to the upper mast. The winch is operated to take in or let out the strap, thereby raising or lowering the component. 
         [0011]    In another embodiment, a helicopter component hoist is disclosed including a mast that has at least two detachable sections including an upper mast section and a lower mast section. The helicopter component hoist has legs, a first end of each leg being affixed to a bottom end of the lower mast section. Collapsible support arms hold the lower mast section in a substantially vertical orientation; a first end of each collapsible support arm is affixed to the lower mast section and a distal second end of each collapsible support arm is attached to a corresponding leg. A boom extends from the upper mast. A first end of the boom is pivotally connected to a top end of the upper mast section and has a first strap interface. A trolley having a second strap interface is slideably interface to the boom and positionable longitudinally along at least a portion of the boom. An arm has a first end removably connected to the upper mast section and a second end removably connected to an attach point on the boom. A strap is slideably held by the first strap interface and slideably held by the second strap interface. A first end of the strap extends downward from the boom for engagement with a component of a failed helicopter and a second end of the strap is affixed to a winch which is affixed to the upper mast. The winch is operated to take in or let out the strap, thereby raising or lowering the component. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which: 
           [0013]      FIG. 1  illustrates a top plan view of an exemplary helicopter with a collapsible component lift. 
           [0014]      FIG. 2  illustrates a front plan view of an exemplary helicopter with the collapsible component lift. 
           [0015]      FIG. 3A  illustrates a side plan view of the collapsible component lift with a trolley boom. 
           [0016]      FIG. 3B  illustrates a side plan view of the collapsible component lift with a static boom. 
           [0017]      FIG. 4  illustrates a perspective view of the collapsible lift with the static boom. 
           [0018]      FIG. 5  illustrates a perspective view of the trolley boom of the collapsible component lift. 
           [0019]      FIG. 6  illustrates a side plan view of the static boom and upper mast of the collapsible component lift. 
           [0020]      FIG. 7A  illustrates an exploded view of the collapsible component lift with a trolley boom. 
           [0021]      FIG. 7B  illustrates an exploded view of the collapsible component lift with a static boom. 
           [0022]      FIG. 8  illustrates a perspective view of an exemplary carrying case for the collapsible component lift shown holding the components of the collapsible component lift. 
       
    
    
     DETAILED DESCRIPTION 
       [0023]    Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures. Although shown specifically to be transported by a helicopter, the collapsible component lift is anticipated to be transported in any way know including, but not limited to, in a backpack, land vehicle, dropped from a parachute, other type of aircraft, etc. Likewise, the collapsible component lift is shown in the repair of a failed helicopter, but is not limited in any way to only the repair of helicopters. 
         [0024]    Referring to  FIGS. 1 and 2 , views of an exemplary helicopter  10  shown with the collapsible component lift  20  will be described. The helicopter  10  is, for example, disabled in a remote location and a maintenance helicopter (not shown) is flown to that location along with the collapsible component lift  20  and whatever replacement components are needed (e.g. engine or transmission). The exemplary helicopter  10  has a fuselage  18  and tail section  16 . In  FIGS. 1 and 2 , the cowling  14  is shown in place, covering the engine and transmission. The cowling  14  is removed to access the engine and transmission. 
         [0025]    The collapsible component lift  20  is positioned near the skids  12 / 13 . A first end of the collapsible component lift legs  50  attaches to the lower mast  22  via a connection point  52  (see  FIG. 2 ) on the collapsible component lift  20 . Level adjusters  55  (see  FIGS. 3A and 3B ) are positioned at a distal end of the collapsible component lift legs  50 . Collapsible support arms  53  interface between the collapsible component lift legs  50  and an upper attach point  23  on the lower mast  22  to keep the lower mast  22  positioned substantially vertically. In some embodiments, stabilizers  51  extend between each of the collapsible component lift legs  50  to maintain substantially equal spacing between the collapsible component lift legs  50 . The stabilizers  51  are anticipated to be either stiff spacing members or, resilient members (as shown in  FIG. 4 ) similar to bungee cords. In embodiments in which the stabilizers  51  are resilient, some adjustment of the spacing between the collapsible component lift legs  50  is possible to account for placement on uneven terrain. 
         [0026]    The boom  21  extends out over the helicopter  10  for lifting of components on/off the helicopter  10 . 
         [0027]    Individual mast and boom components of the collapsible component lift  20  are shown and will be described in detail in subsequent figures. 
         [0028]    Referring to  FIG. 3A , a side plan view of the collapsible component lift  20  with a trolley boom  21   a  is shown. Although shown with peculiar overall dimensions and assembly, other configurations and dimensions are anticipated, achieving the same results. In general it is desirable that each individual component not exceed the cargo area dimensions of the target rescue vehicle. For example, if the collapsible component lift  20  is to be carried in a back pack, it is desirable that the components not be too long as to interfere with walking/climbing. 
         [0029]    In this example of the collapsible component lift  20 , the mast  22 / 26   a  comprises two sections, a lower mast  22 , and an upper mast  26   a . It is anticipated that any number of mast sections  22 / 26   a  be used to achieve the required height for accessing the failed component (e.g. engine—not shown) of the helicopter  10 . The mast sections  22 / 26   a  disengage into component mast sections  22 / 26   a  that are short enough as to fit within, for example, the maintenance helicopter (not shown) for transportation to the sight of the failed helicopter  10 . Although any known means for connecting the mast sections  22 / 26   a  to each other is anticipated, in this embodiment, the bottom end of the upper mast section  26   a  fits snuggly within the top end of the lower mast section  22  and limited in penetration depth by, for example, a thrust bearing  27 . In some embodiments, the top end of the lower mast section  22  has a bearing  25  such as a crown bearing  25  to ease rotation of the upper mast section  26   a  with respect to the lower mast section  22 . It is anticipated that the mast sections  22 / 26   a  are made from any suitable material and/or cross-sectional geometry, for example, aluminum tubing. 
         [0030]    The lower mast section  22  is supported and held substantially vertical by component lift legs  50  that attach to the lower mast section  22  at the connection point  52 . Level adjusters  55  and feet  57  at a distal end of the collapsible component lift legs  50  enable adjustments to compensate for uneven surfaces as often is the case in remote locations. It is anticipated that, in some embodiments, the feet  57  swivel to conform to irregularities in the surfaces. The support arms  53  interface between the collapsible component lift legs  50  and an upper attach point  23  on the lower mast  22 . The support arms  53  provide structural support and help keep the lower mast  22  positioned substantially vertically when in use. The support arms  53 , in some embodiments, either collapse against the lower mast  22  or are removable for transporting the collapsible component lift  20 . 
         [0031]    The bearings  25 / 27  enable rotation of the upper mast section  26   a  and, therefore, the trolley boom  21   a  with respect to the failed helicopter  10 . Although it is anticipated that the bearings  25 / 27  are made of any suitable material, in one embodiment, the bearings  25 / 27  are made of nylon. 
         [0032]    In some embodiments, a level sensing device (not shown) is attached to one of the mast sections  22 / 26   a  to facilitate proper, vertical orientation of the mast sections  22 / 26   a , being that it is anticipated that the failed helicopter  10  is often located on uneven surfaces. 
         [0033]    Attached by a pivot  40  to a top end of the upper mast section  26   a  is a trolley boom  21   a . The trolley boom  21   a  extends outward from the mast  22 / 26   a  and reaches over the helicopter  10  facilitating removal and/or replacement of the target component, as shown in  FIG. 1 . The trolley boom  21   a  is shown in detail in  FIG. 5 . The trolley boom  21   a  has a trolley  37  over which or through which a strap  90  passes to facilitate component lifting. The strap  90  is, for example, a 2 inch nylon strap capable of supporting the weight of the target component. A nylon strap  90  is preferred, though not required, to reduce scratching of the helicopter  10  that may occur with a chain. Any known strap  90  is anticipated, including a rope, or a chain having sufficient tensile strength and flexibility. The strap  90  is threaded over/between the rollers  30 / 36  and removably attached at one end to the helicopter  10  component as known in the industry such as with a hook (not shown). The other end of the strap  90  is attached to a winch  60 . A handle  64  of the winch  60  is cranked to wrap the strap  90  around the winch spool  62  and, resultantly, lift the component. The handle  64  is turned in reverse to lower the component. Any known winch  60  is anticipated including motorized winches or hoists. In some embodiments, the winch  60  includes a ratchet mechanism. 
         [0034]    The trolley  37  is adjusted along a track  39  by a mechanism. Although there are many mechanisms  39  possible, one exemplary mechanism is a knob  39   a  (see  FIG. 5 ) and threaded shaft  39   b  (see  FIG. 5 ) that are fixed to, yet rotatable within the trolley boom  21   a . The exemplary mechanism is interfaced to a threaded hole (not visible) in a flange of the trolley  37 , the threads matching in pitch and diameter of the threaded shaft such that, as the threaded shaft  39   b  is rotated by turning of the knob  39   a , the trolley  37  moves up or down the threaded shaft  39   b  and, hence, up or down the track  39 , dependent upon the direction of rotation of the knob  39   a.    
         [0035]    To provide leverage and structural strength, an arm  44  connects at one end to a bracket  45  on the trolley boom  21   a  and at the opposite end to a bracket  47  on the upper mast  26   a.    
         [0036]    Referring to  FIG. 3B , a side plan view of the collapsible component lift  20  with a stationary boom  21   b  is shown. Although shown with particular overall dimensions and assembly arrangement, other configurations and dimensions are anticipated to achieve the same results. In this example of the collapsible component lift  20 , the mast  22 / 26   b  comprises two sections, a lower mast  22 , and an upper mast  26   b . It is anticipated that any number of mast sections  22 / 26   b  be used to achieve the required height for accessing the failed component (e.g. engine—not shown) of the helicopter  10 . The mast sections  22 / 26   b  disengage into component mast sections  22 / 26   b  that are short enough as to fit within the maintenance helicopter (not shown) for transportation to the site of the helicopter  10 . Although any known means for connecting the mast sections  22 / 26   b  to each other is anticipated, in this embodiment, the bottom end of the upper mast section  26   b  fit snuggly within the top end of the lower mast section  22  and limited in penetration depth by, for example, a thrust bearing  27 . In some embodiments, the top end of the lower mast section  22  has a bearing  25  such as a crown bearing  25  to ease rotation of the upper mast section  26   b  with respect to the lower mast section  22 . It is anticipated that the mast sections  22 / 26   b  are made from any suitable material and/or cross-sectional geometry, for example, aluminum tubing. 
         [0037]    The lower mast section  22  is supported and held substantially vertical by component lift legs  50  that attach to the lower mast section  22  at the connection point  52 . Level adjusters  55  and feet  57  at a distal end of the collapsible component lift legs  50  provide for adjustments that compensate for uneven surfaces as often is the case in remote locations. It is anticipated that, in some embodiments, the feet  57  swivel to conform to irregularities in the surfaces. The support arms  53  interface between the collapsible component lift legs  50  and an upper attach point  23  on the lower mast  22 . The support arms  53  provide structural support and help keep the lower mast  22  positioned substantially vertically when in use. In some embodiments, the upper attach point  23  is a sleeve. The support arms  53 , in some embodiments, either collapse against the lower mast  22  or are removable for transporting the collapsible component lift  20 . 
         [0038]    The bearings  25 / 27  enable rotation of the upper mast section  26   b  and, therefore, the stationary boom  21   b  with respect to the failed helicopter  10 . Although it is anticipated that the bearings  25 / 27  are made of any suitable material, in one embodiment, the bearings  25 / 27  are made of nylon. 
         [0039]    In some embodiments, a level sensing device (not shown) is attached to one of the mast sections  22 / 26   b  to facilitate proper, vertical orientation of the mast sections  22 / 26   b , being that it is anticipated that the failed helicopter  10  is often located on uneven surfaces. 
         [0040]    Attached by a pivot  40  to a top end of the upper mast section  26   b  is a stationary boom  21   b . The stationary boom  21   b  extends outward from the mast  22 / 26   b  and reaches over the helicopter  10  facilitating removal and/or replacement of the component as shown in  FIG. 1 . The stationary boom  21   b  is shown in detail in  FIG. 6 . The stationary boom  21   b  has a pulley  36   b  through/over which a strap  90  passes to facilitate component lifting. The strap  90  is, for example, a 2 inch nylon strap capable of supporting the weight of the target component. A nylon strap  90  is preferred to reduce scratching of the helicopter  10 . Any known strap  90  is anticipated, including a rope, or a chain having sufficient tensile strength and flexibility. The strap  90  is threaded over/between the rollers  30 / 36   b  and removably attached at one end to the helicopter  10  component as known in the industry such as with a hook (not shown). The other end of the strap  90  is attached to a winch  60 . A handle  64  of the winch  60  is cranked to wrap the strap  90  around the winch spool  62  and, thereby, lifting the component. The handle  64  is turned in reverse to lower the component. Any known winch  60  is anticipated including motorized winches or hoists. In some embodiments, the winch  60  includes a ratchet mechanism. 
         [0041]    To provide leverage, structural strength and adjustability to the stationary boom  21   b , an arm  44  removably connects at one end to a bracket  46  on the stationary boom  21   b  and at the opposite end to a bracket  47  on the upper mast  26   b . By selecting one of the several holes  46   a - 46   d  (at least one hole is required) in the bracket  46  on the stationary boom  21   b , the angle of the stationary boom  21   b  is adjusted to compensate for different sizes and styles of helicopters  10 . Since the stationary boom  21   b  is pivotally connected to the upper mast  26   b  by a pivot  40 , the stationary boom  21   b  is freely raised and lowered to adapt to the height of several types of helicopters. Once adjusted to the proper height, the stationary boom  21   b  is held and supported by a pin, screw, or other device between the adjustment arm  44  and one of the adjustment holes  46   a - d , thereby holding and supporting the stationary boom  21   b  at the proper height. 
         [0042]    Referring now to  FIGS. 4 and 6 , a perspective view of the collapsible lift  20  with the stationary boom  21   b  ( FIG. 4 ) and a plan view of the stationary boom  21   b  are shown. The base components  50 / 51 / 52 / 53 / 55 / 57 / 22 / 23  are as described in  FIGS. 1 and 2 . 
         [0043]    In this view, the static boom  21   b  has a bracket  46  that is shown with four attachment points  46   a - 46   d , although any number of attachment points  46   a - d  is anticipated. Note, for simplicity, the attachment points  46   a - 46   d  are holes on the bracket  46  through which fasteners pass (not visible). For example, a fastener such as a pin or a screw passes through a hole in one side of the bracket  46 , then through a hole in one end of the arm  44 , and then through a hole in the opposite side of the bracket  46 ; and preferably the protruding portion of the fastener is bent or fastened at the opposite side to prevent the fastener from falling out. Note that it is anticipated that any type and any number of attachment points are anticipated, including attachment points that do not require a fastener such as snap-type attachment points. The attachment point  46   a  farthest from the upper mast  26   a  positions the static boom  21   a  at a lower position and the attachment point  46   d  closest to the upper mast  26   b  positions the static boom  21   b  at a higher position. 
         [0044]    Referring now to  FIG. 5 , a perspective view of the trolley boom  21   a  of the collapsible component lift  20  is shown. In this, the pivot  40  (hole) is shown, though not connected to the mast  26   a  (the mast  26   a  is not shown in  FIG. 5 ). Likewise, the bracket  45  is shown disconnected from to the arm  44  for clarity reasons. The trolley  47  travels along a slot  39  under control of a mechanical system such as a threaded shaft  39   b  with a knob  39   a  at one end. In this example, the threaded shaft  39   b  is rotatably held to the trolley boom  21   a  and a flange (not visible) of the trolley  37  has mating threads such that, as the knob  39   a  is turned in a first direction and the threaded shaft  39   b  turns in that direction, the trolley  37  moves in in a first direction along the slot  39 . Reversing of the turning moves the trolley  37  in the opposite direction along the slot  39 . Any mechanism for moving the trolley  37  is anticipated, including no mechanism, in which the trolley  37  is manually positioned to a location along the slot  39 . In the later, it is preferred to have stops or detents to retain the trolley  37  in the selected position. 
         [0045]    The strap  90  wraps over a pin or wheel interface  36 . The pin or wheel interface  36  is connected to the trolley  37 . 
         [0046]    Referring now to  FIGS. 7A and 7B , exploded view of the collapsible component lift with a trolley boom ( FIG. 7A ) and a static boom ( FIG. 7B ) are shown. In each view, the collapsible component lifts with either boom  21   a / 21   b  are shown with the individual components separated. The individual components, once separated, are easily transported to/from the site of a failed helicopter  10  and are sized (in length) to fit within the rescue helicopter or other carrying system. Since turbulence is often encountered, it is desired that the components are held within a carrier (see  FIG. 8 ), though there is no requirement for such a carrier and, for some uses, the components are strapped or tied together for safety reasons, etc. 
         [0047]    Referring now to  FIG. 8 , a perspective view of an exemplary carrying case for the collapsible component lift is shown holding the components of the collapsible component lift. Although it is anticipated that, after disassembly, the collapsible component lift  20  is carried in any suitable container, box, sack, etc., it is preferred, especially for air travel within a rescue craft, that the components be held statically and apart to prevent damage to the rescue craft, rattles, noise, as well as damage to components of the collapsible component lift  20  due to friction during transportation. 
         [0048]    Many such carrying cases are anticipated, the carrying case shown in  FIG. 8  being an example of such. As shown in  FIG. 8 , the carrying case has a frame  91  made of a sturdy material such as aluminum, plastic, PVC, or any other sturdy material. It is preferred, though not required, that the material be light weight. 
         [0049]    In some embodiments, there is a plurality of aligned holes (not visible) for accepting mast  22 / 26   a , the boom sections (not visible), the leg supports  53 , etc. In some embodiments, there are retainer clips (not shown) for holding the mast  22 / 26   a  and boom  21   a / 21   a  sections within the frame. In some embodiments, a handle (not shown) is pivotally attached to the frame to facilitate carrying by maintenance personnel. 
         [0050]    Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result. 
         [0051]    It is believed that the system and method as described and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.