Auto-Capture Hook
An ultra-rugged military device that streamlines the process of delivering helicopter payloads and reduces man-power.
The Client
After decades of experience working as lead engineer for a unique dual-rotor helicopter, George Schafer is now pursuing his own ideas as an entrepreneur.
George came to Inspira in need of expertise for upgrading the electronics system for his patented hook invention, the ACH-250.
The Challenge
The objective of our work was to simplify the battery recharge process for the ACH-250 and to harden the electronics in preparation for electromagnetic compatibility (EMC) testing.
The previous design had an internal battery inside the hook itself which made it difficult to recharge due to the substantial weight of the hook itself and the need to haul it around to plug into an outlet.
The previous design was not ready for EMC testing due to the electronics system having been implemented with more of a hobbyist approach.
The Outcome
The entire electrical system ended up being redesigned. A new module to the system was introduced, the Battery Module, which greatly simplified the charging process due to its being external to the hook and much lighter.
Additionally, shielding was meticulously applied to the entire system, every cable shielded, the controller screen protected with a micro-mesh conductive film, and several other measures were taken to prepare for EMC testing.
Features
High Strength
Stainless steel construction ensures high durability and boasts a carrying capacity of 25,000 lbs.
Faraday Cage
Solid metal exterior in addition to shielded cables, connectors, and OLED to eliminate RF interference.
Extreme Environments
Uninterrupted operation from -40C to 80C including winter tundra, desert, and marine environments.
Water Ingress
Sealed shell, bolts, cables, and connectors protects electronic systems from water ingress.
Controller
Simple user interface, custom-designed for the project, that enables navigation through different menus.
Error notification screen with alerts akin to a “check engine light” to enhance trouble-shooting.
Built-in redundancy between Controller and Battery Module to independently verify button actions and prevent anomalous input.
Battery Module
Houses a seven-cell battery pack delivering 28 volts and up to 40 amps of current to the motors of the hook.
Hibernation mode with 50 uA current draw and shutoff mode with 12.5 uA enables long-term storage on the order of years with virtually no battery loss.