This video demonstrates conversion of a standard C-130H Hercules to a Dorsal cargo carrier.

Using existing, proven, off-the-shelf aircraft and control components reduces development time and costs a small fraction of new aircraft development.

Dorsal Technology uses the Dorsal Intermodal Container as part of the aircraft primary structure shifting the container weight from the payload weight to the aircraft structural weight allowing more payload to be carried.

Our hybrid drone technology includes an add-on pilot module as an on board monitor until FAA drone systems exist to allow unmanned drones to operate in manned airspace.

 

Drone Cargo Aircraft Main Cost Reduction Factors:

  1. Drone cargo aircraft permit lower crash load requirements resulting in significant system weight reduction.
     
  2. Unmanned systems allow slower and lower flight operations targeting fuel efficiencies.
     
  3. Use of modular containers as aircraft structure greatly reduce dead weight.
     
  4. Dorsal drone cargo aircraft finally incorporate the rail, ship, and truck Intermodal system for flying aircraft moving whole containers versus moving pallets (reduces or eliminates double handling).
     
  5.  Summary of Cost and Weight Reduction Potential Across Drone Cargo Aircraft
 

Increased Fuel Efficiency

Summary

Biosphere "Dorsal" drone cargo aircraft fly lower and slower allowing use of turboprops proven to be more efficient than current jet aircraft.

We estimate the standard Dorsal Heavy (Quad) with a range of 5,600 miles is 19.79% more fuel efficient than the A380F and 10.77% more fuel efficient than 747-8F published aircraft data.

We estimate the refueled Dorsal Heavy (QuadR) with a range of 3,136 unrefueled, is 43.86% more fuel efficient than the A380F and 37.54% more fuel efficient than 747-8F published aircraft data.

 

Increased Payload Capability

Summary

The Biosphere Aerospace drone air cargo system is able to shift part of the aircraft structure to payload (by reduced safety factors and flying lower and slower), and by shifting the weight of the fuel savings towards payload.

The A380 has a published empty weight of 556,000 lbs and a maximum payload of 336,000 lbs or it carries 0.604 lbs of payload for every lb of empty structural weight.

The 747-8F has a published empty weight of 421,200 lbs and a maximum payload of 295,800 lbs or it carries 0.702 lbs of payload for every lb of empty structural weight.

The Dorsal Quad has an estimated empty weight of 350,295 lbs and a maximum payload of 350,000 lbs or it carries 1.00 lbs of payload for every lb of empty structural weight.

The Dorsal Quad R (with refueling capability) has an empty weight of 350,295 lbs with a maximum payload weight of 500,000 or it can carry 1.427 lbs of payload for every lb of empty structural weight. The Quad R may have to have its basic structure enhanced which means a lower payload capability but the potential does exist.
 

In all cases, Biosphere Aerospace dedicated drone cargo aircraft offer additional savings in fabrication, maintenance and operational costs than existing cargo aircraft. Additional systemic cost reductions may be realized by end users moving whole containers versus moving pallets (less double handling).

 

The Shape of Things to Come

External Article by John L. Petersen for the AOPA (Aircraft Owners and Pilots Association)

"Why Pilots and Planes Will Become Obsolete In The Near Future . . . And What We Can Do About It"

 

Dorsal Summary of Cost and Weight Reduction potential across all Platforms

Drone Cargo Aircraft means great weight reduction

  • Normal manned safety factor is 1.5 x Limit Load.  Drone can be 1.2 x Limit Load
  • Manned aircraft require 16 g crash loads.  Drone design crash loads are zero
  • Manned aircraft require environmental controls and pressurization.  Drone have no such requirements.
  • Manned aircraft require triple redundancy.  Drone aircraft can be done with only double redundancy

Cargo containers sharing flight loads with the airframe means additional weight savings

  • Containers and spine support flight loads thus containers are no longer dead weight
  • Airframe is able to fly empty with no containers.  This increases overall duration of the aircraft as it flies empty with a big portion of the flight structure removed, i.e. flying empty with no container means the aircraft flight structure is reduced as they would be flying with less air load structure as the container structure would not be there
  • Cargo containers are infinitely customizable while the aircraft spine remains the same

Special Intermodal Container save handling time

  • Intermodal containers can be loaded by the customer and emptied by another customer with no handling of cargo in the middle
  • Intermodal means transportation is able to be done across various transportation segments interchangeably
  • Containers are infinitely customizable as opposed to the aircraft requiring modifications
  • Special containers can be designed for different load requirements

Drone cargo aircraft means cheaper operational and construction costs

  • Aircraft can fly at slow speed without regard for pilots on board
  • Slower speeds mean more efficient fuel use
  • Slower speeds mean less stressed structure which in turn means lighter structure
  • Slower speeds mean thicker wings that can be straighter which makes them a lot easier and cheaper to manufacture
  • Structure can be optimized for functionality as opposed to looks

Modular construction saves time and money both in the spine components and the containers themselves

  • Modular containers means high volume production economics can be brought to bear to reduce costs and increase efficiency
  • Modular construction allows for quick replacement reducing maintenance labor
  • Modular components means existing aircraft and helicopter parts can be incorporated into the Dorsal design a lot easier

Pre-assembled Cargo Containers mean fast load and unload

  • Slide out one assembly and replace it with another quickly
  • Full in flight release capability on upper spine versions
 

Winged and Helidrone Air Frames

Biosphere Aerospace is developing the following types of drone cargo aircraft:

QUAD Civilian

Description
362,000 lbs useful load capacity;
12 x 40 foot containers or any combination 5’, 10’,20’, and 40’.     
8,400 nm range

Function
Establish a new commerce transportation bridge across oceans

QUAD Military

Description
362,000 lbs useful load capacity;
12 x 40 foot containers or any combination 5’, 10’, 20’, and 40’.
Oversize cargo capable such as double wide and double high capacity.
8,400 nm range

Function
Provides an infinitely customizable 362,000 lbs load capability platform. Full load drop capability. Autonomous load drop capability. In flight weapons release capable.

UNO Military

Description
60,000 lbs useful load capacity;
1x 40’ container or any 5’, 10’, 20’, and 40’ combination.
2,000 nm range.

Function
Provides an infinitely customizable 60,000 lbs load capability platform. Full load drop capability. Autonomous load drop capability. In flight weapons release capable.

HELIDRONE Military Platform

Sample Use
Container Transport

MINI HELIDRONE Military

Description
15,000 lbs useful load capacity;
1x 40’ container or any 5’, 10’ 20’ and 40’ combination.
500 nm range

Function
Smallest footprint capable helicopter.  Very clean flying unloaded.  Used to supply hard to reach locations.

 MID HELIDRONE Military

Description
30,000 lbs useful load capacity;
1x 40’ container or any 5’, 10’, 20’ and 40’ combination.
600 nm range

Function
Used for supplying locations with larger clearings.

HEAVY HELIDRONE Military

Description
 60,000 lbs useful load capacity;
2x 40’ containers or any 5’, 10’, 20’ and 40’ combination.
700 nm range

Function
Used for supplying larger bases with no runway capabilities and for oversize cargo capability.

Dorsal C-130 Refurbish Conversion

Description
The C-130 aircraft is a long running program that has produced over 2,158 variant aircraft with a large number stored in graveyards with structurally viable components.

The C-130 Dorsal program would take the tails, engines, wings, and landing gear components of these mothballed aircraft and convert them to a spine-container configuration

The green components are existing C-130 components while the red components are the Dorsal
standard containers and the black components are the new spine and fairings structures.

Each Dorsal 130 drone cargo aircraft will have a 60’ bay able to accommodate 1 x 40’ Dorsal container
and 1 x 20’ Dorsal container or 3 x 20’ Dorsal containers or any combination of 5’ + 10’ + 20’ +
40’ combination. Central hydraulic systems would be replaced with EHA (electro-hydrostatic) local systems with a new spine and fairings with drone controls to produce a reliable low cost package.
This variant can be offered to the US Air Force, Navy, and Marines. This aircraft will have a
payload capability of 31,363 lbs + 15,500 lbs for a total payload of 46,863 lbs.

Dorsal C-27 Refurbish Conversion

Description
For smaller applications, where the US military may want a more modern type of aircraft, the C-
27 Spartan can be modified to accommodate 1 Dorsal 40’ long container.

The C-27 Dorsal program would take the existing tail, wings, engines, and landing gear components and design a spine and fairings to accommodate the Dorsal containers.

The green components are existing C-130 components while the red components are the Dorsal
standard containers and the black components are the new spine and fairings structures.

This design will need to move the landing gear locations such that they can accommodate a longer
container. Payload for this configuration can be increased form the current C-27 limit of 25,353 lbs to 31,363 lbs with the Dorsal improvements.

Dorsal CH-47 Refurbish Conversion

Description
As for vertical takeoff and landing configurations, the CH-47 Chinook helicopter has been a very successful aircraft and over 1,179 units have been built. The Dorsal Helidrone Chinook project would take the rotating wings, engines, guide shaft and landing gear components from the Chinook and incorporate them into the Dorsal spine container concept.

The Dorsal Chinook conversion will accommodate 1 x 40’ container and 1 x 5’ container for a payload capability of 31,363 lbs + 3,600 lbs or a total of 34,963 lbs.

As with all Dorsal concepts, any combination of 5’, 10’, 20’, and 40’ container s can be used to fill the available space.

STEALTH HELIDRONE MINI Military

Description
15,000 lbs useful load capacity;
1x 40’ container or any 5’, 10’ 20’ and 40’ combination.
500 nm range

Function
Smallest footprint capable helicopter.  Very clean flying unloaded.  Used to supply hard to reach locations.