The balloon crane with a 1-tonne payload
as always: across the entire workspace
The terms ‘innovation’ and ‘milestone’ are so overused that we are usually reluctant to use them. Nevertheless, they might well apply to this ‘revolution in balloon construction’.
Together with Ballonbau Wörner, we have developed a completely new balloon with a diameter of 13.4 metres. Why this is so remarkable following our AirCrane test systems with diameters of 18 and 22 metres is not immediately apparent from the “small” balloon at first glance. Its true value lies more in what is inside. What makes it special is what cannot be seen, and the spectacular thing about the whole affair is that it is actually unspectacular.
With our tests in Netzschkau, we had proven that the CargoLifter balloon crane system is capable of lifting, moving and lowering loads with precision. This works under wind and weather conditions comparable to those encountered when working with conventional cranes. Of course, the balloons, which were originally designed for stationary passenger operations, were not ideally suited for economical use as load-lifting equipment on construction sites. Part of the test programme involved defining the requirements for a balloon specifically designed for our balloon crane purposes, as well as its ground infrastructure, including transport and inflation logistics. The following requirements were set:
- Easy transportability of the entire system
- A minimum of ground infrastructure, so that assembly is possible on an open field
- Rapid assembly of the balloon, regardless of gas filling
- Use of hydrogen as a lifting gas as an alternative to helium
The New Model
The balloon is transported on a lightweight trailer, which also serves as a platform for assembly and operation. The aim is to be able to drive the system onto rough terrain using a pickup truck with this trailer and an escort vehicle.
Previously, not only did all parts of the balloon have to be on site, but this also required up to 40 people, along with hundreds of sandbags
, and of course as little wind as possible whilst the balloon had not yet attained its stable aerodynamic shape. The helium had to be ordered weeks in advance specifically for this date.
Our new balloon is based on a concept whereby the balloon is first filled with air relatively quickly, so that the gas filling can be carried out later ‘at leisure’. We do not wish to provide further details on this, as it forms part of our technical and operational know-how. The filling can be completed by four people in less than an hour! A novel harness and mooring system ensures additional safety.
Another minor sensation is the filling of the balloon with hydrogen! Whilst the topic of hydrogen has positive connotations, particularly through
environmentally friendly buses, when it comes to balloons, the image of the burning
Hindenburg – constantly used by the media – somehow springs to mind. Here too, we must refrain from giving details. We, or rather Ballonbau Wörner, submitted a concept to the aviation
authorities that had been reviewed by experts, then built the balloon, attended relevant training courses on
handling hydrogen, obtained the necessary permits and are now filling the balloon with hydrogen.
In terms of operating costs and the availability of helium, the alternative use of hydrogen as a fuel is a crucial step towards the commercial deployment of the CargoLifter balloon crane system.
We have truly reached a milestone and introduced a genuine innovation in the balloon sector. The 13.4-metre balloon
has proven itself as a ‘proof of concept’ for larger balloons.
