Rotatable blade apparatus with individually adjustable blades

Abstract

The lengths and/or chords and/or pitches of wind turbine or propeller blades are individually established, so that a first blade can have a length/chord/pitch that is different at a given time to the length/chord/pitch of a second blade to optimize performance and/or to equalize stresses on the system.

Claims

1. A blade assembly comprising: at least first and second blades coupled to a rotor, the first blade configured for defining a first pitch at a first time, the second blade configured for defining a second pitch at the first time, the first and second pitches not being equal, a conveyance shaft holding the first and second blades, the first and second blades being configured for being identically configured to each other at a second time; and one or more sensors configured for generating signals based at least in part on which pitches are established; wherein the first blade has its chord being different from that of the second blade at the first time.

2. The blade assembly of claim 1, comprising an actuator coupled to at least one blade to establish the pitch of the at least one blade.

3. The blade assembly of claim 1, no blade defining the first pitch at the first time other than the first blade.

4. The blade assembly of claim 1, wherein the first blade has its length being different from that of the second blade at the first time.

5. The blade assembly of claim 1, wherein the first and second pitches are based on respective angular positions of the first and second blades with respect to the rotor.

6. A blade assembly comprising: at least first and second blades coupled to a rotor, the first blade configured for defining a first pitch at a first time, the second blade configured for defining a second pitch at the first time, the first and second pitches not being equal, a conveyance shaft holding the first and second blades, the first and second blades being configured for being identically configured to each other at a second time; wherein the first blade has its length being different from that of the second blade at the first time.

7. The blade assembly of claim 6, comprising one or more sensors configured for generating signals based at least in part on which pitches are established.

8. The blade assembly of claim 6, wherein the first blade has its chord being different from that of the second blade at the first time.

9. The blade assembly of claim 6, comprising an actuator coupled to at least one blade to establish the pitch of the at least one blade.

10. The blade assembly of claim 6, wherein no blade defines the first pitch at the first time other than the first blade.

11. The blade assembly of claim 6, wherein the first and second pitches are based on respective angular positions of the first and second blades with respect to the rotor.

12. A method, comprising: providing a rotor for a blade assembly; providing at least first and second blades for coupling to the rotor, the first blade configured for defining a first pitch at a first time, the second blade configured for defining a second pitch at the first time, the first and second pitches not being equal, the first and second blades being configured for being identically configured to each other at a second time; and providing a conveyance shaft for holding the first and second blades; wherein the first blade is configured for having its length be different from that of the second blade at the first time and/or for having its chord be different from that of the second blade at the first time.

13. The method of claim 12, comprising providing one or more sensors configured for generating signals based at least in part on which pitches are established.

14. The method of claim 12, wherein the first blade is configured for having its length be different from that of the second blade at the first time.

15. The method of claim 12, wherein the first blade is configured for having its chord be different from that of the second blade at the first time.

16. The method of claim 12, comprising providing an actuator coupled to at least one blade to establish the pitch of the at least one blade.

17. The method of claim 12, wherein no blade defines the first pitch at the first time other than the first blade.

18. The method of claim 12, wherein the first and second pitches are based on respective angular positions of the first and second blades with respect to the rotor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic view of a wind turbine in accordance with present principles:

(2) FIG. 2 is a schematic view of a vessel propeller in accordance with present principles;

(3) FIG. 3 is a block diagram showing control elements in accordance with one embodiment;

(4) FIG. 4 is a block diagram showing control elements in accordance with another embodiment;

(5) FIG. 5 is a perspective view of a blade in the extended configuration;

(6) FIG. 6 is a plan view of a blade, showing one preferred non-limiting pressure sensor disposition on the blade;

(7) FIG. 7 is a block diagram of one actuator embodiment, in which a single motor moves plural blade segments:

(8) FIG. 8 is a block diagram of one actuator embodiment, in which respective motors move respective blade segments;

(9) FIG. 9 is a perspective view of a non-limiting actuator:

(10) FIG. 10 is an elevational view of an alternative cam-based system; and

(11) FIG. 11 is a plan view showing that the present principles, in addition to being applied to change the length of a blade, may also be applied in changing the chord and/or pitch of the blade.

DETAILED DESCRIPTION

(12) Referring initially to FIG. 1, a wind turbine blade assembly is shown, generally designated 10, which includes first and second blades 12, 14 that are coupled to a rotor 16, it being understood that present principles apply to two, three, or more blades. The rotor 16 is rotatably supported above the surface 18 of the earth by an upright support 20, which holds the blades 12, 14 in a vertical plane above the earth's surface as shown. In accordance with principles known in the art, wind flowing past the blades causes them to turn to thereby cause an associated generator, shown schematically at 21, to generate electric power.

(13) The rotor 16 defines an axis 22 of rotation, and in accordance with disclosure below at least the first blade 12 and preferably both blades 12, 14 can be moved between a long configuration and a short configuration, as well as to intermediate configurations therebetween, and the blade 12 is not constrained to be in the same configuration as the second blade 14. Thus, to illustrate, FIG. 1 shows that the blade 12 has a blade tip 24 that can be configured to be a relatively long distance d.sub.1 from the axis 22 of rotation. Simultaneously, the tip 26 of the second blade 14 can be configured to be a second distance d.sub.2 from the axis 22 of rotation, with the distances d.sub.1, d.sub.2 being unequal when present principles are applied. For purposes that will shortly become clear, one or more pressure sensors 28 can be disposed on one or both blades 12, 14. Alternatively, wind speed sensors on the blades 12, 14 or elsewhere can be used.

(14) As set forth further below, the principles outlined herein in terms of variable length also apply to variable pitches and chords, so that in addition to or in lieu of different lengths, the pitches and/or chords of the respective blades 12, 14 may be different from each other at the same point in time. It is to be further understood that the assembly 10 may also, at other times, embody conventional operating principles wherein the blades 12, 14 are identically configured in length, chord, and pitch.

(15) FIG. 2 shows that the present principles can also be applied to a propeller blade assembly 30 that has at least first and second blades 32, 34, and potentially additional blades 36, coupled to a rotatable rotor 38 that defines an axis 40 of rotation. The tip 42 of the first blade 32 can be configured to be a first distance from the axis 40 of rotation and simultaneously the tip 44 of the second blade 34 can be configured to be a further distance from the axis 40 of rotation than is the tip 42 of the first blade 32. A shaft 46 of a waterborne vessel 48 can hold the blades 32, 34, 36 in a vertical plane (at neutral vessel pitch) as shown.

(16) As set forth further below, the principles outlined herein in terms of variable length also apply to variable pitches and chords, so that in addition to or in lieu of different lengths, the pitches and/or chords of the respective blades 32, 34, 36 may be different from each other at the same point in time. It is to be further understood that the assembly 30 may also, at other times, embody conventional operating principles wherein the blades are identically configured in length, chord, and pitch.

(17) For illustration purposes the disclosure below focuses on a wind turbine application, it being understood that the principles embodied therein may be applied to the propeller assembly 30, in which, e.g., the blade 34 has plural portions 50 that can telescope or otherwise move in the axial dimension of the blade 34 relative to each other (and, as stated above, potentially can also move relative to each other in the chord dimension).

(18) FIGS. 3 and 4 show various system configurations for controlling the lengths (and/or chords and/or pitches) of the blade 12, and preferably also of the blade 14. A controller or processor 52 can receive input from the pressure sensors 28 on the blades and/or from an encoder 54 that outputs a signal representing the angular position of the rotor 16. The controller or processor 52 controls an actuator with motor 56 to establish the length (and/or chord and/or pitch) of the blades. The motor may be a stepper motor or other appropriate motor, and as set forth further below may be located within the blade 12 or outside the blade 12. From time to time herein, “actuator” may be used to refer to both a motor and the linkages that couple the motor to the movable blade portions, and to just the linkages themselves.

(19) In some implementations, the length of each blade 12, 14 is established based on its angular position. Thus, in non-limiting embodiments a blade can assume the long configuration when at the top dead center position (pointing straight up vertically from the rotor) and the short configuration in the opposite position, and can have intermediate lengths when moving therebetween. In terms of the two-blade application of FIG. 1, the first blade 12 is in the long configuration at the same time the second blade 14 is in the short configuration.

(20) In addition to or in lieu of using angular position to establish the lengths of the blades, the lengths of the blades can depend on respective pressure signals from the sensors 28, which are representative of fluid pressure on the blades. In this embodiment, the controller or processor 52 establishes blade length both to optimize performance while minimizing load imbalances on the rotor by, e.g., establishing blade lengths that result in equal pressures on both blades 12, 14 while providing optimum length based on wind speed, to ensure that the blades rotate as fast as feasible while remaining below angular velocity limits.

(21) FIG. 4 shows further details of the controls of one illustrative non-limiting embodiment. As shown, the pressure sensors 28 on the blade 12 are electrically connected to a sensor bus 58 within the blade. The bus 58 is connected to the controller or processor 52 through a slip ring connector array 60, which, in accordance with slip ring principles known in the art, permits relative rotational movement between the blade 12 and the controller 52 while maintaining electrical connectivity between them. A bidirectional data bus 59 can be provided between the slip ring connector array 60 and the controller 52 to permit the controller 52 to receive pressure signals and to output control signals to the actuators discussed below.

(22) More particularly, electrical power, as well as control signals from the controller 52, is also provided through the slip ring to one or more actuator subsystems 62, each of which can include a respective motor and a respective linkage that connects the actuator to a respective blade portion to move the blade portion. Alternatively, a single motor may be provided within the blade 12 and linked through gears or other linkages as set forth further below to move each of plural individual actuator subsystems that, in such a circumstance, would include only linkages to respective blade portions.

(23) FIGS. 5-8 show further details of non-limiting implementations of the present blade. As shown in FIG. 5 and using the first blade 12 as an example, the blade can have plural portions 64 that move relative to each other in the length dimension of the blade, it being understood that similar principles apply to expand and contract the blade in the chord dimension. As shown at 66, an actuator linkage can be coupled to two adjacent substantially rigid hollow blade portions 64 to move the blade portions relative to each other. In the embodiment shown in FIG. 5, the blade portions abut each other along their transverse edges in the short configuration, with facing transverse edges of adjacent blade portions being distanced from each other in the long configuration and, if desired, a flexible membrane 68 (portions of which are removed in FIG. 5 to show the linkage 66) can enclose the space between the portions.

(24) FIG. 6 shows that the pressure sensors 28 can be arranged in two lines along the length of the blade 12, with one line of sensors being disposed on a first side of the “twist” 70, or blade surface aspect change line, and with a second line of sensors being disposed on the opposite side of the twist as shown.

(25) FIG. 7 shows that in some implementations, a single motor 72 can be provided in the blade 12 to turn a lead screw 74 or equivalent structure, with plural nuts 76 or equivalent linking structure riding on the lead screw 74 and connected to respective blade portions to move the blade portions.

(26) In contrast, FIG. 8 shows that each of plural movable blade portions 80, 82 can house its own respective motor and linkage that connects the blade portion to the distally successive blade portion. Thus, the blade portion 80 has a motor 84 with linkage 86 that extends between the blade portions 80, 82 to move the medial blade portion 82 outward from the proximal blade portion 80. Likewise, the medial blade portion 82 supports a motor 88 with associated linkage 90 extending to a distal blade portion 92, to move the distal blade portion 92 outward from the medial blade portion 82. Additional blade portions with motors and linkages may be provided. As mentioned earlier, power can be supplied to the motors through a power line 94 and slip ring assembly 96, and data and control signals can be exchanged through the slip ring assembly 96 and data bus 98 within the blade 12.

(27) As also shown in FIG. 8, instead of using a flexible membrane 68 (FIG. 5) between adjacent blade portions, each adjacent blade portion can, in the short configuration, be partially nested within the immediately proximal portion. Accordingly, in the short configuration the sub-portion 100 (with parts broken away in FIG. 8 to expose the linkage 86) of the medial blade portion 82 is nested within the proximal blade portion 80, whereas in the long configuration shown the sub-portion 100) is telescoped distally beyond the proximal portion 80. All portions of the blade in this embodiment can be substantially rigid. Similarly, a sub-portion 102 (part of which is removed in FIG. 8 to expose the linkage 90) of the distal blade portion 92 is nested within the medial portion 82 in the short configuration and is telescoped distally beyond the medial portion 82 in the long configuration.

(28) FIG. 9 shows an illustrative non-limiting example of one of the motor actuators shown in FIG. 8. A motor 104 such as DC motor is affixed to one blade portion (not shown) to turn a pinion gear 106, which translates rotational motion to longitudinal (with respect to the blade) translational movement of a rack 108. The rack 108 is affixed to the successive blade portion 110, to move it toward and away the blade portion that supports the motor 104.

(29) When the length of the blade is sought to be changed only based on angular position, FIG. 10 shows that instead of using motor actuators, each blade 110, 112 of a wind turbine or propeller can have proximal and distal portions 114, 116 that telescope relative to each other as the blade, which is attached to a rotor 117, rotates past a cam 118 on which a part of the blade between the portions 114, 116 ride. The contour of the surface of the cam is established to establish the desired length-to-angular position relationship. Other mechanisms, including gearing, can be employed.

(30) Other mechanisms for moving a blade are disclosed in U.S. Pat. No. 6,972,498, modified as appropriate to permit the individual establishment of the length of each blade, independently of other blades, as described above.

(31) FIG. 11 schematically illustrates that individual blade configuration may be independently established not just in the length dimension by length adjustment actuators 120 but alternatively or additionally in the chord dimension by chord adjustment actuators 122 and/or in the pitch dimension by a pitch adjustment actuator 124, which rotates the blade about its hub using, as non-limiting examples, the mechanisms described in U.S. Pat. No. 5,733,156. In any case, it is to be appreciated that the length and/or chord and/or pitch of each blade of the present wind turbine or propeller can be established independently of the length and/or chord and/or pitch of one or more other blades as necessary to equalize fluid pressure on the blades, to optimize performance by, e.g., attaining an optimum speed of rotation, and in the case of propellers to lower the rudder profile as necessary to avoid cavitation or even to assist in turning the vessel.

(32) While the particular ROTATABLE BLADE APPARATUS WITH INDIVIDUALLY ADJUSTABLE BLADES is herein shown and described in detail, it is to be understood that the subject matter which is encompassed by the present invention is limited only by the claims. For instance, the principles described herein could be applied to airplane propellers and to helicopter rotor blades.