Wind generator with lightweight adjustable blades
10337494 ยท 2019-07-02
Inventors
Cpc classification
F03D1/0633
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D17/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D1/0675
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D7/0236
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05B2240/2211
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D1/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D13/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D9/25
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/72
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
F03D9/25
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D1/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D7/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D17/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A wind generator system with a plurality of lightweight, surface area adjustable airfoil/sail blades. Each blade is triangular or wedge shape with a narrow inner edge and a wide outer edge. Each blade includes an inner frame connected to a rigid mast that extends radially from a hub assembly. Each blade includes a curved outer skin layer that extends over the inner frame and configured into air foil shape with a large curved leading edge and a thin trailing edge. The outer skin layer is secured along its leading edge and removeably attached along its trailing edge to the inner frame. Coupled to the outer skin layer is a first linear actuator that when activated, causes the outer skin layer to fold or unfold thereby changing the blade's surface area. The internal frame may include a second linear actuator and a telescopic mast over which the blade slides to increase or decrease the sweep area of the blades. Wind or electrical sensors are coupled to the mast and the retractable cable to automatically control the sweep area and the surface areas.
Claims
1. 1. A wind generator system, comprising: a. a wind generator configured to produce electricity when rotated; b. a hub assembly coupled to said wind generator; c. a plurality of lightweight hybrid blades evenly spaced apart and attached to said hub assembly, each said blade includes an internal frame covered by an outer skin layer, said internal frame and said outer skin layer being configured so said blade has an airfoil profile with curved leading edge and a thin trailing edge, said outer skin also configured to act as a sail to capture wind when placed perpendicular into the wind, said internal frame includes a mast, an outer transversely aligned end plate attached at one end of said mast and an inner transversely aligned base plate attached to an end of said mast opposite said end plate, said internal frame also includes a plurality transversely aligned ribs that support said outer skin layer; d. a first linear actuator coupled to said mast configured to fold and unfold said outer skin layer over said internal frame; and, e. a sensor configured to monitor the wind speed or the electrical output from said generator, said sensor coupled to said linear actuator to fold or unfold said outer skin layer to change the surface areas of said blade according to the wind speed, the RPM of said generator or the electrical output detected.
2. The wind generator system, as recited in claim 1, wherein said end cap includes at least one louver that when open allows wind to travel through said end cap.
3. The wind generator system, as recited in claim 2, further including a wind speed detector coupled to said louver that opens said louver when the wind reaches or exceeds a predetermined speed.
4. The wind generator system, as recited in claim 1, wherein said trailing edge of said outer skin layer is attached to said internal frame with a hook and loop connector.
5. The wind generator system, as recited in claim 4, wherein said mast is a telescope tube that includes an inner tube section and an outer tube section.
6. The wind generator system, as recited in claim 5, wherein said blade includes at least one outer bracket affixed to said outer tube section and at least one inner bracket that slides over said inner tube section, said blade configured to move radially outward from said hub assembly when said outer tube section is extended from said inner tube section.
7. A wind generator system, as recited in claim 6, further including a second linear actuator coupled to said blade, said outer tube section and said inner tube section.
8. The wind generator system, as recited in claim 1, wherein said outer skin layer is made of polyethylene film or poly vinyl chloride film.
9. The wind generator system, as recited in claim 1, wherein said outer skin layer includes advertising indicia printed thereon.
10. The wind generator system, as recited in claim 8, wherein said mast is a telescope tube that includes an inner tube section and an outer tube section.
11. The wind generator system, as recited in claim 10, wherein said blade includes at least one outer bracket affixed to said outer tube section and at least one inner bracket that slides over said inner tube section, said blade configured to move radially outward from said hub assembly when said outer tube section is extended from said inner tube section.
12. A wind generator system, as recited in claim 11, further including a second linear actuator coupled to said blade, said outer tube section and said inner tube section.
13. The wind generator system, as recited in claim 1, further including a rigid, elongated shield located adjacent to said mast.
14. The wind generator system, as recited in claim 13, wherein said mast is a telescope tube that includes an inner tube section and an outer tube section.
15. The wind generator system, as recited in claim 14, wherein said blade includes at least one outer bracket affixed to said outer tube section and at least one inner bracket that slides over said inner tube section, said blade configured to move radially outward from said hub assembly when said outer tube section is extended from said inner tube section.
16. A wind generator system, as recited in claim 15, further including a second linear actuator coupled to said blade, said outer tube section and said inner tube section.
17. The wind generator system, as recited in claim 16, wherein said outer skin layer is made of polyethylene film or poly vinyl chloride film.
18. A wind generator system, comprising: a. a wind generator configured to produce electricity when rotated; b. a hub assembly coupled to said wind generator; c. a plurality of lightweight hybrid blades evenly spaced apart and attached to said hub assembly, each said blade includes an internal frame covered by an outer skin layer, said internal frame and said outer skin layer being configured so said blade has an airfoil profile with curved leading edge and a thin trailing edge, said outer skin also configured to act as a sail to capture wind when placed perpendicular into the wind, said internal frame includes a length adjustable mast, outer transversely aligned end plate attached at one end of said mast and an inner transversely aligned base plate attached to an end of said mast opposite said end plate, said internal frame also includes a plurality transversely aligned ribs that support said outer skin layer; d. a first linear actuator coupled to said mast configured to fold and unfold said outer skin layer over said internal frame; e. a sensor configured to monitor the wind speed or the electrical output from said generator, said sensor coupled to said linear actuator to fold or unfold said 5 outer skin layer to change the surface areas of said blade according to the wind speed, the RPM of said generator or the electrical output detected; f. at least one outer bracket affixed to said outer tube section and at least one inner bracket that slides over said inner tube section, said blade configured to move radially outward from said hub assembly when said outer tube section is extended from said inner tube section; and, g. a second linear actuator coupled to said blade, said outer tube section and said inner tube section.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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BEST MODE FOR CARRYING OUT THE INVENTION
(42) Referring to the accompanying
(43) The blades 40 are attached to a lockable or non-lockable hub assembly 20 that connects to direct or indirect drive wind generator system 10. The generator system 10 includes a nacelle 30 housing a wind generator 34 all mounted on top of a lightweight tower 200. Connected to the wind generator 34 is a hub assembly 40. The system 10 may include a hydraulic lift 220 that moves the tower 200 from a horizontal position to a vertical position when winds are sufficiently strong. In the embodiment shown in the Figs, the nacelle 30 is coupled to an optional motor 38 that rotates the nacelle 30 and the hub assembly 20 over the end of the tower 200 so the blades 40 are perpendicularly aligned with the direction of the wind 5 at all times. Directional and wind speed sensors 6 and 7 are provided that constantly measure the direction and velocity of the wind 5.
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(45) A key aspect of the invention is using plurality of lightweight, relatively high surface area, hybrid airfoil-sail blades 40 each designed to capture the energy from the wind similar to a sail, allows it to escape primarily the trailing edge of the blade 40 and rotate around the hub assembly 20 with little or no resistance similar to an air foil. As shown in
(46) Referring again to
(47) The hub assembly 20 is also made aluminum and includes three to eight flat mounting surfaces 22. The mounting surfaces 22 are evenly spaced apart over the outside surface of the hub assembly 20. Attached to the mounting surface 22 is the mounting plate 47 on a blade 40 that securely holds the blade 40 radially outward.
(48) Attached over the back surface of the internal frame 44 is a thin outer skin layer 70. When attached to the internal frame 44, the outer skin layer 70 simulates the top surface of an airfoil. Each blade 40 is oriented on the hub assembly 20 so the outer skin layer 70 faces downwind and the leading large curve surface of the blade 40 travels along the path of rotation (denoted by the letter Q in
(49) The internal frame 44 holds the outer skin layer 70 in an airfoil/sail configuration. The leading edge of the outer skin layer 70 is affixed to the frame's tubular leading support member 46. The trailing edge of the outer skin layer 70 is removably attached to the frame's trailing support member 50. Each blade 40 as a relatively large surface area used to generate high torque needed to rotate the generator. As shown in
(50) During operation, the hub assembly 20 rotates so that the cupped or inside surface of each blade 40 faces into the wind 5. A large portion of the wind 5 is captured by the curved section of the blade 40, the end cap 60, and rigid wind spars 62 and redirected laterally over the trailing edge of the blade 40. The wind spars 62 also keep the wind 5 from flowing outward to the outer sections of the blade 50. As each blade 40 rotates, a small portion of the wind travels over the blade's leading edge 41. The dual movement of the wind 5 over the blade 40, creates a highly efficient blade system the captures a higher percentage of wind energy.
(51) The end caps 60 are flat planar structures transversely aligned on the outside surface of each blade 40. They are supported by the distal ends of the leading edge support member 46 and the trailing edge support member 50. In the preferred embodiment, the end caps 60 have an airfoil profile slightly larger but has the same cross-sectional profile as an airfoil. During operation, the end caps 60 prevent wind from moving longitudinally over the end of the blade 40 directing it over the trailing edge 43.
(52) In high wind events, the trailing edges 73 of the outer skin layer 70 are designed to automatically release preventing damage to the blade 40 or hub assembly 20. After the trailing edges are released, the trailing edges 73 of the outer skin layers 70 must be manually reconnected. To control activation of the automatic release feature, it may be desirable to allow wind 5 to escape over the end cap 60 of the blade 40.
(53) The outer skin layer 70 is made of sail cloth material or durable polyethylene film or poly vinyl chloride film. The outer skin layer 70 may be transparent or painted and may include advertising indicia 79 printed thereon.
(54) When a minor or small wind gust occurs, the wind 5 may cause the trailing edge 73 of the outer skin layer 70 to release. To prevent this, the end cap 60 may include one or more louvers 120 that close at lower wind speeds and automatically open at higher wind speeds. The louvers 120 are coupled to motors and wind speed sensors that automatically open the louvers 120 to allow wind to partially or completely flow over the end of the blade 40 to prevent automatically release of the trailing edges.
(55) Using a wind generator as an advertising sign, is important because it allows the wind generator to generate advertising revenue when the winds are low to product electricity When the blade 40 includes advertising indicia 79 (see
(56) In one embodiment, the leading edge of the outer skin layer 70 includes a beaded edge 74 that fits inside a slot 48 formed on the tubular leading support member 46. The trailing edge 72 of the outer skin layer 70 is attached to the trailing support member 50 via hook and loop connectors 80, 82. The hook and loop connectors 80, 82 are parallel and disposed longitudinally along the trailing edge of the outer skin layer 70 and loop around the trailer support member 50 during installation The outer sections of each blade 40 generates the high torque. During high winds, the outer sections of the blades 40 are first to auto-release. As the outer sections are released, the middle and inside sections are then sequentially released until the entire trailing edge 72 of the blade 40 is released. The leading edge or beaded edge 71 of the outer skin layer 70 remains attached to the leading support member 46. Various types of hook and loop connectors 80, 82 with different holding properties may adjust the holding or attachment strength so the trailing edges 72 release at different high wind speeds.
(57) In some high wind events, not all of the hook and loop connectors 80, 82 on the trailing edges of the blades will release automatically. Blades 40 in an elevated position on the hub assembly 20 are exposed to greater winds and auto-release while blades 40 in the lower locations (or location not exposed to direct wind) remain connected. Auto releasing of some but not all of the blades 40 creates an imbalance on the hub assembly 20 that can cause damage. To prevent this unbalance from occurring, a simultaneous trailing edge release mechanism is provided along the trailing edge adjacent to the outer sections of the blades 40 that when activated, causes all of said trailing edges located along the outer sections of each blade to be disconnect from the internal frame. Because, the middle and inside sections typically release sequentially when the outer section of the blade 40 release, only the outer sections of the blades require the simultaneous release mechanism.
(58) The simultaneous trailing edge release shown in
(59) Located on the end plate 60 is a pin 160 attached to release cables 162 that move the push pull rod 182 between blocking and releasing positions. When moved to a releasing position, the push-pull rod causes the rod 182 to release the grommets 184 enabling the trailer edge of the outer skin layer 70 to be released. In the preferred embodiment, the cables are connected to pulleys and motors in the hub assembly 20. The motors are coupled to the wind sensors 7 that monitor the wind for excessive wind speeds.
(60) As discussed above, changing the sweep area of the blades 40 changes the amount of wind energy captured and converted into electrical energy.
(61) In addition to adjusting the longitudinal position of the blades 40 on the mast 570 and moving them relative to the hub assembly 40, in an alternative embodiment of the blades 500 the surface area of each blade 500 may be adjusted. As shown in
(62) More specifically, the first linear actuator frame includes a large inner tube 565 and a small outer tube 568. Affixed to the large inner tube 565 are two perpendicular brackets 570. Attached to the two brackets 570 and extending longitudinally in front of the inner tube 565 are two support arms 569, 571. Mounted on the inner tube is an electric actuator 575.
(63) Attached to the distal end of the small outer tube 568 is a cable connector 581 Attached to the cable connector 581 is a loop cable 551. The ends of the loop cable 551 extend through bores formed on the end bracket and connected to the distal ends of wires that extend longitudinally on the outer skin layer as shown in
(64) Referring to
(65) Each blade 40 may also include a longitudinally aligned rigid guide shield 800 disposed adjacent to the mast 570.
(66) As shown in
(67) Attached to the proximal end of the blade 500 is a slide ring bracket 590 configured to slide over the inner tube 575. Attached to the distal end of the blade 500 is a fixed outer end plate. The drive motor 585 is connected to a wind speed sensor 600, or to a RPM tip speed sensor 605, or to a programmable logic controller (PLC) 610 that continuously monitors the electrical energy produced by the generator. When the sensors 600, 605, or PLC 610 detects low wind speeds, low RPM speed, or low electrical output, respectively, the drive motor 585 is activated which causes the mast 570 to expand its length 25-50%. When the sensor 600, 605, or PLC 610 detects high wind speeds, high tip speed, or excessive electrical output, the drive motors 585 are activated in the reverse direction which causes the masts 570 to retract entirely or to a suitable length.
(68) As stated above, the above generator systems 10 may be configured to the hub assembly 20 is located downstream from the tower 200 as shown in
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(70) Extending upward and coaxially aligned with the lower disc 725 is a rotating cylindrical neck 750. Mounted on the lower edge of the neck 750 is a fixed ring gears 760 with teeth that mesh with a tooth 662 on the locking lever 760. The generator assembly is attached to a generator attachment plate attached to the upper end of the neck 750.
(71) During operation, the locking arm 740 and the linear actuator 730 electrically connected to a voltage sensor (not shown). Programmed in the PODS on-board computer are algorithms that when the voltage reaches a predetermined level the locking arm 740 engages. This maximizes efficiency and eliminates unwanted yaw as a result of wind speed fluctuations. Because the hub assembly is downwind and not tail rudder is used, a phenomena known as wind wandering which reduces efficiently. At any moment, the wind speed and the direction of the wind is constantly changing. When the locking mechanism 760 is used, an inverter (not shown) connected to the generator system 10 extracts power which creates resistance which results in an undesired yawing or twisting. The locking system prevents rotation or yawing of the hub assembly.
(72) In summary, during low to moderate winds the locking mechanism is unlocked so that it may wander and find the wind direction. When a weather front arrives bringing suitable winds, and output voltage reaches a desired level (ie. 150V). The locking mechanism is activated thereby locking the hub assembly in a fixed position. The locking mechanism remains locked until: (a) the system detects a low voltage below present minimum voltage for 10 min; or (b) the system detects high voltages above below a present maximum voltage. When the voltage is below or above the present amounts, the locking mechanism unlocks and the hub assembly may wander.
(73) In compliance with the statute, the invention described has been described in language more or less specific as to structural features. It should be understood however, that the invention is not limited to the specific features shown, since the means and construction shown, comprises the preferred embodiments for putting the invention into effect. The invention is therefore claimed in its forms or modifications within the legitimate and valid scope of the amended claims, appropriately interpreted under the doctrine of equivalents.
INDUSTRIAL APPLICABILITY
(74) This invention has application in the wind generator industry.