System and Method for Reducing Load Fluctuations in Propeller-Driven Machines
20250155006 ยท 2025-05-15
Inventors
Cpc classification
F16H35/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
Abstract
An apparatus for attenuating or counterbalancing external load fluctuations on a propeller driver machine is disclosed. In one embodiment a set of non-circular gears coupled to a rotor shaft or to the gearbox of the machine are further coupled to an auxiliary flywheel. The shapes and inertial characteristics of the non-circular gears and the inertial characteristics of the auxiliary flywheel are designed to counterbalance cyclic load fluctuations experienced by the rotor shaft. In another embodiment, an inertial element is flexibly attached to a rotor shaft by a set of flexible elements of the machine wherein the moment of inertia of the inertial element and the stiffness of the flexible elements are selected to absorb and attenuate external load fluctuations on the rotor shaft. The propeller driven machine may be a HAWG type wind turbine and the external load fluctuations caused by wind shear and tower shadowing effects.
Claims
1. An apparatus for balancing external load fluctuations experienced by a propeller driven machine, wherein the propeller driven machine is driven by a rotor shaft connected to a set of propellers, the apparatus comprising: a first rotatable shaft; an auxiliary flywheel rigidly connected to the first rotatable shaft; a first non-circular gear rigidly connected to the first rotatable shaft; a second rotatable shaft; and a second non-circular gear rigidly connected to the second rotatable shaft; wherein the first non-circular gear and the second non-circular gear are mechanically engaged to rotate in tandem; and wherein the second rotatable shaft is driven at an angular speed n times the angular speed of the rotor shaft.
2. The apparatus of claim 1, where n is the number of propellers in the set of propellers.
3. The apparatus of claim 1, where n is the periodicity of load fluctuations experienced by the propeller driven system.
4. The apparatus of claim 1, further comprising a first gear rigidly attached to the rotor shaft and a second gear rigidly attached to the second rotatable shaft; wherein the ratio of the relative size of the first gear to the second gear determines the angular speed of the second rotatable shaft in relation to the angular speed of the rotor shaft.
5. The apparatus of claim 1, further comprising a gearbox, wherein: the rotor shaft is coupled to the input of the gearbox; the second rotatable shaft is coupled to an output of the gearbox; and a transmission function of the gearbox determines the angular speed of the second rotatable shaft in relation to the angular speed of the rotor shaft.
6. The apparatus of claim 1, wherein the shape of the first and second non-circular gears cause an applied auxiliary torque on the rotor shaft that counterbalances the external load fluctuations on the propeller driven machine while operating.
7. The apparatus of claim 6, where that ratio n:1 is set by the timing of the applied auxiliary torque as required to counterbalance the external load fluctuations.
8. The apparatus of claim 6, wherein the propeller driven machine is a HAWG type wind turbine and wherein the external load fluctuations are due to wind shear and tower shadowing effects.
9. The apparatus of claim 1, wherein: the first rotatable shaft is a cylindrical sleeve concentric to the rotor shaft; the cylindrical sleeve moves independently of the rotor shaft; and the flywheel is concentric to the rotor shaft.
10. An apparatus for balancing external load fluctuations experienced by a propeller driven machine, wherein the propeller driven machine is driven by a rotor shaft connected to a set of propellers, the apparatus comprising: a first rotatable shaft; an auxiliary flywheel rigidly connected to the first rotatable shaft; a first non-circular gear rigidly connected to the first rotatable shaft; and a second non-circular gear rigidly connected to the rotor shaft; wherein the first non-circular gear and the second non-circular gear are mechanically engaged to rotate in tandem; and wherein the second rotatable shaft is driven at an angular speed n times the angular speed of the rotor shaft.
11-22. (canceled)
23. An apparatus for balancing external load fluctuations experienced by a propeller driven machine, wherein the propeller driven machine is driven by a rotor shaft connected to a set of propellers, the apparatus comprising: a first rotatable shaft; a first non-circular gear rigidly connected to the first rotatable shaft; a second rotatable shaft; a second non-circular gear rigidly connected to the second rotatable shaft; wherein the first non-circular gear and the second non-circular gear are mechanically engaged to rotate in tandem; and wherein the second rotatable shaft is driven at an angular speed n times the angular speed of the rotor shaft.
24. The apparatus of claim 23 further comprising: a first circular gear rigidly connected to the first rotatable shaft; and a second circular gear rigidly connected to an auxiliary flywheel; wherein the first circular gear and the second circular gear are mechanically engaged to rotate in tandem; and wherein the relative sizes of the first circular gear and the second circular gear determine the angular speed of the auxiliary flywheel.
25. The apparatus of claim 23 further comprising an auxiliary flywheel rigidly connected to the first rotatable shaft.
26. The apparatus of claim 23 further comprising an auxiliary flywheel indirectly coupled to the rotor shaft so as to rotate at the angular speed of the second non-circular gear.
27. The apparatus of claim 23 further comprising an auxiliary flywheel indirectly coupled to the rotor shaft so as to rotate at an angular speed different than the angular speed of the second non-circular gear.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. The illustrative embodiments, however, as well as a preferred mode of use, further objectives and features thereof, will best be understood by reference to the following detailed description of an illustrative embodiment of the present disclosure when read in conjunction with the accompanying drawings, wherein:
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DETAILED DESCRIPTION
[0024] The illustrative embodiments recognize and take into account that wind turbines are used to generate electrical power from wind energy. The illustrative embodiments also recognize and take into account that gearbox failures are common today in wind turbines due to uneven torque loading.
[0025] The illustrative embodiments provide a method to modulate the torque on the wind turbine rotor shaft to even the torque load in the wind turbine.
[0026]
[0027] The aerodynamic efficiency of the blade is, in general, maximized at a tip speed ratio (TSR=R/U, where is the rotational speed of the rotor, R is the radius of the rotor and U is the wind speed) in the range TSR=6-7. This results, for a turbine with a diameter D=100 m (300 ft), and a wind speed of 10 m/s (22 mph) to about 12-15 revolutions per minute or about 0.2 Hz. Smaller turbines (for example D=50 m (150 ft)) rotate faster (about 20-30) revolutions per minute.
[0028] Wind loads on a wind turbine vary as the turbine blades rotate due to the wind shear. As shown in the graph 200 of
[0029] The fluctuations repeat for each cycle of the blades about their axis of rotation. A turbine, which in general has a life of approximated 20 years, undergoes approximately 200 to 300 million revolutions. Since the rotor has 3 blades the gearbox is subject to about 600-900 million cycles in 20 years (current designs aim to last 30 years). The combination of wind shear and tower shadow effects result in a cyclic load fluctuation which reduces the life of bearings and gears thereby reducing the overall life of the turbine. Reduction of cyclic load fluctuations can also help with voltage/current regulation while generating electric power.
[0030] The novel methodology is disclosed herein where an auxiliary load fluctuation is generated to counterbalance an unwanted load fluctuation that can exist in a wind turbine. The novel methodology may be applied to rotating machines generally.
[0031] An embodiment that applies the novel methodology is shown in
[0032] According to
[0033] Input shaft 305 rotates at angular speed .sub.i while output shaft 302, non-circular gear 304, and flywheel 303 rotate at angular speed .sub.0. In
[0034] In some embodiments, circular gears 307 and 308 are not required in the load balancing assembly as shown in
[0035] Rotor shaft 301 experiences existing external torque fluctuations. Non-circular gears 304 and 306 are both non-circular and may also be non-uniform in thickness. In one embodiment, the shape of the existing external torque fluctuation is used to determine the shape of the non-circular gear pair that couples the rotating wind turbine to the auxiliary flywheel. In other embodiments, a non-uniform thickness of the non-circular gears is modulated and or other inertial characteristics of the non-circular gears are modulated to counterbalance the existing external torque fluctuation.
[0036] In the embodiment of
[0037]
[0038] From the conservation of energy, the power supplied to the system plus the power extracted from the system equals the rate at which power is being stored in the system:
where .sub.i, T.sub.i and I.sub.i are the angular speed, torque, and mass moment of inertia of the input, where .sub.o, T.sub.o and I.sub.o those relative to the output. Variation in T.sub.i is the cyclic torque fluctuation experienced by the turbine. To eliminate the cyclic torque fluctuation, we impose {dot over ()}=0; Since the output shaft is free to rotate T.sub.o=0 and our goal is to have T.sub.i=const and .sub.i=const, equation (1) reduces to
[0039] Using a prime to designate the geometrical derivative with respect to the angular position v.sub.i of the input, the above relationship can be rearranged as
[0040] In the above expression, the term in the parenthesizes is a scaling factor and is speed dependent. In order to determine the transmission function for the non-circular gear pair, the angular position of the output v.sub.o f(v.sub.i) is obtained by solving the above 2.sup.nd order non-linear ODE (Ordinary Differential Equation).
[0041] One boundary condition to be satisfied is that the initial position of the output is aligned with the initial input position such that v.sub.o(0)=0 and a second boundary condition is that the final position is v.sub.o(2)=2 (one revolution of the input non-circular gear yields one revolution of the output non-circular gear).
[0042] Another novel methodology is disclosed where an auxiliary load fluctuation is generated to attenuate load fluctuations that exist in a wind turbine.
[0043] In another embodiment, auxiliary load fluctuations are generated to attenuate unwanted load fluctuations that are inherent in rotating shafts of wind turbines due to wind shear, tower shadowing, surrounding topography, and/or a turbine's location within a wind farm. An example of the alternative embodiment is illustrated in
[0044] In another embodiment, each wind turbine within a wind farm can have a customized load mitigation mechanism comprising of non-circular gears of embodiment X1, tuned vibration absorber of embodiment X2, or a combination of embodiments X1 and X2.
[0045] According to the methodology summarized in
where COE is the cost of energy ($/kWh), ICC is the initial capital cost ($), FCR is the fixed charge rate (%/year) and AEP is the annual energy production (kWh/year).
[0046] According to step 500 of
[0047] According to step 510 of
[0048] In the methods of
[0049] In additional steps, the disclosed torque balancing concept may be integrated into new gearboxes or retrofitted to existing gearboxes.
[0050] The illustrations provided by the disclosed embodiments that reduce the torque load on the bearings and other rotor components in the
[0051] As used herein, the phrase a number means one or more. The phrase at least one of, when used with a list of items, means different combinations of one or more of the listed items may be used, and only one of each item in the list may be needed. In other words, at least one of means any combination of items and number of items may be used from the list, but not all of the items in the list are required. The item may be a particular object, a thing, or a category.
[0052] For example, without limitation, at least one of item A, item B, or item C may include item A, item A and item B, or item C. This example also may include item A, item B, and item C or item B and item C. Of course, any combinations of these items may be present. In some illustrative examples, at least one of may be, for example, without limitation, two of item A; one of item B; and ten of item C; four of item B and seven of item C; or other suitable combinations.
[0053] The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive nor is the present invention limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiment. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed here.
[0054] Further, different illustrative embodiments may provide different features as compared to other illustrative embodiments. The embodiment or embodiments selected are chosen and described in order to best explain the principles of the embodiments, the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.
[0055] Some features of the illustrative examples are described in the following clauses. These clauses are examples of features not intended to limit other illustrative examples.
Clause 1
[0056] An apparatus for balancing external load fluctuations experienced by a propeller driven machine, wherein the propeller driven machine is driven by a rotor shaft connected to a set of propellers, the apparatus comprising: [0057] a first rotatable shaft; [0058] an auxiliary flywheel rigidly connected to the first rotatable shaft; [0059] a first non-circular gear rigidly connected to the first rotatable shaft; [0060] a second rotatable shaft; and [0061] a second non-circular gear rigidly connected to the second rotatable shaft; [0062] wherein the first non-circular gear and the second non-circular gear are mechanically engaged to rotate in tandem; and [0063] wherein the second rotatable shaft is driven at an angular speed n times the angular speed of the rotor shaft.
Clause 2
[0064] The apparatus of clause 1, where n is the number of propellers in the set of propellers.
Clause 3
[0065] The apparatus of clause 1, where n is the periodicity of load fluctuations experienced by the propeller driven system.
Clause 4
[0066] The apparatus of clause 1, further comprising a first gear rigidly attached to the rotor shaft and a second gear rigidly attached to the second rotatable shaft; wherein the ratio of the relative size of the first gear to the second gear determines the angular speed of the second rotatable shaft in relation to the angular speed of the rotor shaft.
Clause 5
[0067] The apparatus of clause 1, further comprising a gearbox, wherein: [0068] the rotor shaft is coupled to the input of the gearbox; [0069] the second rotatable shaft is coupled to an output of the gearbox; and [0070] a transmission function of the gearbox determines the angular speed of the second rotatable shaft in relation to the angular speed of the rotor shaft.
Clause 6
[0071] The apparatus of clause 1, wherein the shape of the first and second non-circular gears cause an applied auxiliary torque on the rotor shaft that counterbalances the external load fluctuations on the propeller driven machine while operating.
Clause 7
[0072] The apparatus of clause 6, where that ratio n:1 is set by the timing of the applied auxiliary torque as required to counterbalance the external load fluctuations.
Clause 8
[0073] The apparatus of clause 6, wherein the propeller driven machine is a HAWG type wind turbine and wherein the external load fluctuations are due to wind shear and tower shadowing effects.
Clause 9
[0074] The apparatus of clause 1, wherein: [0075] the first rotatable shaft is a cylindrical sleeve concentric to the rotor shaft; [0076] the cylindrical sleeve moves independently of the rotor shaft; and [0077] the flywheel is concentric to the rotor shaft.
Clause 10
[0078] An apparatus for balancing external load fluctuations experienced by a propeller driven machine, wherein the propeller driven machine is driven by a rotor shaft connected to a set of propellers, the apparatus comprising: [0079] a first rotatable shaft; [0080] an auxiliary flywheel rigidly connected to the first rotatable shaft; [0081] a first non-circular gear rigidly connected to the first rotatable shaft; and [0082] a second non-circular gear rigidly connected to the rotor shaft; [0083] wherein the first non-circular gear and the second non-circular gear are mechanically engaged to rotate in tandem; and [0084] wherein the second rotatable shaft is driven at an angular speed n times the angular speed of the rotor shaft.
Clause 11
[0085] A tuned vibration absorber for attenuating external torque fluctuations experienced by a wind turbine, wherein the wind turbine is driven by a rotor shaft connected to a propeller apparatus, the tuned vibration absorber comprising an inertial element connected by a set of flexible elements to the rotor shaft.
Clause 12
[0086] The apparatus of clause 11 wherein the inertial element is a toroid.
Clause 13
[0087] The apparatus of clause 11 wherein m.sub.1 is the inertia of the rotor shaft and propeller apparatus; m.sub.2 is the added moment of inertia of the inertial element and k is the stiffness of the flexible elements and wherein the values of m.sub.2 and k are selected to cause the tuned vibration absorber to reduce the external torque fluctuations.
Clause 14
[0088] The apparatus of any of the clauses 11-13 wherein the wind turbine is a HAWG type wind turbine and wherein the external torque fluctuations are due to wind shear and tower shadowing effects.
Clause 15
[0089] A method for attenuating external torque fluctuations experienced by a rotor shaft of a propeller driven machine, the method comprising the step of accelerating an auxiliary flywheel coupled to the rotor shaft to create an auxiliary torque fluctuation on the rotor shaft that counters the external torque fluctuation.
Clause 16
[0090] The method of clause 15 wherein the step of acceleration includes positive and negative angular accelerations.
Clause 17
[0091] The method of clause 15 further comprising the steps of: [0092] coupling a set of non-circular gears to the rotor shaft; and [0093] rigidly attaching the auxiliary flywheel to a non-circular gear of the set of non-circular gears.
Clause 19
[0094] The method of clause 15 further comprising the steps of: [0095] coupling a set of non-circular gears to the rotor shaft; and [0096] indirectly coupling the auxiliary flywheel to a non-circular gear of the set of non-circular gears so that the auxiliary flywheel rotates an angular speed different than the angular speed of the non-circular gear.
Clause 19
[0097] The method of clause 18 further comprising the step of determining the shapes of the set of non-circular gears and the inertial characteristics of the auxiliary flywheel such that the net torque fluctuations on the rotor shaft is reduced.
Clause 20
[0098] The method of clause 15 further comprising the step of determining the inertial characteristics of the auxiliary flywheel such that the net torque fluctuations on the rotor shaft is reduced.
Clause 21
[0099] A method for attenuating external torque fluctuations experienced by a wind turbine, the method comprising the step of coupling a tuned vibration absorber to the rotor shaft wherein the tuned vibration absorber adds an auxiliary torque fluctuation on the rotor shaft that absorbs and attenuates the external torque fluctuation.
Clause 22
[0100] The method of clause 21 further comprising the steps of: [0101] coupling an added inertial element to the rotor shaft by a set of flexible elements; and, [0102] selecting the moment of inertia of the added inertial elements and the stiffness of the flexible elements to cause an absorption of the external torque fluctuations thereby reducing the net torque fluctuation on the rotor shaft.
Clause 23
[0103] An apparatus for balancing external load fluctuations experienced by a propeller driven machine, wherein the propeller driven machine is driven by a rotor shaft connected to a set of propellers, the apparatus comprising: [0104] a first rotatable shaft; [0105] a first non-circular gear rigidly connected to the first rotatable shaft; [0106] a second rotatable shaft; [0107] a second non-circular gear rigidly connected to the second rotatable shaft; [0108] wherein the first non-circular gear and the second non-circular gear are mechanically engaged to rotate in tandem; and [0109] wherein the second rotatable shaft is driven at an angular speed n times the angular speed of the rotor shaft.
Clause 24
[0110] The apparatus of clause 23 further comprising: [0111] a first circular gear rigidly connected to the first rotatable shaft; and [0112] a second circular gear rigidly connected to an auxiliary flywheel; [0113] wherein the first circular gear and the second circular gear are mechanically engaged to rotate in tandem; and [0114] wherein the relative sizes of the first circular gear and the second circular gear determine the angular speed of the auxiliary flywheel.
Clause 25
[0115] The apparatus of clause 23 further comprising an auxiliary flywheel rigidly connected to the first rotatable shaft.
Clause 26
[0116] The apparatus of clause 23 further comprising an auxiliary flywheel indirectly coupled to the rotor shaft so as to rotate at the angular speed of the second non-circular gear.
Clause 27
[0117] The apparatus of clause 23 further comprising an auxiliary flywheel indirectly coupled to the rotor shaft so as to rotate at an angular speed different than the angular speed of the second non-circular gear.