Deployable Shell Reversible Camber Sail System

Abstract

One embodiment of a deployable reversible camber sail system, based on a deployable shell (58) contained within a mast-sail assembly (11, 12) and supported and controlled by additional assemblies (13-15), is disclosed. The embodiment may be easily and quickly configured into the furled, feathered, port tack and starboard tack sail forms. In addition, this embodiment represents a highly efficient sail module which may be controlled by a single human operator or automated computer-based control system. Additional embodiments, utilizing assemblages of the first embodiment sail system module, are described.

Claims

1. A deployable sail system, comprising: a. a deployable shell (31-37), b. a first assembly (11, 12) providing storage and support of said deployable shell, c. a system of second and third assemblies (13, 14), connected to said first assembly, providing means of deployment, and means of guidance and support of deployed shell (58), and d. a fourth assembly (15), connected to the base of combined said deployable shell, first, second and third assemblies, providing means of support and rotation of combined said deployable shell, first, second and third assemblies, whereby application of energy to said second and third assemblies causes said shell to retract, deploy, or change cross-section configuration; and application of energy to said fourth assembly causes combined said shell, second and third assemblies, to rotate as a rigid body.

2. The deployable sail system of claim 1 wherein said first assembly comprises: a. a central mast (56), b. surrounding said mast, a control and guide connection tube (57), c. surrounding said control and guide connection tube, said deployable shell (31-37), d. impinging on said deployable shell system, two shell compression rollers (54), e. surrounding said compression rollers, an inner fairing (52), f. attached to said inner fairing, two fairing sheet take-up rolls (53), g. surrounding said fairing sheet take-up rolls, an outer aerodynamic fairing (51), h. attached to said deployable shell and said fairing sheet take-up rolls, two flexible fairing sheets (55).

3. The deployable sail system of claim 2 wherein said deployable shell comprises: a. an outer shell panel (31), b. an inner shell panel (32), c. a plurality of elongated web elements (33), d. a plurality of web-to-panel hinges (35), e. a mandrel (36), f. a mandrel-to-shell connection device (37), g. a plurality of web support and guides (41).

4. The deployable sail system of claim 3 wherein said web elements and hinges may be fabricated integrally of a core material and fiber reinforced polymer.

5. The deployable sail system of claim 2 wherein said compression rollers (54) are not continuous in said deployable shell vertical direction and are connected to said inner fairing (52) by means of spring structures.

6. The deployable sail system of claim 2 wherein said fairing sheet take-up rolls (53) are continuous in said deployable shell vertical direction and are spring loaded so as to exert a tensile membrane force on said flexible fairing sheets (55).

7. The deployable sail system of claim 1 wherein each said second and third assembly comprises: a. a control and guide assembly housing (61), b. attached to the outside of said control and guide assembly housing, a shell support and guide track (62), c. contained within said control and guide assembly housing, a guide track-cam connection pin (63), d. contained within said control and guide assembly housing, a sail module connection flange (64), e. contained within said control and guide assembly housing, a fairing support ring (65), f. contained within said control and guide assembly housing and attached to said mandrel (36), a cam plate (66), g. contained within said control and guide assembly housing and providing a means of rotational energy, a fairing rotation torque motor (67), h. contained within said control and guide assembly housing and providing a means of rotational energy, a cam plate-mandrel torque motor (68), i. contained within said control and guide assembly housing and providing support to said cam plate (66), a first tapered roller bearing (82), j. contained within said control and guide assembly housing and providing support to said fairing support ring (65), a second tapered roller bearing (82), k. attached to the outside of said control and guide assembly housing when sail module is configured singly, a mast top cover (71). l. located inside of said mast top cover (71), a mast alignment ball bearing (72).

8. The deployable sail system of claim 7 wherein said guide track-cam connection pin (63) spring is compressed by means of either mechanical, electrical, hydraulic energy, or combination thereof.

9. The deployable sail system of claim 7 wherein said fairing rotation torque motor (67) is actuated by means of electric or hydraulic energy.

10. The deployable sail system of claim 7 wherein said cam plate-mandrel torque motor (68) is actuated by means of electric or hydraulic energy.

11. The deployable sail system of claim 1 wherein said fourth assembly comprises: a. a mast step-module rotation housing (85), b. contained within said mast step-module rotation housing, a mast alignment ball bearing (72), c. a sail module support flange (81), d. contained within said mast step-module rotation housing, a first tapered roller bearing (82), e. contained within said mast step-module rotation housing, a second tapered roller bearing (82), f. contained within said mast step-module rotation housing, an outer support tube (83), g. contained within said mast step-module rotation housing, a sail module torque motor (84).

12. The deployable sail system of claim 11 wherein said module torque motor (84) is actuated by means of electric or hydraulic energy.

13. A mast head assembly, comprising: a. a mast head assembly housing (91), b, attached to said mast head assembly housing, a forestay attachment fitting (92), c, attached to said mast head assembly housing, a plurality of shroud attachment fittings (93), d, attached to said mast head assembly housing, a backstay attachment fitting (94), e, contained within said mast head assembly housing, a mast alignment ball bearing (72), f, contained within said mast head assembly housing, a first tapered roller bearing (82), g, contained within said mast head assembly housing, a second tapered roller bearing (82), h. supporting said first and second tapered roller bearings, a sail module connection flange (95), whereby connection of said mast head assembly to the upper control and guide assembly (13) of a sail module, and fixation of said attachment fittings (92-94) to secured standing rigging enables additional external support of said sail module or assemblage of said sail modules.

Description

DRAWINGS—FIGURES

[0024] In the drawings, closely related figures have the same number but differing alphabetical suffixes.

[0025] FIGS. 1A through 1D illustrate the first embodiment basic assemblies of the sail system in furled, port tack, feathered and starboard tack configurations, respectively.

[0026] FIGS. 2A through 2D illustrate the first embodiment sail system configurations for typical sailing conditions: furled, starboard tack, feathered and port tack, respectively.

[0027] FIGS. 3A and 3B show horizontal cross-sections of the mandrel and deployable shell in both furled and deployed configurations.

[0028] FIGS. 4A and 4B illustrate end and side views of a typical web element, and attached hinges and web support-guide.

[0029] FIGS. 5A through 5D are cross-sectional views of the mast and mast-sail assemblies for the furled, port tack, feathered and starboard tack configurations, respectively.

[0030] FIGS. 6A through 6G illustrate a typical control and guide assembly: overall side view, plan view, plan detail 1, cross-section detail 1, plan detail 2, cross-section detail 2, mandrel base-cam plate detail.

[0031] FIGS. 7A and 7B are cross-section and plan views of the upper control and guide assembly cover for use in free-standing sail module applications.

[0032] FIGS. 8A and 8B are mast step-sail rotation assembly plan and cross-section views.

[0033] FIGS. 9A through 9C show, for use with standing rigging applications, the additional embodiment mast head assembly overall views, and cross-section details.

[0034] FIG. 10 illustrates a conceptual high performance yacht additional embodiment.

[0035] FIG. 11 shows a conceptual purpose-built commercial sailing vessel additional embodiment.

[0036] FIG. 12 illustrates a conceptual sail-augmented commercial transport vessel additional embodiment.

[0037]

TABLE-US-00003 Drawings - Reference Numerals 11 furled mast-sail assembly 12 deployed mast-sail assembly 13 upper control and guide assembly 14 lower control and guide assembly 15 mast step - module rotation assembly 21 true wind direction 31 outer shell panel 32 inner shell panel 33 typical web element 34 typical web support location 35 typical web-to-panel hinge 36 mandrel 37 mandrel-to-shell connection device 41 web support and guide 51 outer aerodynamic fairing 52 inner fairing 53 fairing sheet take-up roll 54 shell compression roller 55 flexible fairing sheet 56 mast 57 control and guide connection tube 58 deployed shell 59 airfoil chord 61 control and guide assembly housing 62 shell support and guide track 63 guide track - cam connection pin 64 sail module connection flange 65 fairing support ring 66 cam plate 67 fairing rotation torque motor 68 cam plate - mandrel torque motor 69 guide track rotation center pin 71 mast top cover 72 mast alignment ball bearing 81 sail module support flange 82 tapered roller bearing 83 outer support tube 84 sail module torque motor 85 mast step - module rotation housing 91 mast head assembly housing 92 forestay attachment fitting 93 shroud attachment fitting 94 backstay attachment fitting 95 sail module connection flange

EMBODIMENT DETAILED DESCRIPTIONS

First Embodiment—FIGS. 1A through 2D

[0038] FIGS. 1A through 1D illustrate, respectively, four views of this embodiment: the sail system in the furled configuration, port tack, feathered and starboard tack configuration. As shown in the figures, this sail system embodiment is composed of four assemblies: the mast-sail assembly 11 and 12, the upper control and guide assembly 13, lower control and guide assembly 14, and the mast step and sail rotation assembly 15. Detailed descriptions of these assemblies are given in the following paragraphs.

[0039] Actual usage of the sail system embodiment is symbolically shown in FIGS. 2A through 2D for various sailing conditions where the large arrow 21 indicates the direction of the true wind. The initial sail system furled condition is shown in FIG. 2A. FIG. 2B illustrates use of the system for a starboard tack wind. During a tacking maneuver, a feathered sail system configuration may be employed, as shown in FIG. 2C. Following completion of the tacking maneuver, the port tack configuration is shown in FIG. 2D. All of the sail system configuration changes shown in these figures are performed using motors contained in the individual assemblies. These motors may be controlled manually or by a computerized control system

First Embodiment, Mast-Sail Assembly—FIGS. 3A through 5D

[0040] The heart of the embodiment is a deployable shell, as described in detail in the Cross-reference, and shown in FIGS. 3A and 3B. FIG. 3A illustrates an enlarged cross-section of the un-deployed, or furled, shell. It consists of an elastic outer panel 31 and a similar inner panel 32 connected by hinged 35 curved webs 33. Both panels are attached to an elongated hinged connection device 37 which is, in turn, connected to a cylindrical mandrel 36. Upon clockwise rotation of the mandrel, the shell is deployed (unfurled) as illustrated in FIG. 3B. Position of the deployed shell is controlled by guide devices attached to the web ends whose location 34 is shown on the cross-section. In FIG. 3B, the guide devices are constrained within linear tracks (not shown) located along the centerline of the deployed shell.

[0041] FIGS. 4A and 4B show enlarged views of a typical web 33, one end of which is illustrated. Also shown are typical integral hinges 35 and web guide-support 41 which is bedded within the web. It is noted that, in this depiction, webs and integral hinges would be constructed of core material and fiber reinforced polymer (FRP) where the rotation region of the hinge remains flexible.

[0042] A cross-section of the entire furled mast-sail assembly is depicted in FIG. 5A. In addition to the stowed shell, the central region contains the mast 56 and the control and guide connection tube 57. The mast 56 is not directly connected to the sail assembly, but is firmly anchored to the vessel and helps stabilize the sail assembly. Also shown is the outer aerodynamic fairing 51 and inner fairing 52. Attached to and contained within the outer fairing are two flexible aerodynamic sheet take-up and storage spools 53. The spring-loaded spools release the flexible sheets 55 as the sail shell is deployed and store the sheets as the sail is furled. Contained within the inner fairing are shell compression rollers 54. The roller suspensions, which are attached to the inner fairing, are pre-sprung so as to provide a radial inward force to the furled shell, thus maintaining a compact furled configuration.

[0043] FIGS. 5B through 5D illustrate cross-sections of the mast-sail assembly for three deployed shell configurations: port tack, feathered and starboard tack, respectively. It is seen that both flexible aerodynamic sheets 55 are attached to the shell panels approximately half-way along the deployed shell. Also, it is seen that the aerodynamic fairings. 51 and 52, rotate together about the mast centerline to positions which depend on the deployed configuration. For aerodynamic parameter (lift and drag coefficients as functions of relative wind angle measured from the airfoil chord) definitions, the airfoil chord 59 is shown for both port and starboard tack configurations.

[0044] Upon deployment of the shell 58 and rotation of the fairings 51 and 52, the embodiment is in the port tack configuration, FIG. 5B. From this configuration, rotation of the mandrel 36 and attached shell 58 results in the feathered configuration, FIG. 5C. Further rotation of the mandrel and attached shell results in the starboard tack configuration, FIG. 5D. Also, the fairings 51 and 52 are rotated during these embodiment configuration changes.

First Embodiment, Control and Guide Assembly—FIGS. 6A through 7B

[0045] Side and plan views of the overall control and guide assembly are shown in FIGS. 6A and 6B. The purpose of this assembly is provision of means for rotation of the deployable shell mandrel and the aerodynamic fairing system. In addition, the assembly provides a secure base for the shell support and guide track. Only one assembly is described since the upper and lower assemblies are mirror images. For clarity, the deployable shell 58 and internal structural bracing of the assembly body 61 are not shown. Included in the plan view are the fairings 51 and 52. A portion of fairing 51 is also shown in FIG. 6A. The shell support and guide track 62 is shown in the feathered configuration position, FIG. 6B.

[0046] FIGS. 6C and 6D are a detailed plan and cross-section of the mast end of the control and guide assembly. The luff-end of the support and guide track 62 is attached, by means of pin 63 to the cam plate 66 which is, in turn, attached to and forms the base of mandrel 36. The guide and control assembly connection tube 57 is attached to both upper and lower guide and control assemblies by means of the sail module connection flange 64 thus assuring that both assemblies synchronously rotate about the mast centerline. Both of the fairings 51, 52 are connected to the fairing support ring 65. This ring and the cam plate 66 are supported by the assembly connection tube 57 by means of tapered roller bearings 82. The circular cam plate is rotated by means of a motor 68. An additional motor 67 rotates the fairing support ring 65 which is not circular due to the limited rotary motion of the fairings. Both of the motors may be powered by either electric or hydraulic means.

[0047] FIGS. 6E and 6F are plan and cross-section details of the guide and control assembly leech end. Shown are the support track 62 end and track rotation center pin 69. In addition to centering track rotation, pin 69 captures the track, in a slot, so as to allow longitudinal track movement with respect to the assembly body 61.

[0048] FIG. 6G is a detail plan view of the cam plate 66 and mandrel 36 cross-section. The guide track-cam connection pin 63 rides in the cam plate groove. In the fully furled configuration, the connecting pin is located at the outermost groove end. During shell deployment, the pin follows the groove inward until it reaches the innermost groove end at full deployment. The pin 63 is spring loaded so that upon reaching the inner groove end, it extends into the circular depression at the groove end, thus translationally locking the track end to the cam plate. This allows the track end and mandrel to synchronize during sail embodiment tacking configuration changes. At the beginning of the furling configuration change, the pin 63 is forced out of the locking depression by mechanical or hydraulic means, thus allowing the pin to follow the cam plate 66 groove during mandrel rotation for shell retraction.

[0049] FIGS. 7A and 7B are cross-section and plan views of the mast top alignment bearing 72 and cover 71. This small assembly is used for stand-alone single embodiment module applications, such as those illustrated in FIGS. 2A through 2D where the cover flange is attached to the upper control and guide assembly 13.

First Embodiment, Mast Step and Sail Module Rotation Assembly—FIGS. 8A and 8B

[0050] FIGS. 8A and 8B are plan and cross-section views of the mast step and sail module rotation assembly. The purpose of this assembly is for secure fixation of the mast base to the vessel and for the means of rotation of the entire sail system. Vertical support of the sail system is provided by the sail module support flange 81. The vertical support force is, in turn, transmitted through bearings 82 to the outer support tube 83, and thus, to the vessel. Horizontal force transmitted from the sail to the vessel is resisted by composite bending of the mast 56, support flange 81 and outer support tube 83, as well as by shear resistance of these components. A means of rotational force applied to the support flange is provided by the sail module torque motor 84.

First Embodiment—Construction and Operation

[0051] Construction of this sail system is straightforward, even for the deployable shell portion of the mast-sail assembly. As described in the Cross-reference, construction of this sub-assembly is easily accomplished by first attaching the outer and inner shell panels 31, 32 to a construction mandrel of similar dimensions to that of the embodiment mandrel 36. The web-hinge-support panels (33, 35, 41) are preassembled. For each web, the hinges are attached to both of the shell panels after which the construction mandrel is rotated and the process repeated for all webs. Thus, proper spacing of the hinge-to-panel connections is automatically ensured.

[0052] A variety of construction materials is possible. Due to the versatility and high strength to weight ratio of fiber reinforced polymers (FRPs), these materials are well-suited for the deployable shell design. High strength to weight metals, such as heat-treated aluminum alloy, are suitable for the mast 56 and assembly covering skins. For those portions of the embodiment requiring high strength and durability, such as the mast step-sail rotation assembly (81 and 83) and the load bearing portions of the control and guide assembly (65 and 66), a high strength steel alloy is appropriate.

[0053] Operational ease and efficiency are important design requirements of this embodiment. FIGS. 2A through 2D illustrate typical operational configurations. A transition from furled, FIG. 2A, to starboard tack. FIG. 2B, configurations requires operation of only motors 67 (fairing rotation) and 68 (mandrel rotation). Motor 84 is then utilized for rotational trimming the embodiment to obtain maximum driving force. Transition from the starboard tack to port tack. FIG. 2D, configurations is accomplished while passing through the feathered configuration, FIG. 2C. Only small movements of mandrel and fairing are required while the embodiment rotational position is adjusted to account for the vessel course change. All of these operations may be easily accomplished by a single human operator. Alternatively, using input from wind and course sensors, operation of the embodiment configuration change motors may be automated utilizing programmed computer control. Experimentally determined module lift and drag coefficients, as functions of relative wind angle of attack, would be utilized in computer automation.

Additional Embodiments—FIGS. 9A through 12

[0054] Among many possible, three additional, embodiments are briefly described. These embodiments illustrate usage of the first embodiment module for creation of multi-module applications. The additional embodiments are configured for actual vessel usage. Thus, dimensions of a typical first embodiment module are taken to be: total height (excluding mast step and rotation assembly)—10 m, total maximum horizontal width—4 m. Therefore, for embodiments requiring two or more stacked modules, additional lateral support, in addition to inherent module strength, may be required. This is accomplished with conventional standing rigging.

Additional Embodiments, Mast Head Assembly—FIGS. 9A through 9C

[0055] For standing rigging attachment to stacked modules, a mast-head rigging attachment assembly is required which is attached to the top of the uppermost sail module. Overall exterior views of the mast head assembly 91 are illustrated in FIG. 9A. Fittings are provided for: forestay 92, shroud lines 93 and backstay 94 fittings. FIGS. 9B and 9C are cross-section details of the mast attachment region. The assembly is securely attached to the mast 56 at its top end, thus constraining the assembly alignment to that of the vessel. The preponderance of vertical rigging loads are carried by the mast directly to the vessel through the mast step assembly. Some vertical load and horizontal axis bending moments induced by the rigging are carried by bearings 82 and flange 95 which is attached to the upper surface of the uppermost sail module. Bearings 72 also carry some of the bending moment induced horizontal force as well as providing alignment with the mast.

Additional Embodiments, High Performance Yacht—FIG. 10

[0056] Non-commercial applications of the first embodiment sail system include recreational and competitive vessels. FIG. 10 illustrates a high performance yacht embodiment where two basic sail modules are vertically combined on a single mast, including mast step 15 and head 91 assemblies, with full standing rigging support. From the basic module dimensions assumed, this embodiment sail area is nominally 80 square m with overall aspect ratio 5.0. Also, conventional sails, such as a jib and spinnaker could be used in the forward part of the yacht. The resulting vessel would be highly efficient, and when used in regatta environments, very competitive.

Additional Embodiments, Commercial Applications

[0057] Due to the exceptional efficiency and operability of the first embodiment sail system module, adaptations of this sail embodiment to commercial uses is both profitable and extremely environmentally friendly. Crew numbers required for both maintenance and operation of a large number of sail modules is small. Both efficiency and operability of the sail modules is enhanced through computer controlled automation of the module configuration modification motors. Also, prevailing wind patterns would be included in course planning so as to minimize use of conventional fuels while maintaining acceptable passage times.

Additional Embodiments, Purpose-built Sailing Vessel—FIG. 11

[0058] In the 19th and early 20th centuries, the fabric-sailed multi-masted schooner was one of the most popular ship configurations. However, sail handling required a sizable crew which, together with relatively inefficient sails, contributed to poorer economics when compared with fossil fuel powered vessels. However, very efficient sail design and automated operations results in much greater cost-effectiveness which, in turn, could be realized in modern commercial sailing vessels.

[0059] A conceptual purpose-built sailing vessel is illustrated in FIG. 11 where thirteen basic sail modules are combined to form a five-masted schooner (three masts with three modules each and two masts with two modules each) having a total sail area of 520 sq m (based on nominal module dimensions, 4 m×10 m). This vessel could be effectively utilized for coastal cargo transport or fishing operations. In addition, “wind-jammer” passenger cruises are becoming increasingly popular. This type of vessel would be perfectly suited for medium capacity passenger cruises.

Additional Embodiments, Sail-augmented Commercial Transport Vessel—FIG. 12

[0060] Hybrid sail-fossil fuel powered commercial vessels are feasible where a conventional propulsive system is augmented with wind power. This system would be effective for relatively low vessel speed operations in generally favorable prevailing wind regions. The key for realizing sail power propulsive augmentation is computerized control of the sail modules based on experimentally derived lift-drag data for expected wind speeds and sail module configurations.

[0061] FIG. 12 illustrates a conceptual sail module system utilized on a medium capacity commercial bulk liquid transport vessel. An important factor is the ability to easily and inexpensively modify existing conventionally powered vessels with sail module based structures. The figure shows how groups of six sail modules may be assembled onto bridge-like structures which are attached to the vessel gunwales.

Additional Embodiments—Advantages

[0062] A number of advantages are evident in the embodiments described above:

[0063] (a) Inherent modularity of the first embodiment sail system allows great flexibility when building additional embodiments utilizing module combinations.

[0064] (b) Recreational usage embodiments enable safe and easily manageable, yet fast and efficient yachting vessels.

[0065] (c) Embodiments targeting competition usage have the advantages of high speeds due to module efficiency and rapid configuration changes due to ease of module operation.

[0066] (d) Commercial usage embodiments enable cost-effective utilization of sail power, due to efficiency and operability, for vessels whose primary motive energy source is wind and for sail power augmentation where the primary energy source is fossil fuels.

CONCLUSION, RAMIFICATIONS AND SCOPE

[0067] A deployable shell reversible camber sail system has been disclosed. This system is relatively simple in concept and construction, yet is highly efficient and easily operable with the following capabilities: [0068] it has a compact furled configuration which is easily and quickly converted to the deployed configuration; [0069] in its deployed configuration, it has a very large stiffness to weight ratio which results in low weight, deformations and flutter, [0070] when deployed, it easily and quickly modified into the feathered, port tack, starboard tack and furled configurations; [0071] in its deployed configuration, it forms a highly efficient reversible camber airfoil; [0072] operation of the system is accomplished using servo-motors which enables easy operability and the ability to automate operation; and [0073] due to the first embodiment's inherent modularity, many recreational, competitive and commercial additional embodiment designs are possible using combinations of the basic module.

[0074] Althrough the above discussion contains many specificities, these should not be construed as limiting the scope of the embodiments, but as merely providing illustrations of some of several embodiments. Thus the scope of the embodiments should be determined by the appended claims and their legal equivalents, rather than by the examples given.