Wind Turbine

Abstract

A wind driven electric generator including a rotor which intercepts air movement to turn a drive line including a first right angle drive swivelly coupled on the top of a support tower and a second right angle drive located proximate ground level to deliver rotational energy of a drive line to an electric generator located proximate ground level.

Claims

1. A wind turbine, comprising: a swivel assembly including: a swivel plate having a top and a bottom; a swivel sleeve extending from said bottom of said swivel plate; a swivel sleeve passage extending axially through said swivel plate and said swivel sleeve; and an upper platform mountable on a support tower, said upper platform having an aperture element through which said swivel sleeve extends, said swivel sleeve rotatable within said aperture element.

2. The wind turbine of claim 1, further comprising an adaptor sleeve coupled to said swivel plate, said adaptor sleeve having an adaptor passage between an adaptor sleeve first and second ends.

3. The wind turbine of claim 2, further comprising an adaptor shaft having adaptor shaft first and second ends, said adaptor shaft having an adaptor shaft external surface rotationally journaled in said adaptor sleeve.

4. The wind turbine of claim 3, further comprising a first right angle drive having a first right angle drive input shaft orthogonal to a first right angle drive output shaft, said first right angle drive mounted on said top of said swivel plate, said first right angle drive input shaft connected to said adaptor shaft second end, said first right angle drive output shaft extending through said swivel sleeve passage.

5. The wind turbine of claim 4, further comprising a rotor including one or more rotor vanes connected in radial spaced apart relation about a rotor hub, said rotor having a rotor axis defined by a rotor shaft extending from said rotor hub, said rotor shaft connected to said adaptor shaft first end.

6. The wind turbine of claim 5, further comprising a tail vane connected to said swivel plate, said tail vane disposed in orthogonal relation to said rotor.

7. The wind turbine of claim 6, further comprising a pivot shaft secured in a pivot mount coupled to said swivel plate, said tail vane pivotally coupled to said pivot shaft.

8. The wind turbine of claim 7, further comprising a brake linkage connected between said tail vane and a brake lever, said brake linkage responsive to pivoting of said tail vane toward parallel with said rotor, said brake lever operable to control constriction and expansion of a band brake disposed circumferentially about an external surface of said rotor hub.

9. The wind turbine of claim 6, wherein said support tower has support tower top and bottom ends, said upper platform mounted on said support tower top end, said support tower bottom end coupled to a foundation set in a ground.

10. The wind turbine of claim 9, wherein said support tower comprises three supports, said three supports correspondingly vertically disposed in each corner of an equilateral triangle.

11. The wind turbine of claim 9, further comprising a second right angle drive having a second right angle drive input shaft orthogonal to a second right angle drive output shaft, said second right angle drive located on said foundation, said first right angle drive output shaft connected to said second right angle drive input shaft by a drive line.

12. The wind turbine of claim 11, further comprising an electric generator having a generator input shaft, said generator input shaft connected to said second right angle drive output shaft.

13. The method of making a wind turbine, comprising: providing a swivel assembly including: a swivel plate having a top and a bottom; a swivel sleeve extending from said bottom of said swivel plate; a swivel sleeve passage extending axially through said swivel plate and said swivel sleeve; and extending said swivel sleeve through an aperture element of an upper platform mountable on a support tower, said swivel sleeve rotatable within said aperture element.

14. The method of claim 13, further comprising coupling an adaptor sleeve to said swivel plate, said adaptor sleeve having an adaptor passage between an adaptor sleeve first and second ends.

15. The method of claim 14, further comprising rotationally journaling an adaptor shaft external surface of an adaptor shaft in said adaptor sleeve, said adaptor shaft having adaptor shaft first and second ends.

16. The method of claim 15, further comprising mounting a first right angle drive on said top of said swivel plate, said first right angle drive having a first right angle drive input shaft orthogonal to a first right angle drive output shaft, connecting said first right angle drive input shaft to said adaptor shaft second end, and extending said first right angle drive output shaft through said swivel sleeve passage.

17. The method of claim 16, further compressing connecting one or more rotor vanes in radial spaced apart relation about a rotor hub of a rotor, said rotor having a rotor axis defined by a rotor shaft extending from said rotor hub, and connecting said rotor shaft to said adaptor shaft first end.

18. The method of claim 17, further comprising connecting a tail vane to said swivel plate, and disposing said tail vane in orthogonal relation to said rotor.

19. The method of claim 18, further comprising securing a pivot shaft in a pivot mount coupled to said swivel plate, and pivotally coupling said tail vane to said pivot shaft.

20. The method of claim 19, further comprising connecting a brake linkage between said tail vane and a brake lever, said brake linkage responsive to pivoting of said tail vane toward parallel with said rotor, said brake lever operable to control constriction and expansion of a band brake disposed circumferentially about an external surface of said rotor hub.

21. The method of claim 20, wherein said support tower has support tower top and bottom ends, further comprising mounting said upper platform on said support tower top end, and coupling said support tower bottom end to a foundation set in a ground.

22. The method of claim 21, wherein said support tower comprises three supports, further comprising correspondingly vertically disposing said three supports in each corner of an equilateral triangle.

23. The method of claim 22, further comprising locating a second right angle drive on said foundation, said second right angle drive having a second right angle drive input shaft orthogonal to a second right angle drive output shaft, and connecting said first right angle drive output shaft to said second right angle drive input shaft by a drive line.

24. The method of claim 23, further comprising connecting a generator input shaft of an electric generator to said second right angle drive output shaft.

Description

IV. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a first perspective elevation view of an embodiment of the inventive wind driven electric generator.

[0009] FIG. 2 is a second perspective elevation view of the embodiment of the inventive wind turbine shown in FIG. 1.

[0010] FIG. 3 is an exploded view of an upper portion of the embodiment of the inventive wind turbine shown in FIG. 1.

[0011] FIG. 4 is a front perspective view of the swivel assembly of the embodiment of the inventive wind turbine shown in FIG. 1.

[0012] FIG. 5 is a back perspective view of the swivel assembly of the embodiment of the inventive wind turbine shown in FIG. 1.

[0013] FIG. 6 is a first side view of the swivel assembly.

[0014] FIG. 7 is a second side view of the swivel assembly.

[0015] FIG. 8 is a first end view of the swivel assembly.

[0016] FIG. 9 is a second end view of the swivel assembly.

[0017] FIG. 10 is a top view of the swivel assembly.

[0018] FIG. 11 is a bottom view of the swivel assembly.

[0019] FIG. 12 is a partial cross section view 12-12 as shown in FIG. 9.

[0020] FIG. 13 is an enlarged portion of the cross section view shown in FIG. 12.

[0021] FIG. 14 is an elevation view of the wind driven electric generator and front elevation view of a transmission system coupled to an electric generator.

[0022] FIG. 15 is an enlarged front elevation view of the transmission system coupled to an electric generator shown in FIG. 14.

V. DETAILED DESCRIPTION OF THE INVENTION

[0023] Now referring primarily to FIGS. 1 and 2, which provide a general overview of particular embodiments of an inventive wind driven electric generator (1) which can include a rotor (2) having one more rotor vanes (3) connected to a rotor hub (4) which rotates about a rotor axis (5). The hub (4) of the rotor (2) can be connected directly or indirectly to a first drive line (6) rotatably driven by rotation of the rotor (2) about the rotor axis (5). The first drive line (6) can be coupled to an input shaft (7) of a first right angle drive (8) swivelly coupled on a top end (9) of a support tower (10). A second drive line (11) can be connected between an output shaft (12) of the first right angle drive (8) swivelly coupled on the top end (9) of the support tower (10) and an input shaft (13) of a second right angle drive (14) located proximate a bottom end (15) of the support tower (10). A third drive line (16) can be connected between an output shaft (17) of the second right angle drive (14) and a power transmission assembly (18). The power transmission assembly (18) can be coupled to an electric generator (19). The electric generator (19) converts mechanical energy from rotation of the rotor (2) into electrical energy (20).

[0024] Now referring primarily to FIGS. 1 through 3, the rotor (2) can take the form of one or a plurality of vanes (3) connected directly or indirectly in radially spaced apart relation about the perimeter of the rotor hub (4). The one or more vanes (3) each radially extend a distance from the rotor hub (4) to intercept air movement (21) past the vanes (3). The vanes (3) can, but need not necessarily, be designed like wings to maximize extracted kinetic energy up to the limit of Betz law. Depending upon the design, beyond three vanes (3), it is thought that only a few extra percents of energy may be captured by any design of the one or more vanes (3); however, this theory is not meant to limit the invention to any particular number of vanes (4). The kinetic energy of the air movement (21) captured by the vanes (3) can be converted into mechanical energy to rotate the rotor hub (4) about the rotor axis (5). The illustrative example of FIGS. 1 through 3 show a rotor (2) in the constructional form of a wheel assembly similar to those available from Aermotor Windmill Company, Inc.; however, embodiments of the invention can utilize a wide variety of vane (3) designs.

[0025] Again, referring primarily to FIGS. 1 through 3, the rotor hub (4) of the rotor (2) can be connected directly or indirectly to the first drive line (6). The first drive line (6) can be rotatably driven by rotation of the rotor (2) about the rotor axis (5). The first drive line (6) can, as to certain embodiments, include a rotor hub shaft (22) having a rotor hub shaft first and second ends (23)(24). The rotor hub shaft first end (23) can be fixedly connected to the rotor hub (4) such that rotation of the rotor hub (4) correspondingly generates rotation of the rotor hub shaft (22) about the rotor axis (5). A rotor hub shaft adaptor (25) can include an internal adaptor passage (26) which communicates with the adaptor first end (27). The adaptor passage (26) receives the rotor hub shaft second end (24) and can dispose the rotor hub shaft (22) in fixed relation with the rotor hub shaft adaptor (25) such that rotation of the rotor hub shaft (22) causes rotation of the rotor hub shaft adaptor (25). The rotor hub shaft adaptor (25) can have an adaptor second end (28) configured to mate in fixed relation with the input shaft (7) of the first right angle drive (8) such that rotation of the rotor hub shaft adaptor (25) causes rotation of the input shaft (7) of the first right angle drive (8). The rotor hub shaft (22) or the rotor hub shaft adaptor (25) can be rotationally journaled in a shaft adaptor sleeve (29) which supports the combination of the rotor (2) and first drive line (6). The shaft adaptor sleeve (29) can, but need not necessarily, include adaptor sleeve bearing elements (30) which can be a solid, roller element, or other type of bearing element (30).

[0026] Now referring primarily to FIGS. 3 through 13, embodiments of the inventive wind driven electric generator (1) can include a swivel assembly (31) coupled to the top end (9) of the support tower (10). The first right angle drive (8) can be mounted to the swivel assembly (31) to swivelly couple the first right angle drive (8) to the top end (9) of the support tower (10). A wide variety of right angle drives (8) may be suitable for use in embodiments of the invention.

[0027] The swivel assembly (31) includes a swivel plate (32) having a centrally located swivel plate aperture element (33). The first right angle drive (8) can have a first right angle drive mounting flange (34) which abuttingly fastens to the swivel plate top surface (35) with the output shaft (12) of the first right angle drive (8) passing through the swivel plate aperture element (33). A swivel sleeve (36) can be mounted to a swivel plate bottom surface (37). The swivel sleeve (36) can include a tubular sleeve (38) having a tubular sleeve first end (39) and a tubular sleeve second end (40). The tubular sleeve (38) defines a sleeve external surface (41) of substantially cylindrical form and a sleeve internal surface (42) that defines a swivel sleeve passage (43) open at the tubular sleeve first end (39) and at the tubular sleeve second end (40) through which the output shaft (12) of the first right angle drive (8) can pass. An annular member (44) can be concentrically positioned about the tubular sleeve first end (39) to define an annular space (45) between the tubular sleeve first end (39) and the annular member (44). As to particular embodiments, each of the first right angle drive mounting flange (34), the swivel plate (32), and the tubular sleeve first end (39) integrally connected to annular member (44) can include a plurality of mounting holes (46) which can be aligned to receive a corresponding plurality of mechanical fasteners (47) to position in fixed unmoving relation the first right angle drive (8), the swivel plate (32), and the swivel sleeve (36).

[0028] An upper platform (48) can be coupled to the top end (9) of the support tower (10). The upper platform (48) can include a centrally located substantially circular aperture element (49) defining a substantially circular opening (50). A bearing (52) can be disposed inside of an annular space (45). A bearing external surface (53) can engage the annular member (44) and a bearing internal surface (53) can define a bearing open area (54) within the circular opening (50) of the circular aperture element (49) of the upper platform (48). The diameter of the bearing internal surface (53) can be selected to engage the sleeve external surface (41).

[0029] Now referring primarily to FIGS. 3, 12 and 13, the swivel assembly (31) can be positioned above the upper platform (48) by passing the tubular sleeve (38) through the circular bearing (52) to locate the circular tubular member (51) and the circular bearing (52) inside of the annular space (45) between the sleeve external surface (41) and the annular member (44). The tubular sleeve (38) can extend a sufficient distance below the upper platform (48) to allow a locking collar (54) to be disposed in fixed relation about the sleeve external surface (41) of the tubular sleeve (38) to limit axial movement of the tubular sleeve (38) within the circular bearing (52) while allowing rotational movement of the tubular sleeve (38) within the circular aperture element (49). The circular bearing (52) can be of any type which allows the swivel assembly (31) to rotate above the upper platform (48) through a part of or entirely through 360 degrees, depending upon the design.

[0030] Now referring primarily to FIGS. 4 through 11, the swivel assembly (31) can include one or more support arms (55) connected to the swivel plate (32) by support arm first end(s)(56) and extending outwardly from the swivel plate (32) to allow one or more support arm second end(s)(57) to be connected to the shaft adaptor sleeve (29).

[0031] Again referring primarily to FIGS. 1 through 3, the swivel assembly (31) can further include a tail assembly (58) including a tail vane (59) extending outward from the swivel plate (32). The tail vane (59) can be configured to align with air (21) moving past the tail vane (59) to correspondingly rotate the swivel assembly (31) to maintain the rotor (2) facing into the air movement (21) during normal and turbulent wind conditions. If the tail vane (59) is properly sized, the rotor (2) will face the core air movement (21) direction to maximize rounds per minute of the rotor (2) and correspondingly the first drive line (6). The easiest way to establish the tail vane area (60) is to relate it to the sweep area (61) of the rotor (2) (as shown in the example of FIGS. 3 and 14). The sweep area (61) of a rotor (2) is the square of the rotor radius (R)(62) times pi (3.1415). Sweep Area=R.sup.2×3.1415. The tail vane area (60) should be no less than five percent of the sweep area (61) of the rotor (2). The larger the tail vane area (60), the more influence it will have on maintaining proper orientation of the rotor (2) to the direction of the air (21) movement. The tail vane (59) can pivot about a pivot (63) disposed in a pivot mount (64) supported by a pivot frame (65) extending upwardly from the swivel plate (32). As to particular embodiments, a springing element (66) attached between the pivot frame (64) and the tail vane (59) springingly resists rotation of the tail vane (59) about the pivot (63).

[0032] Again referring primarily to FIGS. 2 and 3, slowing or halting the rotor (2) involves converting its kinetic energy into heat. As to particular embodiments of the tail assembly (58), the tail vane (59) can pivot about the pivot (63) to actuate a brake linkage (67) connecting the tail vane (59) and a brake lever (68) which operates to control constriction and expansion of a band brake (69) disposed circumferentially about the external surface of the rotor hub (2). A band brake (69) suitable for use with embodiments of the invention can be obtained from Aermotor Windmill Company, Inc., Part No. 690 windmill band brake. The brake linkage (67) can be responsive to pivoting of the tail vane (59) toward parallel with the rotor (2) to correspondingly operate the brake lever (68) to constrict the brake band (69) and slow or halt rotation of the rotor (2). As to particular embodiments, a springing element (66) can be connected between the pivot frame (65) and the tail vane (59) to urge the tail vane (59) toward orthogonal relation with the rotor (2) and correspondingly operate the brake to expand the brake band (69) and allow the rotor (2) to rotate freely.

[0033] Now referring primarily to FIGS. 1, 2, 14, and 15 embodiments of the invention can further include a support tower (10) which elevates the rotor (2), so the rotor vanes (3) safely clear the ground, and reach cleaner, stronger winds at higher elevations. At higher elevations, the air movement (21) can be greater and less turbulent. Power output from embodiments of the invention can be the cube of the wind speed, so even small increases in air movement (21) captured by the rotor (2) on a taller support tower (10) can have significant impact on energy production. While the support tower (10) can be just tall enough to allow the rotor vanes (3) to clear ground level (85), typically, the support tower height (70) will be about twenty feet or greater than twenty feet. Particular embodiments of the support tower (10) can comprise a free standing lattice support tower (10) typically including three or more tower supports (71) (as shown in the example of FIG. 1); however, this illustrative example is not intended to limit the invention solely to free standing lattice support towers (10) and embodiments can include guyed support towers, free standing tubular towers, floating towers, or the like.

[0034] As one illustrative example, a free standing lattice support tower (10) (as shown in the example of FIG. 1) can include three tubular tower supports (71) each having a length of about 20 feet (for example each support can be schedule 40 black pipe 21 feet in length). The tower supports (10) can be vertically disposed in the corners of an equilateral triangle (as shown in the example of FIG. 2). The tubular support first ends (72) can be directly or indirectly coupled to load bearing foundation (73), such as concrete foundation. The tubular support second ends (74) can be directly or indirectly connected to the upper platform (48). The tower supports (71) can be interconnected by a structural cross lattice (75)(for example one quarter inch thick steel angle having equal legs of one inch having the ends cut at 45 degrees). A plurality of second drive line sleeves (76) can be centrally located in spaced apart relation within the support tower (10). As shown in the examples of FIGS. 1 and 2, the second drive line sleeves (76) can be spaced apart in increments of about 5 feet to about 10 feet. As an illustrative example, the second drive line sleeves (76) can comprise a pillow block (77) having about a two-inch internal diameter such as NorTrac pillow block, Part No. 189780. As to particular embodiments, the second drive line sleeves (76) can each be supported by a drive line sleeve plate (78) configured to interconnect the plurality of tower supports (71) and to orient the corresponding drive line sleeve (76) in alignment with the second drive line (11).

[0035] Again referring primarily to FIGS. 1, 2, 14, and 15, the second drive line (11) can have a second drive line first end (78) connected to the output shaft (12) of the first right angle drive (8). The second drive line (11) can pass through the plurality of second drive line sleeves (76), and the second drive line second end (80) can be connected to the input shaft (13) of the second right angle drive (14). As an illustrative example, the second drive line (11) can be a pipe having an internal diameter of about 1¼ inches and an external diameter of about 1⅜ inches. The second right angle drive (14) can be mounted in fixed immovable relation to the load bearing foundation (73) at a location that aligns the input shaft (13) of the second right hand drive (14) with the second drive line (11) passing through the plurality of second drive line sleeves (76).

[0036] Again referring primarily to FIGS. 1 and 2, embodiments of the invention can further include an electric generator (19) mounted to the load bearing foundation (73). A third drive line (16) can be connected between the output shaft (17) of the second right angle drive (14) and the input shaft (81) of the electric generator (19). The third drive line (16) can include a transmission assembly (18) which can, but need not necessarily, include a gear box (82) which adjusts the rotations per minute of the output shaft (17) of the second right angle drive (14) to the operational rotations per minute of the electric generator (19). A clutch assembly (83) and a brake assembly (84) can be interposed between the output shaft (17) of the second right angle drive (14) and the gearbox (82) to respectively uncouple the output shaft (17) of the second right angle drive (14) from the gearbox (82) or to slow or halt rotation of the input shaft (81) to the electric generator (19).

[0037] As can be easily understood from the foregoing, the basic concepts of the present invention may be embodied in a variety of ways. The invention involves numerous and varied embodiments of a wind driven electric generator and methods for making and using such wind driven electric generator including the best mode.

[0038] As such, the particular embodiments or elements of the invention disclosed by the description or shown in the figures or tables accompanying this application are not intended to be limiting, but rather exemplary of the numerous and varied embodiments generically encompassed by the invention or equivalents encompassed with respect to any particular element thereof. In addition, the specific description of a single embodiment or element of the invention may not explicitly describe all embodiments or elements possible; many alternatives are implicitly disclosed by the description and figures.

[0039] It should be understood that each element of an apparatus or each step of a method may be described by an apparatus term or method term. Such terms can be substituted where desired to make explicit the implicitly broad coverage to which this invention is entitled. As but one example, it should be understood that all steps of a method may be disclosed as an action, a means for taking that action, or as an element which causes that action. Similarly, each element of an apparatus may be disclosed as the physical element or the action which that physical element facilitates. As but one example, the disclosure of a “generator” should be understood to encompass disclosure of the act of “generating”—whether explicitly discussed or not—and, conversely, were there effectively disclosure of the act of “generating”, such a disclosure should be understood to encompass disclosure of a “generator” and even a “means for generating.” Such alternative terms for each element or step are to be understood to be explicitly included in the description.

[0040] In addition, as to each term used it should be understood that unless its utilization in this application is inconsistent with such interpretation, common dictionary definitions should be understood to be included in the description for each term as contained in the Random House Webster's Unabridged Dictionary, second edition, each definition hereby incorporated by reference.

[0041] All numeric values herein are assumed to be modified by the tell “about”, whether or not explicitly indicated. For the purposes of the present invention, ranges may be expressed as from “about” one particular value to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value to the other particular value. The recitation of numerical ranges by endpoints includes all the numeric values subsumed within that range. A numerical range of one to five includes for example the numeric values 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, and so forth. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. When a value is expressed as an approximation by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” generally refers to a range of numeric values that one of skill in the art would consider equivalent to the recited numeric value or having the same function or result. Similarly, the antecedent “substantially” means largely, but not wholly, the same form, manner or degree and the particular element will have a range of configurations as a person of ordinary skill in the art would consider as having the same function or result. When a particular element is expressed as an approximation by use of the antecedent “substantially,” it will be understood that the particular element forms another embodiment.

[0042] Moreover, for the purposes of the present invention, the term “a” or “an” entity refers to one or more of that entity unless otherwise limited. As such, the terms “a” or “an”, “one or more” and “at least one” can be used interchangeably herein.

[0043] Thus, the applicant(s) should be understood to claim at least: i) each of the wind driven electric generators herein disclosed and described, ii) the related methods disclosed and described, iii) similar, equivalent, and even implicit variations of each of these devices and methods, iv) those alternative embodiments which accomplish each of the functions shown, disclosed, or described, v) those alternative designs and methods which accomplish each of the functions shown as are implicit to accomplish that which is disclosed and described, vi) each feature, component, and step shown as separate and independent inventions, vii) the applications enhanced by the various systems or components disclosed, viii) the resulting products produced by such systems or components, ix) methods and apparatuses substantially as described hereinbefore and with reference to any of the accompanying examples, x) the various combinations and permutations of each of the previous elements disclosed.

[0044] The background section of this patent application provides a statement of the field of endeavor to which the invention pertains. This section may also incorporate or contain paraphrasing of certain United States patents, patent applications, publications, or subject matter of the claimed invention useful in relating information, problems, or concerns about the state of technology to which the invention is drawn toward. It is not intended that any United States patent, patent application, publication, statement or other information cited or incorporated herein be interpreted, construed or deemed to be admitted as prior art with respect to the invention.

[0045] The claims set forth in this specification, if any, are hereby incorporated by reference as part of this description of the invention, and the applicant expressly reserves the right to use all of or a portion of such incorporated content of such claims as additional description to support any of or all of the claims or any element or component thereof, and the applicant further expressly reserves the right to move any portion of or all of the incorporated content of such claims or any element or component thereof from the description into the claims or vice-versa as necessary to define the matter for which protection is sought by this application or by any subsequent application or continuation, division, or continuation-in-part application thereof, or to obtain any benefit of, reduction in fees pursuant to, or to comply with the patent laws, rules, or regulations of any country or treaty, and such content incorporated by reference shall survive during the entire pendency of this application including any subsequent continuation, division, or continuation-in-part application thereof or any reissue or extension thereon.

[0046] Additionally, the claims set forth in this specification, if any, are further intended to describe the metes and bounds of a limited number of the preferred embodiments of the invention and are not to be construed as the broadest embodiment of the invention or a complete listing of embodiments of the invention that may be claimed. The applicant does not waive any right to develop further claims based upon the description set forth above as a part of any continuation, division, or continuation-in-part, or similar application.