WO2006097836A2 - Tension wheel in a rotor system for wind and water turbines - Google Patents

Tension wheel in a rotor system for wind and water turbines Download PDF

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Publication number
WO2006097836A2
WO2006097836A2 PCT/IB2006/000605 IB2006000605W WO2006097836A2 WO 2006097836 A2 WO2006097836 A2 WO 2006097836A2 IB 2006000605 W IB2006000605 W IB 2006000605W WO 2006097836 A2 WO2006097836 A2 WO 2006097836A2
Authority
WO
WIPO (PCT)
Prior art keywords
rotor
blades
hub
tension wheel
blade
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/IB2006/000605
Other languages
French (fr)
Other versions
WO2006097836A3 (en
Inventor
James G. P. Dehlsen
Matthew Brown
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Clipper Windpower LLC
Original Assignee
Clipper Windpower Technology Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to DK06755831.2T priority Critical patent/DK1861619T3/en
Priority to DE602006015927T priority patent/DE602006015927D1/en
Priority to AT06755831T priority patent/ATE476599T1/en
Priority to EP06755831A priority patent/EP1861619B1/en
Priority to US11/885,481 priority patent/US20080253892A1/en
Priority to CA002600007A priority patent/CA2600007A1/en
Priority to JP2008501442A priority patent/JP2008538597A/en
Priority to MX2007011249A priority patent/MX2007011249A/en
Priority to PL06755831T priority patent/PL1861619T3/en
Priority to CN2006800080705A priority patent/CN101137842B/en
Application filed by Clipper Windpower Technology Inc filed Critical Clipper Windpower Technology Inc
Priority to BRPI0608467-2A priority patent/BRPI0608467A2/en
Publication of WO2006097836A2 publication Critical patent/WO2006097836A2/en
Publication of WO2006097836A3 publication Critical patent/WO2006097836A3/en
Anticipated expiration legal-status Critical
Priority to NO20075122A priority patent/NO20075122L/en
Ceased legal-status Critical Current

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F03D1/0608—Rotors characterised by their aerodynamic shape
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03B—MACHINES OR ENGINES FOR LIQUIDS
    • F03B17/00—Other machines or engines
    • F03B17/06—Other machines or engines using liquid flow with predominantly kinetic energy conversion, e.g. of swinging-flap type, "run-of-river", "ultra-low head"
    • F03B17/061—Other machines or engines using liquid flow with predominantly kinetic energy conversion, e.g. of swinging-flap type, "run-of-river", "ultra-low head" with rotation axis substantially in flow direction
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03B—MACHINES OR ENGINES FOR LIQUIDS
    • F03B3/00—Machines or engines of reaction type; Parts or details peculiar thereto
    • F03B3/12—Blades; Blade-carrying rotors
    • F03B3/14—Rotors having adjustable blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F03D1/065—Rotors characterised by their construction elements
    • F03D1/0658—Arrangements for fixing wind-engaging parts to a hub
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2240/00—Components
    • F05B2240/20—Rotors
    • F05B2240/21—Rotors for wind turbines
    • F05B2240/221—Rotors for wind turbines with horizontal axis
    • F05B2240/2211—Rotors for wind turbines with horizontal axis of the multibladed, low speed, e.g. "American farm" type
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2250/00—Geometry
    • F05B2250/30—Arrangement of components
    • F05B2250/36—Arrangement of components in inner-outer relationship, e.g. shaft-bearing arrangements
    • Y—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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/20—Hydro energy
    • Y—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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction

Definitions

  • the invention relates to a rotor system for a fluid-flow turbine comprising a hub mounted on a shaft, and a plurality of rotor blades .
  • a nacelle In a typical horizontal-axis wind turbine, a nacelle is mounted on a tall vertical tower.
  • the nacelle houses power-transmitting mechanisms, electrical equipment and supports a rotor system at one end.
  • Rotor systems for horizontal-axis wind turbines ordinarily include one or more blades attached to a rotor hub on a shaft. Wind flow turns the rotor, which turns the shaft in the nacelle. The shaft turns gears that transmit torque to electric generators.
  • the nacelle typically pivots about the vertical tower to take advantage of wind flowing from any direction. The pivoting about this vertical-axis in response to changes in wind direction is known as yaw or yaw response and the vertical-axis is referred to as the yaw-axis.
  • the yaw-axis As wind moves past the blades with enough speed the rotor system rotates and the wind turbine converts the wind energy into electrical energy through the generators . Electrical outputs of the generators are connected to a power
  • a hemispherical shape that is, having a shape approximating that of half of a sphere bounded by a great circle, is the ideal geometry for a highly loaded component such as the hub of a wind or water turbine. For this reason, hemispherical hubs are in common use. However the hemispherical shape is compromised by the penetration of equally spaced holes to accommodate each of several blade roots . Since these holes remove some of the structural strength of the hub, the remaining material of the hub becomes more highly stressed. The hub size, weight, and cost are determined by the ratio of the blade holes to the hemispherical diameter. The blade bending moments deflect the hemispherical shape, concentrating stress in the material remaining between the blade holes.
  • blade length imposes structural requirements on the blade root end which adds weight which in turn imposes even greater structural requirements, which in the end limits blade up-scaling possibilities .
  • a rotor system for a fluid-flow turbine comprises a hub mounted on a shaft, and a plurality of rotor blades, and is characterized by a tension wheel, the tension wheel comprising a rim structure mounted to the hub by a plurality of spokes, the rotor blades being attached to the rim structure of the tension wheel.
  • the outer section comprises blades
  • the inner section comprises airfoils, such as blades or sails, to i harness the wind energy in the area circumscribed by the rim
  • spokes comprises airfoils, such as blades or sails, to harness the wind energy i further.
  • the invention has the advantage of limiting blade length to
  • FIGURE 1 is a front view of a rotor system and fork-top tower in which applicant's invention is embodied;
  • FIGURE 2 is a side view of a the rotor system shown in FIGURE 1 having twin drivetrains;
  • FIGURE 3 is a side view of a the rotor system shown in FIGURE 1 having a single drivetrain;
  • FIGURE 4 is a cross sectional view of the wheel hub and blade mounted on the wheel rim,-
  • FIGURE 5 is a partial sectional view of the wheel hub with sails or blades mounted on the wheel spokes;
  • FIGURE 6 is an illustration of the approximate net energy capture accomplished by extending the area swept by the rotor by using a ! tension wheel hub;
  • FIGURE 7 is a perspective schematic view of the rotor system showing in more detail the tension wheel;
  • FIGURE 8 shows in more detail the blade mount to the tension wheel and the hub
  • FIGURE 9 shows the inner blade mount to the hub
  • FIGURE 10 shows the outer blade mount to the rim structure of the tension wheel
  • FIGURE 11 shows in more detail the mount of the tension wheel to the hub and of the hub to the tower.
  • FIGURE 1 is a front view of a rotor system and fork-top tower 1 in which applicant's invention is embodied.
  • the wind power-generating device includes an electric generator housed in a turbine nacelle 2, which is mounted by a fork-top section, 132, to a yaw base 102 atop a tall tower structure 104 anchored to the ground 105.
  • the turbine yaw base 102 is free to rotate in the horizontal plane such that it tends to remain in the path of prevailing wind current.
  • the turbine has a tension wheel hub assembly 106 comprising a tension wheel mounted on a hub 8.
  • the tension wheel consist of a rim structure 3 supported by spokes 7 attached to the hub 8.
  • the rim structure 3 (shown in more detail in Figures 4 and 5) comprises an inner rim 112 (to which the spokes 7 are attached) and an outer rim 107.
  • the main blades 108 are attached to the outer rim 107.
  • the blades 108 rotate in response to wind current.
  • Each blade root 122, 124, 126, 128, 130 is mounted to the tension wheel outer rim 107.
  • Each of the blades 108 may have a blade extension section that is variable in length to provide a variable diameter rotor and may be geared to change pitch.
  • the nacelle 2 houses power-transmitting mechanisms, electrical equipment and a shaft that supports the rotor.
  • the rotor system shown in FIGURE 1 has five blades 108 attached to the outer rim 107 of the tension wheel hub assembly 106, which turns a shaft in the nacelle 2.
  • the shaft turns gears that transmit torque to electric generators.
  • the nacelle 2 pivots about a vertical axis to take advantage of wind flowing from any direction. The pivoting about this vertical-axis in response to changes in wind direction is known as yaw or yaw response and the vertical-axis is referred to as the yaw-axis.
  • the yaw-axis As wind moves past the blades 108 with enough speed the rotor system rotates and the wind turbine converts the wind energy into electrical energy through the generators . Electrical outputs of the generators are connected to a power grid.
  • the rotor diameter may be controlled to fully extend the rotor at low flow velocity and to retract the rotor as flow velocity increases such that the loads delivered by or exerted upon the rotor do not exceed set limits.
  • the turbine is held by the tower structure in the path of the wind current such that the turbine is held in place horizontally in alignment with the wind current .
  • the electric generator is driven by the turbine to produce electricity and is connected to power carrying cables inter-connecting to other units and/or to a power grid.
  • FIGURE 2 is a side view of the rotor system shown in FIGURE 1.
  • the yaw base 102 supports a fork top tower having two sections 132, 134 on top of which two nacelles 136, 138 are attached.
  • FIGURE 3 is a side view of an alternative rotor system supporting only one nacelle 142.
  • the yaw base 102 supports a single tower section 140 on top of which nacelle 142 is attached.
  • FIGURE 4 is a cross sectional view of the tension wheel hub assembly 106 illustrating how the blade root 130 is mounted on the wheel outer rim 107 using a blade bearing 131.
  • FIGURE 5 is a partial sectional view of the wheel hub with sails or blades mounted on the wheel spokes 7.
  • a blade or sail 150 is shown attached to the spoke 7 between the inner rim 112 and the hub 8, which is attached to the main shaft of the nacelle 2.
  • the result in this hybrid arrangement is that otherwise lost wind energy in the area circumscribed by the tension wheel rim 3 is captured by the blade or sail 150.
  • main blades 108 may be extended partially or fully into the area circumscribed by the tension wheel rim 3 to capture lost wind energy in the area circumscribed by the tension wheel rim. If main blades 108 are extended fully into the area circumscribed by the tension wheel rim they may be attached to an appropriately sized hub 8 in a conventional manner. If necessary, the main blades 108 may be tapered in this area in order to accommodate the spokes 7. The blades or sails may also be employed on the spokes 7 to fill in the remaining areas left vacant by the extended main blades . In the hybrid designs described, the stress on the hub 8 will be much less than in a conventional rotor, enabling the use of much longer blades 108.
  • FIGURE 6 which illustrates the approximate net energy : capture accomplished by extending the area swept by the rotor by using a tension wheel hub.
  • FIGURES 7 - 11 show the rotor system comprising the tension wheel i in more detail.
  • FIGURE 7 shows the tension wheel hub assembly 106 mounted to a nacelle 2 which is supported by the tower 1.
  • I tension wheel hub assembly 106 comprises a rim structure 3
  • I main blades 108 are mounted to the hub 8 and attached to the rim structure 3 of the tension wheel. The blades 108 are attached to
  • blades 108 between the rim structure 3 and the hub 8 comprises an i airfoil, wherein an inner blade shaft 10 (shown in FIGURE 8) i provides structural support for the airfoil and provides partial
  • the tension wheel additionally provides axial
  • tension wheel structure allows greater rotor diameter compared to unsupported conventional blade/rotor structures .
  • the outer sections 5 of the blades 108 includes the airfoil outside the tension wheel rim structure 3. Both the inner blade section 4 and the outer blade section 5 are airfoils mounted on a common structural spar or beam 10 that extents from the hub 8 to near the blade tip.
  • the tension ring provides structural support for the blades for thrust loads (wind from the front) , lead-lag loads (gravity effect on the blades) and negative thrust loads (the rare event where rapid wind shift impinges on the rotor from behind) .
  • the blades 108 shown in FIGURE 7 may have a retractable outer section 6. Furthermore, the blades 108 may operate with independent blade pitch control (IBPC) . Large rotors benefit from IBPC due to the usual difference in wind velocity from the top of the rotor to the bottom.
  • IBPC independent blade pitch control
  • the spokes 7 extending from different axial positions of the hub 8 to the tension wheel rim structure 3 serve to: a) provide structural support to the blades 108 for thrust loads from the wind, b) keep the rim structure 3 from bowing as blades in the plane of rotation flex (the lead-lag mode) by maintaining a rigid structural arc between the blades, and c) transmit the torque from the blades/rim to the hub 8.
  • the hub or spindle 8 supports the rotor and transmits the torque of the rotor to the drive train and generating system.
  • the spokes 7 comprise aft spokes 11 and forward spokes 12 (see FIGURE 8) .
  • the aft spokes 11 resist loads in the forward direction and transmit torsional loads from the blades 108 and the rim 3 to the spindle (hub) drive shaft of the gear box connecting to the generators.
  • the forward spokes 12 support the tension wheel and blades to resist the thrust loading from the winds.
  • These spokes 12 are also attached to the forward end of the spindle (or hub) at a tangentially located position on the spindle. This enable rotation of the rim to be transmitted through the tension of the spokes 12 to a rotational force on the spindle .
  • the outer blade mount 9 is a hinging mechanism that attaches the blade to the rim structure 3 and provides: a) for pitching the blade 108 from a feathered position to the full range of operating positions (angles of attack) , b) structural support for the blade 108 to enable larger rotor diameters than is possible with blades only attached to the hub 8 at the blade root, and c) allows for mass of the rotor to be supported (along with the spokes in tension) by transmitting the load to the blade shafts 10.
  • the inner blade section 4 comprises an inner blade shaft 10 which is a structural member that may be a beam or spar or some combination thereof as it extents from the hub 8 or spindle to the outer segment 5 of the blade 108.
  • the shaft 10 provides structural support for the aerodynamic blade surfaces and the loads encountered by the blades and rotor.
  • the shaft 10 and blades 108, 4, 5 may be rotated along the axis of the blade to provide aerodynamic pitching of the blade 108.
  • Inner blade mounts 13 support the blade 108 in bending and axial loads, and combines with the blade shafts 10 and outer blade mount 9 and spokes 7 to support the mass of the rotor.
  • a blade pitch drive 14 is mounted on the spindle (or hub 8) and serves to rotate the blades in pitch, as driven by the blade pitch motor 15.
  • FIGURE 10 shows the outer blade mount 9 in more detail .
  • the inner blade section 4 comprises a spar splice 20 which is the mating of the structural beam that connects the inner and the outer blade sections 4, 5.
  • the rim structure 3 of the tension wheel comprises a bearing mount 19 and a bearing 18.
  • the inner section 4 and the outer section 5 each comprise a lag 17 for receiving an axle 16 for attaching the inner section 4 and the outer section 5 of the blade to the rim structure 3.
  • FIGURE 11 shows the wheel mount in more detail.
  • a forward main bearing 21 and a aft main bearing 22 support the drivetrain main shaft which connects to the rotor spindle and transfers the moment and thrust loads of the rotor to the machine base 25, and the torque from the rotor through the gearbox to the generators 23.
  • FIGURE 8 there is schematically shown an aerodynamic fairing 24 for the spokes 7 which are provided to reduce the drag of the spokes 7.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • Sustainable Development (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Energy (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Power Engineering (AREA)
  • Wind Motors (AREA)
  • Other Liquid Machine Or Engine Such As Wave Power Use (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Hydraulic Turbines (AREA)

Abstract

A rotor system for a fluid- flow turbine comprising a hub mounted on a shaft, a plurality of rotor blades, and a tension wheel, the tension wheel comprising a rim structure mounted to the hub by a plurality of spokes. Each rotor blade is attached to the rim structure of the tension wheel . The lost energy in the area of the rotor circumscribed by the tension wheel rim structure is captured by applying airfoils, such as blades or sails, to the spokes of the tension wheel and/or an inner section of the rotor blades.

Description

TENSION WHEEL IN A ROTOR SYSTEM FOR WIND AND WATER TURBINES
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a rotor system for a fluid-flow turbine comprising a hub mounted on a shaft, and a plurality of rotor blades .
2. Prior Art
In a typical horizontal-axis wind turbine, a nacelle is mounted on a tall vertical tower. The nacelle houses power-transmitting mechanisms, electrical equipment and supports a rotor system at one end. Rotor systems for horizontal-axis wind turbines ordinarily include one or more blades attached to a rotor hub on a shaft. Wind flow turns the rotor, which turns the shaft in the nacelle. The shaft turns gears that transmit torque to electric generators. The nacelle typically pivots about the vertical tower to take advantage of wind flowing from any direction. The pivoting about this vertical-axis in response to changes in wind direction is known as yaw or yaw response and the vertical-axis is referred to as the yaw-axis. As wind moves past the blades with enough speed the rotor system rotates and the wind turbine converts the wind energy into electrical energy through the generators . Electrical outputs of the generators are connected to a power grid.
Conventional rotor systems tend to move in response to changes in wind direction during operation by hunting for a proper yaw position relative to a new wind direction, rather than tracking such changes in a stable manner. Wind direction changes or wind gusts pivot the rotor system of typical wind turbines away from a proper yaw position and the system then hunts for a proper position relative to the mean wind direction when the transient wind dissipates. Unstable hunting motions result in undesirable vibration and stress on the rotor system. Blade and rotor hub fatigue and ultimate failure of the blade and rotor hub where the blade and rotor hub meet is directly related to the number of hunting motions and the speed at which they occur. Rapid changes in yaw dramatically increase the forces acting against the rotational inertia of the entire rotor system, magnifying the bending moments at the blade root where it meets and is attached to the rotor hub. Vibration and stress cause fatigue in the rotor hub and blade root thereby decreasing the useful life of the equipment and reducing dependability.
A hemispherical shape, that is, having a shape approximating that of half of a sphere bounded by a great circle, is the ideal geometry for a highly loaded component such as the hub of a wind or water turbine. For this reason, hemispherical hubs are in common use. However the hemispherical shape is compromised by the penetration of equally spaced holes to accommodate each of several blade roots . Since these holes remove some of the structural strength of the hub, the remaining material of the hub becomes more highly stressed. The hub size, weight, and cost are determined by the ratio of the blade holes to the hemispherical diameter. The blade bending moments deflect the hemispherical shape, concentrating stress in the material remaining between the blade holes.
As wind turbine rotor size increases in the multi-megawatt size range, blade length imposes structural requirements on the blade root end which adds weight which in turn imposes even greater structural requirements, which in the end limits blade up-scaling possibilities .
It is therefore desirable to limit blade length to materials and designs which provide sound structural margins but increase rotor diameter, to provide a greater rotor swept area resulting in greater wind energy capture.
It is also desirable to provide a rotor hub geometry that has a sound structure while increasing the rotor swept area.
SUMMARY OF THE INVENTION
In accordance with the principles of this invention a rotor system for a fluid-flow turbine comprises a hub mounted on a shaft, and a plurality of rotor blades, and is characterized by a tension wheel, the tension wheel comprising a rim structure mounted to the hub by a plurality of spokes, the rotor blades being attached to the rim structure of the tension wheel.
I i In a preferred embodiment the rotor blades are mounted to the hub and comprise an inner section between the hub and the rim
! structure and an outer section outside the rim structure. i Preferably, not only the outer section comprises blades, but also the inner section comprises airfoils, such as blades or sails, to i harness the wind energy in the area circumscribed by the rim
> structure. In a preferred embodiment also the spokes comprises airfoils, such as blades or sails, to harness the wind energy i further.
)
) The invention has the advantage of limiting blade length to
I materials and designs which provide sound structural margins but
. increase the rotor swept area (rotor diameter) by replacing a conventional hub design with a tension wheel hub arrangement with blades attached to the rim of the tension wheel.
While the increase in swept area is accomplished with blades of a length, which meets suitable structural requirements, it does so at the cost of not harnessing the wind energy in the area of the rotor circumscribed by the tension wheel hub. The lost energy can, however be captured by applying airfoils, such as blades or sails, to the spokes of the tension wheel or by blades comprising an outer blade section attached to the rim of the tension wheel and an inner blade section between the rim and the hub.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE 1 is a front view of a rotor system and fork-top tower in which applicant's invention is embodied;
FIGURE 2 is a side view of a the rotor system shown in FIGURE 1 having twin drivetrains;
FIGURE 3 is a side view of a the rotor system shown in FIGURE 1 having a single drivetrain;
FIGURE 4 is a cross sectional view of the wheel hub and blade mounted on the wheel rim,-
FIGURE 5 is a partial sectional view of the wheel hub with sails or blades mounted on the wheel spokes;
i FIGURE 6 is an illustration of the approximate net energy capture accomplished by extending the area swept by the rotor by using a ! tension wheel hub; FIGURE 7 is a perspective schematic view of the rotor system showing in more detail the tension wheel;
FIGURE 8 shows in more detail the blade mount to the tension wheel and the hub;
FIGURE 9 shows the inner blade mount to the hub;
FIGURE 10 shows the outer blade mount to the rim structure of the tension wheel; and
FIGURE 11 shows in more detail the mount of the tension wheel to the hub and of the hub to the tower.
DETAILED DESCRIPTION OF THE INVENTION
Refer to FIGURE 1, which is a front view of a rotor system and fork-top tower 1 in which applicant's invention is embodied. The wind power-generating device includes an electric generator housed in a turbine nacelle 2, which is mounted by a fork-top section, 132, to a yaw base 102 atop a tall tower structure 104 anchored to the ground 105. The turbine yaw base 102 is free to rotate in the horizontal plane such that it tends to remain in the path of prevailing wind current. The turbine has a tension wheel hub assembly 106 comprising a tension wheel mounted on a hub 8. The tension wheel consist of a rim structure 3 supported by spokes 7 attached to the hub 8. The rim structure 3 (shown in more detail in Figures 4 and 5) comprises an inner rim 112 (to which the spokes 7 are attached) and an outer rim 107. The main blades 108 are attached to the outer rim 107. The blades 108 rotate in response to wind current. Each blade root 122, 124, 126, 128, 130 is mounted to the tension wheel outer rim 107. Each of the blades 108 may have a blade extension section that is variable in length to provide a variable diameter rotor and may be geared to change pitch.
The nacelle 2 houses power-transmitting mechanisms, electrical equipment and a shaft that supports the rotor. The rotor system shown in FIGURE 1 has five blades 108 attached to the outer rim 107 of the tension wheel hub assembly 106, which turns a shaft in the nacelle 2. The shaft turns gears that transmit torque to electric generators. The nacelle 2 pivots about a vertical axis to take advantage of wind flowing from any direction. The pivoting about this vertical-axis in response to changes in wind direction is known as yaw or yaw response and the vertical-axis is referred to as the yaw-axis. As wind moves past the blades 108 with enough speed the rotor system rotates and the wind turbine converts the wind energy into electrical energy through the generators . Electrical outputs of the generators are connected to a power grid.
The rotor diameter may be controlled to fully extend the rotor at low flow velocity and to retract the rotor as flow velocity increases such that the loads delivered by or exerted upon the rotor do not exceed set limits. The turbine is held by the tower structure in the path of the wind current such that the turbine is held in place horizontally in alignment with the wind current . The electric generator is driven by the turbine to produce electricity and is connected to power carrying cables inter-connecting to other units and/or to a power grid.
Refer to FIGURE 2, which is a side view of the rotor system shown in FIGURE 1. In this embodiment, the yaw base 102 supports a fork top tower having two sections 132, 134 on top of which two nacelles 136, 138 are attached.
Refer to FIGURE 3, which is a side view of an alternative rotor system supporting only one nacelle 142. In this embodiment, the yaw base 102 supports a single tower section 140 on top of which nacelle 142 is attached.
Refer to FIGURE 4, which is a cross sectional view of the tension wheel hub assembly 106 illustrating how the blade root 130 is mounted on the wheel outer rim 107 using a blade bearing 131.
Refer to FIGURE 5, which is a partial sectional view of the wheel hub with sails or blades mounted on the wheel spokes 7. A blade or sail 150 is shown attached to the spoke 7 between the inner rim 112 and the hub 8, which is attached to the main shaft of the nacelle 2. The result in this hybrid arrangement is that otherwise lost wind energy in the area circumscribed by the tension wheel rim 3 is captured by the blade or sail 150.
It will be understood by those skilled in the art that the main blades 108 may be extended partially or fully into the area circumscribed by the tension wheel rim 3 to capture lost wind energy in the area circumscribed by the tension wheel rim. If main blades 108 are extended fully into the area circumscribed by the tension wheel rim they may be attached to an appropriately sized hub 8 in a conventional manner. If necessary, the main blades 108 may be tapered in this area in order to accommodate the spokes 7. The blades or sails may also be employed on the spokes 7 to fill in the remaining areas left vacant by the extended main blades . In the hybrid designs described, the stress on the hub 8 will be much less than in a conventional rotor, enabling the use of much longer blades 108. This is because the tension wheel structure design in accordance with the present invention relieves stress on the hub 8. It will also be understood that in the situation wherein the blades 108 are extended into the area circumscribed by the tension wheel rim, pitch control for the main blades 108 and the spoke-mounted blades/sails can be retained at the hub 8 as is i conventional .
Refer to FIGURE 6, which illustrates the approximate net energy : capture accomplished by extending the area swept by the rotor by using a tension wheel hub.
I FIGURES 7 - 11 show the rotor system comprising the tension wheel i in more detail. FIGURE 7 shows the tension wheel hub assembly 106 mounted to a nacelle 2 which is supported by the tower 1. The
I tension wheel hub assembly 106 comprises a rim structure 3
I supported by a plurality of spokes 7 attached to the hub 8. The
I main blades 108 are mounted to the hub 8 and attached to the rim structure 3 of the tension wheel. The blades 108 are attached to
! the tension wheel rim structure via a hinging mechanism which is
! shown in more detail in FIGURE 10. The inner section 4 of the
!■ blades 108 between the rim structure 3 and the hub 8 comprises an i airfoil, wherein an inner blade shaft 10 (shown in FIGURE 8) i provides structural support for the airfoil and provides partial
' structural support for the entire rotor mass by allowing the rotor
$ to be supported by both the lower half spokes - acting in tension
) - and the upper half blade shafts acting in compression as
) rotation occurs . The tension wheel additionally provides axial
I (lead-lag) structural support between the blades to reduce cycling
I loads due to gravity effects on the blades on each revolution which particularly stresses the root section of the blade. So tension wheel structure allows greater rotor diameter compared to unsupported conventional blade/rotor structures .
The outer sections 5 of the blades 108 includes the airfoil outside the tension wheel rim structure 3. Both the inner blade section 4 and the outer blade section 5 are airfoils mounted on a common structural spar or beam 10 that extents from the hub 8 to near the blade tip. The tension ring provides structural support for the blades for thrust loads (wind from the front) , lead-lag loads (gravity effect on the blades) and negative thrust loads (the rare event where rapid wind shift impinges on the rotor from behind) .
The blades 108 shown in FIGURE 7 may have a retractable outer section 6. Furthermore, the blades 108 may operate with independent blade pitch control (IBPC) . Large rotors benefit from IBPC due to the usual difference in wind velocity from the top of the rotor to the bottom.
The spokes 7 extending from different axial positions of the hub 8 to the tension wheel rim structure 3 serve to: a) provide structural support to the blades 108 for thrust loads from the wind, b) keep the rim structure 3 from bowing as blades in the plane of rotation flex (the lead-lag mode) by maintaining a rigid structural arc between the blades, and c) transmit the torque from the blades/rim to the hub 8.
The hub or spindle 8 supports the rotor and transmits the torque of the rotor to the drive train and generating system. The spokes 7 comprise aft spokes 11 and forward spokes 12 (see FIGURE 8) . The aft spokes 11 resist loads in the forward direction and transmit torsional loads from the blades 108 and the rim 3 to the spindle (hub) drive shaft of the gear box connecting to the generators. The forward spokes 12 support the tension wheel and blades to resist the thrust loading from the winds. These spokes 12 are also attached to the forward end of the spindle (or hub) at a tangentially located position on the spindle. This enable rotation of the rim to be transmitted through the tension of the spokes 12 to a rotational force on the spindle .
As already mentioned, the blades 108 are supported by an outer blade mount 9 and an inner blade mount 13. The outer blade mount 9 is a hinging mechanism that attaches the blade to the rim structure 3 and provides: a) for pitching the blade 108 from a feathered position to the full range of operating positions (angles of attack) , b) structural support for the blade 108 to enable larger rotor diameters than is possible with blades only attached to the hub 8 at the blade root, and c) allows for mass of the rotor to be supported (along with the spokes in tension) by transmitting the load to the blade shafts 10. The inner blade section 4 comprises an inner blade shaft 10 which is a structural member that may be a beam or spar or some combination thereof as it extents from the hub 8 or spindle to the outer segment 5 of the blade 108. The shaft 10 provides structural support for the aerodynamic blade surfaces and the loads encountered by the blades and rotor. The shaft 10 and blades 108, 4, 5 may be rotated along the axis of the blade to provide aerodynamic pitching of the blade 108. Inner blade mounts 13 support the blade 108 in bending and axial loads, and combines with the blade shafts 10 and outer blade mount 9 and spokes 7 to support the mass of the rotor. A blade pitch drive 14 is mounted on the spindle (or hub 8) and serves to rotate the blades in pitch, as driven by the blade pitch motor 15.
FIGURE 10 shows the outer blade mount 9 in more detail . At its outer end the inner blade section 4 comprises a spar splice 20 which is the mating of the structural beam that connects the inner and the outer blade sections 4, 5. The rim structure 3 of the tension wheel comprises a bearing mount 19 and a bearing 18. The inner section 4 and the outer section 5 each comprise a lag 17 for receiving an axle 16 for attaching the inner section 4 and the outer section 5 of the blade to the rim structure 3.
FIGURE 11 shows the wheel mount in more detail. A forward main bearing 21 and a aft main bearing 22 support the drivetrain main shaft which connects to the rotor spindle and transfers the moment and thrust loads of the rotor to the machine base 25, and the torque from the rotor through the gearbox to the generators 23.
In FIGURE 8 there is schematically shown an aerodynamic fairing 24 for the spokes 7 which are provided to reduce the drag of the spokes 7.
The invention has been shown and described with reference to a wind turbine mounted atop a land-based tower, those skilled in the art will realize that the invention is also applicable to underwater turbines wherein the turbine is tethered underwater and the blades are turned by the force of water current . While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and detail may be made therein without departing from the scope of the invention.

Claims

C l a i m s
1. A rotor system for a fluid-flow turbine, comprising: a hub (8) mounted on a shaft, and a plurality of rotor blades (108) , characterized by a tension wheel, the tension wheel comprising a rim structure (3) mounted to the hub (8) by a plurality of spokes (7), the rotor blades (108) being attached to the rim structure (3) of the tension wheel.
2. The rotor system of claim 1, characterized in that the spokes (7) comprise airfoils, such as blades or sails, to harness the wind energy in the area circumscribed by the rim structure (3) .
3. The rotor system of claim 1 or 2, characterized in that the rotor blades are attached to the hub and comprise an inner section (4) between the hub (8) and the rim structure (3) and an outer section (5) outside the rim structure (3) .
4. The rotor system of claim 3 , wherein the inner sections of the rotor blades comprise airfoils.
5. The rotor system of any of claims 1 - 4, characterized in that the rim structure (3) comprises an outer rim (107) and an inner rim (112) interconnected with each other, wherein the rotor blades (108) are mounted to the outer rim (107) and the spokes are attached to the inner rim (112) .
PCT/IB2006/000605 2005-03-15 2006-03-14 Tension wheel in a rotor system for wind and water turbines Ceased WO2006097836A2 (en)

Priority Applications (12)

Application Number Priority Date Filing Date Title
PL06755831T PL1861619T3 (en) 2005-03-15 2006-03-14 Tension wheel in a rotor system for wind and water turbines
AT06755831T ATE476599T1 (en) 2005-03-15 2006-03-14 TRAVEL IN A ROTOR SYSTEM FOR WIND AND WATER TURBINES
EP06755831A EP1861619B1 (en) 2005-03-15 2006-03-14 Tension wheel in a rotor system for wind and water turbines
US11/885,481 US20080253892A1 (en) 2005-03-15 2006-03-14 Tension Wheel Hub in a Rotor System for Wind and Water Turbines
CA002600007A CA2600007A1 (en) 2005-03-15 2006-03-14 Tension wheel in a rotor system for wind and water turbines
JP2008501442A JP2008538597A (en) 2005-03-15 2006-03-14 Rotor system tension wheel for wind and hydro turbines
MX2007011249A MX2007011249A (en) 2005-03-15 2006-03-14 Tension wheel in a rotor system for wind and water turbines.
DK06755831.2T DK1861619T3 (en) 2005-03-15 2006-03-14 Drive wheel for a rotor system for wind and water turbines
DE602006015927T DE602006015927D1 (en) 2005-03-15 2006-03-14 ACCESSORIES IN A ROTOR SYSTEM FOR WIND AND WATER TURBINES
CN2006800080705A CN101137842B (en) 2005-03-15 2006-03-14 Tensioner pulleys in rotor systems for wind and water turbines
BRPI0608467-2A BRPI0608467A2 (en) 2005-03-15 2006-03-14 tensioning wheel in a rotor system for wind and hydraulic turbines
NO20075122A NO20075122L (en) 2005-03-15 2007-10-09 Tightening wheels in a rotor system for wind and water turbines

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US66216005P 2005-03-15 2005-03-15
US60/662,160 2005-03-15

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WO2006097836A3 WO2006097836A3 (en) 2006-11-16

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EP (1) EP1861619B1 (en)
JP (1) JP2008538597A (en)
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CN (1) CN101137842B (en)
AT (1) ATE476599T1 (en)
BR (1) BRPI0608467A2 (en)
CA (1) CA2600007A1 (en)
DE (1) DE602006015927D1 (en)
DK (1) DK1861619T3 (en)
ES (1) ES2348252T3 (en)
MX (1) MX2007011249A (en)
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NO20075122L (en) 2007-10-30
KR20070116107A (en) 2007-12-06
CN101137842A (en) 2008-03-05
JP2008538597A (en) 2008-10-30
PL1861619T3 (en) 2011-01-31
ES2348252T3 (en) 2010-12-02
ATE476599T1 (en) 2010-08-15
WO2006097836A3 (en) 2006-11-16
CN101137842B (en) 2012-11-28
DE602006015927D1 (en) 2010-09-16
MX2007011249A (en) 2007-10-18
CA2600007A1 (en) 2006-09-21
DK1861619T3 (en) 2010-11-29
EP1861619A2 (en) 2007-12-05
BRPI0608467A2 (en) 2010-01-05
PT1861619E (en) 2010-10-11
EP1861619B1 (en) 2010-08-04
US20080253892A1 (en) 2008-10-16

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