Abstract:
Several embodiments that enhance and improve the efficiencies of vertical axis wind turbine generators by expanding their normal range of useful operations. Stationary vanes provided external to the rotor blades provide directional control of wind/air flow into the blades for decreased drag and increased differential wind pressure. Control scenarios for adjusting stationary wind vanes and additional ducting of air to increase efficiencies.

Description:
RELATED APPLICATIONS  
       [0001]    This application claims benefit of priority to provisional application Ser. No. 61/208,409 filed Feb. 24, 2009; and is related to co-pending non-provisional application Ser. No. 12/386,865 filed Apr. 25, 2009, which is incorporated herein by reference. 
     
    
     BACKGROUND  
       [0002]    1. Field of the Invention 
         [0003]    The invention is directed to the field of wind turbine generators and more specifically to the area of techniques that improve the operating efficiencies of such turbines. 
         [0004]    2. Description of the Prior Art 
         [0005]    Although wind can be found everywhere on the planet, and is always blowing somewhere, it is erratic. It is erratic as to where it blows, when it blows, at what speed it blows, the length of time it blows and what kind of wind it is . . . steady, gusting, changing direction . . . or all at the same time. This erratic factor is constantly (conveniently) overlooked when manufacturers and government reports on wind energy claim energy efficiencies from wind turbines. Large 3 bladed horizontal axis wind turbines (“HAWT”) require a “clean” flow of air in a narrow window of speed (generally 10-28 mph) to efficiently produce energy from wind. This is due to the basic design of the turbine and their outdated generators. 
         [0006]    Manufacturers have greatly increased the size of their turbine blades and the height of their masts to try and reduce the negative effects of these issues. The wind blows stronger at higher heights above the ground and larger blades more efficiently capture the wind&#39;s energy. They are close to the limit of negative return because of the greatly increased weight of the blades and the large increase in initial, shipping, installation and maintenance costs. 
         [0007]    The maximum efficiency of a three bladed HAWT is about 45%, if wind is constantly blowing at 18 mph. If one considers typical fluctuating wind energy, the average efficiency drops to about 25%. To be truly efficient a turbine has to operate over a much larger wind speed range and in all types of wind. 
         [0008]    Large numbers of 3 bladed HAWTs have been successfully installed worldwide to meet the strategic need to reduce dependency on foreign oil and reduce carbon emissions from coal and oil fired electricity generation plants. However, they are all remarkably similar in overall design and component design and layout. 
         [0009]    Although commercially successful, largely due to subsidies, 3 bladed HAWTs have several major issues:
   High product, shipping, installation and maintenance costs   Narrow operational window (wind speeds of 10-28 mph=5-13 m/s)   Inability to operate effectively in “turbulent” air   Large land usage requirements (about 5 acres per Megawatt)   Installation sites typically far from users   Environmental and health issues (noise, flicker, wildlife, etc.)   Supply chain and delivery issues (weights of approximately 125 tons and 8000 parts)   Regulatory issues (large delays to obtain licenses)   
 
         [0018]    It is well known that three bladed HAWTs produce electricity in response to wind motion over their blades and are designed to operate within a narrow range of wind velocities (design window). Wind that is too low in velocity (below the window) will not be sufficient to cause the blades to turn. Wind that is too strong (above the window) causes associated sensors to feather the blades or apply brakes to prevent the blades from turning. Otherwise, the blades would turn to turn too fast for safe operation. (Because wind turbine generators are not in operation when the wind velocity is outside the design window, they generally have low operating efficiencies.) Consequently, the placement of wind turbine generators is critical to their output efficiencies and locations are chosen in which the velocity of wind is predominantly within the design window. The most ideal site would be one where the wind velocities are constantly occurring and remain in the upper range of the design window. 
         [0019]    Current 3 bladed HAWTs use generators essentially the same as those powered by diesel engines in the 1940&#39;s. They generally weigh about 15 tons and require huge inefficient gearboxes to convert the slow turning propeller blade (80 rpm) shaft to 2000 rpm&#39;s to generate electricity. This transmission configuration is the main cause of the 3 bladed HAWTs inability to generate electricity in less than a 10 mph wind and to close down above 30 mph. 
         [0020]    Prior art vertical axis wind turbine (“VAWT”) designs, such as is shown in  FIG. 1 , have been found to be successful in eliminating some of the major issues experienced with 3 bladed HAWTs and at a significantly lower cost. Vertical axis wind turbines (also generally known as Savonius turbines) produce large amounts of torque over a wider range of wind speeds as compared to HAWTs. However, the basic efficiency (ability to capture wind energy) of conventional VAWTs is low when compared to horizontal axis turbines. 
       SUMMARY OF THE INVENTION 
       [0021]    In the present invention improvements are disclosed with regard to higher efficiency VAWT generators. The mounting and configuring of individual turbine modules is disclosed to provide greater power from a smaller footprint and to more efficiently convert wind energy into electrical energy. 
         [0022]    The present invention improves on the simplest vertical axis wind turbine operation which is based on the difference of the drag at each side of its semi-circular half cylinder blade. The advantage of this type of wind turbine is that it can operate in a wider range of wind speeds, can operate in turbulent air, can operate efficiently at ground level, is self-starting, and independent of the wind direction. 
         [0023]    The present invention provides innovative modifications to the design of the blades, both front and rear to optimize the concave wind striking surface and the wind deflecting convex surface. In addition, fixed outer vanes are shown to concentrate wind pressure to selected portions of the turbine blades and thereby achieve significant improvements in power coefficients of VAWTs. Outer vanes may be either fixed, or adjustable. 
         [0024]    Embodiments are included which provide arrays of individual VAWT modules that are directionally sensitive and in stacking configurations to illustrate the significant accumulated efficiencies. 
         [0025]    Further efficiencies are achieved by integrating a high density printed armature generator with the improved turbine. A high density, flat motor type, printed armature electric generator is disclosed that has a 20× improvement in power density over current designs. This generator is extremely compact and lightweight and can produce electrical energy at speeds from 1 or 2 rpm and into the 100 s of rpms with power ratings up to 500 kW. For example a 160 hp generator can produce 120 kW and in this configuration is expected to be no more than 14″ in diameter about 5″ tall, including its own bearings and electronic control system. Since this generator does not require a gearbox and can be mounted within the turbine housing or mounted at ground level, it will simplify both installation and servicing. 
         [0026]    Although referred to as vertical axis turbines, the individual VWAT turbines can be produced as individual power modules that can be mounted to rotate about a vertical or horizontal axis and in a wide range of environments. Arrays of turbine modules allow for more power to be generated from a smaller footprint. 
         [0027]    As detailed below, vertical axis wind turbines can operate on, in and between existing buildings and structures. They can be sited where the energy is required, in order to provide distributed power and potentially eliminate new transmission lines and their associated losses. Also, vertical axis wind turbines utilizing the fixed vane technology of the present invention can be integrated into building structures. They can take advantage of additional wind generated by the wind pressure differentials created by the buildings themselves 
         [0028]    It is an object of the present invention to increase the output efficiencies of wind turbine generators by providing vertical axis turbines with enhanced blade configurations. 
         [0029]    It is an object of the present invention to provide additional blades in a Savonius type turbine to increase its efficiency. 
         [0030]    It is another object of the present invention to provide stationary outer deflector vanes for concentrating wind pressure to the inner rotating blades of a VAWT. 
         [0031]    It is a further object of the present invention to provide an improved electrical generator that is both light weight and efficient and does not require an energy robbing gearbox. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0032]      FIG. 1  is a top plan view of a prior art Savonius type VWAT. 
           [0033]      FIG. 2  is a top plan view of a two bladed VWAT embodiment of the present invention containing a plurality of outer stator wind vanes and secondary rotor blades. 
           [0034]      FIG. 3  is top plan view of a two bladed VWAT embodiment of the present invention containing a plurality of outer stator wind vanes illustrating the effects of wind flow. 
           [0035]      FIG. 4  is a perspective view of the VWAT with several outer stator wind vanes removed. 
           [0036]      FIG. 5  is top plan view of a two bladed VWAT embodiment of the present invention containing a plurality of secondary rotor blades and an outer stator wind vane. 
           [0037]      FIG. 6  is top plan view of a two module array of VWATs with outer stator wind vanes illustrating the effects of wind flow. 
           [0038]      FIG. 7  is a perspective view of a three module array of VWATs with outer stator wind vanes. 
           [0039]      FIG. 8  is top plan view of the three module array shown in  FIG. 7  illustrating the effects of wind flow. 
           [0040]      FIG. 9  is a top plan view of arcuate arrays of VWAT modules, illustrating the effects of wind flow. 
           [0041]      FIG. 10  is a top plan view of a two module array embodiment of VWATs with a secondary duct formed by stationary wind vanes. 
           [0042]      FIG. 11  is a top plan view of a VWAT module embodiment with adjustable stationary wind vanes. 
           [0043]      FIG. 12  is a top plan view of a VWAT embodiment illustrating a mechanism for adjusting stationary wind vanes. 
           [0044]      FIG. 12A  is an enlarged view of a portion of the adjustment mechanism of  FIG. 12 . 
           [0045]      FIG. 13  is a plan view of a VWAT generator assembly. 
           [0046]      FIG. 14  is a plan view of a mast mounted array of VWAT generators. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0047]    In  FIG. 1 , a prior art Savonius type VWAT  10  is shown. Typically, such a VWAT contains a blade  12  that extends vertically parallel with an axis  16  and has an “S” shaped cross-section, wherein the tips of the blades lie along the diameter of a defined cylinder. Blade  12  extends vertically from a rotor  14  to rotate about an axis  16 . Although wind forces f 1  and f 2  shown in the drawings are equal, the resulting effect on the blade  12  is uneven. Wind forces f 1 , incident on the concave surface of blade  12  are greater than the wind forces f 2  applied to the convex portion, since the concave portion tends to collect the forces and the convex portion tends to deflect the forces. The resulting differential results in an imbalance of forces on blade  12  and rotation of rotor  14 . 
         [0048]    Savonius wind turbines are well known for their compactness and relative efficiencies during a wide range of wind speeds from various directions. Savonius turbines are one of the simplest turbines and are considered “drag” type devices. They typically consist of two or more “C” shaped blades having an “S” cross-sectional shape when viewed along its vertical axis of rotation. The backs of the blades do not help with rotation and are typically designed to shed air so as not to increase drag on the turbine. Since the “C” shaped blades collect wind forces directed against their surfaces and the forces are greater on those surfaces than the backs of the blades, the differential in applied forces causes the blades to turn. While the Savonius type VWAT shown in  FIG. 1  is typically used because of its omni-directional properties—the ability to be driven by wind forces from any direction—it is somewhat inefficient because its power is the result of the force differentials applied to the convex and concave portions of the rotating blade. Therefore, the speed of the turbine is always less than the wind speed. 
         [0049]    One embodiment of the present invention, shown in  FIG. 2 , provides improvements to the operation of traditional Savonius type VWATs. A 2-blade turbine  50  is shown with a pair of primary rotor blades  51  and  52  on a rotor  56 . Blades  51  and  52  are substantially semi-circular in cross-section (half a cylinder). Blades  51  and  52  are joined across the axis “X” by an extension piece  55  to create an off-set from the axis X. The offset “D” is shown as the distance the outer edges  53  and  54  of the blades  51  and  52  are from a common diameter line. An additional improvement includes a set of secondary rotor blades  57  and  58  located in advance of the concave portion of each primary rotor blade. Secondary rotor blades  57  and  58  are also attached to the rotor  56 , and function to improve air flow while providing additional surface area for the impinging air flowing into the turbine. Another improvement includes a plurality of fixed stator vanes  61 ,  62  and  63  mounted on a fixed platform  60  equally spaced around the outside of rotor  56 . Fixed stator vanes  61 ,  62  and  63  are slightly curved in the direction of rotation when viewed from outside the turbine. The function of the stator vanes is to improve air flow by deflecting wind towards the concave portion of the blade and secondary vane positioned in front of the concave blade portions and away from the convex portions of the blade as it rotates. In this embodiment, the VWAT displays increased performance while maintaining its omni-directional properties. 
         [0050]    It should be noted that there are several variations in numbers of blades and fixed stator vanes that can be adapted to the disclosed invention. In the embodiments shown, it has been found that the following arrangements are acceptable for the desired performance characteristics: Two rotor blades require at least three fixed stator vanes. Three rotor blades require six fixed stator vanes. Four rotor blades require eight fixed stator vanes, etc. There may be minor efficiencies in increasing the number of fixed stator vanes in each embodiment; however, one must weigh the costs of such additions vs. the efficiencies achieved. 
         [0051]    In the embodiment of  FIG. 3 , a VWAT  150  similar to that shown in  FIG. 2  is shown. In this embodiment, several fixed stator vanes  161 ,  163 ,  165 ,  167 ,  169 ,  171 ,  173  and  175  are disposed on a stationary platform  160 , around rotor  156 . In the position shown, fixed stator vanes direct wind “f” flowing towards the concave surface of rotor blade  152  and deflect wind from the convex surfaces of blade  151 . The result is that the wind is deflected generally in the direction of rotor rotation to result in concentrated wind forces present on the concave (front) surfaces of secondary blades  158  and  157 , as well as primary blades  152  and  151  as they rotate about axis “X”, while minimized opposing wind force vectors present on the convex (back) surfaces of blades  151  and  152 . The result is that the differential forces are increased and the wind forces present on the front surfaces of the rotor blades are increased. The distance between the rotating tip  154  of blade  152  and tip  153  of blade  151 , are spaced from the stationary vanes on platform  160  so as to allow for expansion during high operating speed or ambient temperatures. Although the wind is indicated as coming from a single direction in the  FIG. 3  embodiment, it can be seen that this embodiment is equally sensitive to wind coming from all directions and therefore maintains its omni-directional characteristics. 
         [0052]      FIG. 4  shows a partial cut-away of the VWAT in  FIG. 3  with stationary vanes  163  and  165  removed. This view allows one to see how the VWAT can be mounted on a mast  140  with a cover  142 . In this case the cover  142  is supported by stationary vanes  161 ,  163 ,  165 ,  167 ,  169 ,  171 ,  173  and  175 . Primary rotor blade  152  is shown adjacent to its secondary blade  158 , both mounted on rotor  156 . 
         [0053]      FIG. 5  illustrates another embodiment of the present invention wherein a set of deflector vanes  264  and  262  are provided on one side of a VWAT module  250  to enhance the diversion of air into the power slot of the turbine. In this embodiment, the turbine  250  is a unidirectional turbine and must be adjustably rotated to have the wind forces vectored into the power slot defined between the vanes  264  and  262  and rotor axis “A”. VWAT module  250  module is shown to have primary rotor blades  251  and  252  as well as secondary rotor blades  257  and  258  mounted on rotor  260 . 
         [0054]      FIG. 6  illustrates an array  400  of VWT modules  250  and  350  disposed adjacent to each other to define a unidirectional turbine. In this case, each module has a set of two stationary vanes that both divert air flow into the power slot and away from the drag portion of the rotating blades before they enter the power slot. For instance, in the position illustrated, stationary vanes  275 ,  264  and  262  concentrate wind forces into the power slot defined between vane  262  and the axis “A”, causing the primary and secondary rotor blades  252  and  258  to rotate in a clockwise direction. a Meanwhile, stationary vanes  274  and  272  divert wind forces away from primary blade  251  until primary blade  251  rotates into the power slot where wind forces impinge on its concave surface. At the position shown in  FIG. 6 , the angular rotation of the rotor blades  252  and  258  in turbine module  250  are at the end of the power stroke and the air exits at “G”, with fixed stationary vane  262  in place. In the array  400 , VWAT module  351  is shown to have its rotor blades advanced with respect to the blades in module  250 . VWAT  350  is depicted with stationary vanes  364  and  265  to concentrate wind force into the power slot. The concentration of wind forces provides increased wind speed due to the venturi effect, which translates to higher forces onto the rotor blades. Wind initially impinges on secondary rotor blade  358  and primary rotor blade  352 . In this depiction, the angular rotation of the turbine  350  is also at the end of the power stroke, since the air exits “F”. In each turbine it can be seen that the use of a secondary rotor blade provides enhanced efficiencies due to its location in front of the primary rotor blade in a manner to continue to receive wind forces when the primary blade has been rotated to a point where it is no longer exposed to wind forces. 
         [0055]      FIGS. 7 and 8  illustrate another embodiment of the present invention in which three VWATs are provided in a linear array  500 . A framework  505  provides a rigid mounting for the three turbine modules and the associated stationary vanes set up the unidirectional properties for this embodiment. Turbine module  450  contains stationary vanes  464  and  365  which deflect incoming wind “E” to be concentrated at “F”, and thereby create a Venturi effect. At the same time, stationary vane  365  deflects the wind towards the defined power slot to decrease drag on the convex back side of blade  452  as it rotates towards the power slot. The position of blades in turbine module  450  represents the start of the power stroke, wherein secondary rotor blade  457  is the first surface to receive the wind energy. 
         [0056]    Turbine module  350  is shown to represent the turbine&#39;s angular rotation at its maximum power generation. In this position, stationary vanes  364  and  362  define the outer flow guide for wind into the defied power slot. By using a vane  362 , as shown, the power slot is extended to provide a longer duration of power applied to the rotor blades  352  and  358 . Stationary vane  265  acts a vane  365  does with respect to module  450  to divert wind forces away from the back side of primary blade  351 . 
         [0057]    Turbine module  250  contains all the same elements as turbine module  350  but has its rotor blades oriented to be at the end of it power stroke when turbine module  350  is at its maximum. By orienting the turbine blades at staggered angles of orientation with respect to one another, the power provided by the array can be more evenly distributed with lower peak variations. 
         [0058]    Turbine arrays can be configured in a variety of formats.  FIG. 9  illustrates a semi-circular format which helps to contain the wind, and stabilize the constantly varying wind pressures experienced by turbines. The stabilized air pressure in turn leads to more consistent rotation of the turbines resulting in the generation of “cleaner” electricity. In this embodiment, VWAT modules  620 ,  630 ,  640 ,  650 ,  670  and  680  are disposed on a platform  610  which is pivoted to rotate about an axis “Y”. In this manner, the array can be oriented to the direction of wind flow in order to maintain maximum efficiency. 
         [0059]      FIG. 10  illustrates a further embodiment of the present invention, wherein an additional wind flow path is set up between adjacent VWAT modules in order to increase the power factor of wind/air flow into the turbine. A turbine array  700  is shown which includes a pair of turbine modules  702  and  704 . While the stationary vanes  762 ,  764 ,  775 ,  774 ,  784 ,  792  and  795  are essentially the same as their counterparts in earlier described embodiments, an additional flow path is shown which is defined by stationary vanes  785 ,  786  and the back sides of vanes  764  and  762 . This additional flow path “g” ducts and compresses air flow that is not diverted into the power slot and leads it to the rear of the turbine where it is ducted in at higher speed to the rotating blades ( 758  and  752  in the position illustrated). This embodiment provides not only the enhanced power from vane diverted wind into the defined power slot described above, but also provide additional power be introducing wind forces beyond the defined power slot. In this manner, the ducted air tends to hold the diverted and compressed air in the turbine for an extended period to provide additional power. 
         [0060]    While the foregoing embodiments illustrate how one can enhance an dramatically improve the operational efficiencies of VWATs, at times it may be necessary to adjust the angle of the stationary wind vanes that divert wind into the turbine. In  FIG. 11 , a turbine  800  is shown in which stationary wind vanes  865  and  862  are mounted on a hinge  864 . Similarly, stationary wind vanes  872  and  874  are mounted on a hinge  875 . Depending on the installation, adjustments of these stationary wind vanes may be manually set or remote controlled to accommodate variations in wind strengths. 
         [0061]    In  FIGS. 12 and 12A , a mechanism  900  is illustrated in which stationary wind vanes (one shown)  975  may have their angles of deflection changed. Central turbine rotor  901  is shown to be surrounded by a stationary platform  903 . A control ring  905  is shown to surround platform  903 . Each stationary wind vane  975  is mounted on a pivoting pin  973  extending from stationary platform  903  and contains an adjustment pin  972  which extends from the vane into a slot  907  formed in ring  905 . Through a control mechanism, (not shown) it is possible to rotatable move the control ring  905  with respect to the stationary platform  903  until the vanes are adjusted as desired to change their respective angles of deflection. Movement of control ring  905  may be by a manual or remote adjustment. 
         [0062]      FIG. 13  illustrates a side elevation of a single VWAT  1000  having its turbine  1010  connected to a drive shaft  1050  which rotates when wind energy spins the turbine blades. A wind direction flag  1002  provides orientation of the turbine, while anemometer  1004  provides wind speed information to a controller (not shown). During average wind conditions the rotation of the turbine  1010  and drive shaft  1050  transmits energy to a main generator  1020  which converts the mechanical energy into electrical energy. 
         [0063]    During low wind conditions, sensed by anemometer  1004 , the main generator  1020  may be electronically disconnected from drive shaft  1050  and one or more of the secondary generators  1022  is electronically connected to drive shaft  1050 . The secondary generators  1022  are considerably smaller than the main generator  1020  and have much lower resistance to allow the production of electricity at very low wind speeds. When the wind speed increases to a predetermined level the secondary generator(s)  1022  is(are) electronically disconnected from drive shaft  1050  and the larger main generator  1020  is electronically connected. 
         [0064]    During very high wind conditions, main generator  1020  remains coupled to the drive shaft  1050  and the secondary generators  1022  are also electronically coupled to the drive shaft, allowing the increased energy load to be absorbed and converted into electrical energy. 
         [0065]    During exceptionally high winds, a further step can be taken. The turbine has an electric brake  1030  mounted to drive shaft  1050 . Brake  1030  is used to stop the turbine for servicing and in emergency situations. When the wind speed reaches a predetermined limit and all of the generators have reached their maximum energy loadings electric brake  1030  is automatically engaged to slow the rotation of the turbine. This would normally cause energy to be lost as heat energy. But electric brake  1030  is a regenerative brake, able to convert at least 50% of the braking force into usable electrical energy. 
         [0066]    This configuration of multiple generators and regenerative electric brake allows the turbine to produce electrical energy in very low wind speeds through exceptionally high wind speeds greatly increasing its effective operational window. 
         [0067]      FIG. 14  presents a further array configuration of VWATs in which linear arrays, such as shown in  FIGS. 7 and 8  are stacked in vertical alignment. Electrical generators  1120 A-C are shown to be associated with each stack of turbines. Mast  1110  and bearing  1105  serve to provide the necessary support to the array and provide for rotation of the array into the direction of incoming wind. 
         [0068]    As can be seen by the drawings and accompanying explanation, the present invention is a unique improvement over conventional wind turbine generating systems. And while the embodiments shown here are preferred, depending on the engineering applications and requirements, they shall not be considered to be a restriction on the scope of the claims set forth below.