Patent Publication Number: US-2011062718-A1

Title: Generator platform &amp; drive assembly for alternative power production from aermotor and similar design windmills

Description:
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     CROSS REFERENCE TO RELATED APPLICATIONS 
     Application Ser. No. 11/889,373 Filed Oct. 9, 2007. 
     ‘Conversion kit for generating electricity from water pump windmills’.
 
Current invention describes a uniquely different generator platform and drive assembly from the prior description of a split ring drive assembly.
 
     Inventor: Carlos Fernandez-Bueno 
     FIELD OF INVENTION 
     Relates to the conversion and or retrofit of, prior art, water pumping windmills 
     BACKGROUND OF THE INVENTION 
     Windmills used for pumping water, like the Aermotor® and similar designs, have been in production in the U.S.A. since 1888. The sail design of these windmills is uniquely suited for very low wind applications. They usually have as many as 18 blades. The large surface area of these sails respond to very low winds and have high torque. They also rotate at very low revolutions per minute (rpm). They reach maximum output in the 20 miles per hour (mph) wind range. Sails range from 6 to 16 feet in diameter. The prior art, water pumping Aermotor®, is recognized around the world as an “American Windmill” icon. Their durability is legendary with many of them still in use 100 years after being placed in service. 
     In contrast, modern direct drive, small wind turbines are designed for moderate and strong wind applications. They have a relatively small exposure to the wind featuring only two or three thin blades and must rotate at very high rpm&#39;s. These turbines require winds in excess of 8-10 mph to start producing any usable form of electricity. 
     In the month of August, 2009, at the Potomac Wind Energy testing located in Dickerson, Md., U.S.A., two Aermotor® retrofit conversions were generating power over 80% of the time in contrast to four modern 3 bladed turbines which were generating power less than 20% of the time. The implications are tremendous since in the eastern part of the U.S.A the average wind speeds are lower than 10 mph, making modern 2 or 3 bladed turbines very ineffective and costly in terms of kilowatt power produced per dollar invested. 
     This invention&#39;s ‘Generator Platform and Drive Assembly’ on a 16 foot diameter, 18 sail Aermotor® windmill, starts spinning in a 2 mph breeze. Connected to a direct grid tie inverter this retrofitted windmill starts to sell electricity into the public utility grid in a 3 mph breeze and has achieved an output of 6.2 kilowatts. This is several times more output in a 10 mph wind when compared to the modern a modern three bladed, direct drive, 12 foot diameter turbine. 
     Hundreds, and perhaps thousands of Aermotor® and similar design windmills around the world sit idle because the well has run dry. These can be easily retrofitted to generate electricity, compressed air, hydraulic pressure or any other form of energy which require a generator, at a mere fraction of the cost of installing a brand new turbine to supply required needs. This invention&#39;s ‘Generator Platform and Drive Assembly’ can also be incorporated into the manufacture of brand new, prior art, Aermotor® and similar design windmills. 
     The current manufacturer of the Aermotor® windmill claims on their website that “water and electricity don&#39;t mix”. However new technology in generators, charge controllers, inverters, and transformers, in addition to this invention&#39;s platform and drive assembly, have been combined to successfully produce electricity from these retrofitted, prior art, water pump windmills in a low cost and sustainable manner. 
    
    
     
       BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWING 
       Generator Platform 
         FIG. 1  SIDE VIEW 
         FIG. 2  TOP VIEW 
       Legend for FIGS.  1  and  2   
       
           
             1 —GENERATOR PLATFORM 
             2 —SPLIT PULLEY 
             3 —PLATFORM FASTENERS 
             4 —UTILITY ACCESS PORT 
             5 —GENERATOR PULLEY 
             6 —TOWER MAST SHAFT 
             7 —PRIOR ART GEARBOX 
             8 —PRIOR ART SAIL HUB 
             9 —GENERATOR 
             10 —PLATFORM COVER 
         
      
       DETAILED DESCRIPTION OF SEVERAL VIEWS OF THE DRAWING 
       Split Ring Sprocket/Pulley Assembly 
         FIG. 3  FRONT VIEW 
         FIG. 4  SIDE VIEW 
       Legend for FIGS.  3  and  4   
       
           
             1 —SPLIT RING SPROCKET/PULLEY 
             2 —SPLIT RING RE-ASSEMBLY PLATES 
             3 —‘L’ FASTENING BRACKETS 
             4 —PRIOR ART WINDMILL SAIL/BRAKE HUB 
             5 —PRIOR ART WINDMILL GEARBOX 
         
      
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     This invention has two basic components, A and B, manufactured from steel or similar suitable material. 
     A—Generator Platform. ( FIGS. 1 and 2 ) 
     It provides the structural base for the assembly of all the required components. The design of this platform is unique for this particular application. It is designed and sized to specifically fit unto the upper section of the prior art gearbox of any Aermotor® or similar design windmill. This platform replaces the existing hood on the prior art windmill whose function was to protect the gearbox components from the weather. The platform provides the base onto which the generator is attached. 
     The platform ‘box’ is fabricated from steel ‘channel’ beam, or other suitable material, whose width must clear the height of the internal gears of the prior art gearbox. The ‘lips’ of the channel beam will be used to secure the generator and the entire platform to the prior art gearbox. The bottom of the platform box must snugly fit the outer ‘lips’ of the prior art gearbox to prevent future displacement, misalignment and vibrations of the chain/pulley drive assembly. The cover of the platform, to prevent the elements from entering the oil filled prior art gearbox, is made of steel or other suitable material. The generator is secured to the platform channel beam ‘lips’ with grade 8 bolts. The entire platform assembly is secured by bolts, clamps or weld to the existing prior art windmill gear box by means of the channel beam ‘lips’. 
     This platform incorporates an access port directly above the tower mast shaft to allow fastening of the prior art windmill gearbox to the tower. This access port also secures access to utility lines like electrical, compressed gas or hydraulic. These utility lines utilize the centric, hollow, tower mast shaft as a conduit. 
     B—Split Ring Drive Assembly. ( FIGS. 3 and 4 ) 
     The inner bore of the sprocket or pulley is specifically machined to match the outside diameter of the ‘brake hub’ of the prior art Aermotor® and similar design windmills. It is a unique ‘split’ design which allows the sprocket or pulley to be bolted, clamped or welded onto the brake hub, without having to disassemble or take down the windmill prior art gearbox and sails which can weight in excess of 3,000 pounds. 
     The ‘brake hub’ sprocket or pulley is connected to the generator attached to the ‘platform’ by a chain or belt. The gear ratio between the sail hub and generator is easily adjusted by changing the diameter of the generator sprocket or pulley and depends on the windmill model, the diameter of the sails and the type of the generator used and matched to the specific application requirements. If incorporated into the manufacture of a new, prior art, windmill this sprocket or pulley can be installed on the brake/sail hub as an intact (not split) unit.