U.S. patent application number 13/215140 was filed with the patent office on 2012-03-01 for structure and accelerator platform placement for a wind turbine tower.
This patent application is currently assigned to OPTIWIND CORPORATION. Invention is credited to David H. Leach, Jason A. Martin, Russel H. Marvin.
Application Number | 20120051939 13/215140 |
Document ID | / |
Family ID | 45697530 |
Filed Date | 2012-03-01 |
United States Patent
Application |
20120051939 |
Kind Code |
A1 |
Marvin; Russel H. ; et
al. |
March 1, 2012 |
STRUCTURE AND ACCELERATOR PLATFORM PLACEMENT FOR A WIND TURBINE
TOWER
Abstract
Disclosed herein is a structure for a wind turbine tower. A
plurality of corner posts form the core of the tower with one or
more cross braces spanning the distance between pairs of corner
posts. Rotating support members mounted at the location of the
corner posts are adapted for mounting accelerator platforms and
enabling the accelerator platform to rotate. Horizontal-axis wind
turbines can be mounted on opposite sides of the accelerator
platform. In some towers, the vertical spacing between the rotating
support member from one accelerator platform to an adjacent
accelerator platform is an integer multiple of the vertical spacing
between the intersection points between the cross braces and the
corner posts. In other towers, the rotating support member
locations on the corner posts are proximal to the intersection of
the cross braces and the corner posts.
Inventors: |
Marvin; Russel H.; (Goshen,
CT) ; Martin; Jason A.; (Torrington, CT) ;
Leach; David H.; (Torrington, CT) |
Assignee: |
OPTIWIND CORPORATION
Torrington
CT
|
Family ID: |
45697530 |
Appl. No.: |
13/215140 |
Filed: |
August 22, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12077556 |
Mar 20, 2008 |
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13215140 |
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12315943 |
Dec 8, 2008 |
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12077556 |
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12286054 |
Sep 26, 2008 |
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12315943 |
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12929000 |
Dec 22, 2010 |
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12286054 |
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12286055 |
Sep 26, 2008 |
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12929000 |
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12454526 |
May 19, 2009 |
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12286055 |
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12454527 |
May 19, 2009 |
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12454526 |
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12454823 |
May 21, 2009 |
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12454527 |
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12586998 |
Sep 30, 2009 |
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12454823 |
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12592909 |
Dec 5, 2009 |
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12586998 |
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12460985 |
Jul 27, 2009 |
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12592909 |
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12217916 |
Jul 9, 2008 |
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12460985 |
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12006024 |
Dec 28, 2007 |
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12217916 |
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12077556 |
Mar 20, 2008 |
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12006024 |
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Current U.S.
Class: |
416/244R |
Current CPC
Class: |
F05B 2240/13 20130101;
F05B 2240/40 20130101; F03D 9/25 20160501; F03D 80/85 20160501;
F03D 13/20 20160501; Y02E 10/72 20130101; F03D 1/04 20130101; Y02E
10/728 20130101; F03D 1/02 20130101 |
Class at
Publication: |
416/244.R |
International
Class: |
F04D 29/00 20060101
F04D029/00 |
Claims
1. A tower for mounting wind turbines, comprising: a plurality of
corner posts forming the core of the tower; one or more cross
braces spanning the distance between at least one pair of corner
posts; at least one rotating support member mounted at the location
of at least one corner post; at least one accelerator platform
attached to the at least one rotating support member, wherein the
at least one accelerator platform can rotate on at least one
rotating support member; and at least two horizontal-axis wind
turbines mounted on opposite sides of the at least one accelerator
platform.
2. The tower of claim 1, wherein the vertical spacing between the
rotating support member from the at least one accelerator platform
to an adjacent accelerator platform is substantially an integer
multiple of the vertical spacing between the intersection points
between the cross braces and the corner posts.
3. The tower of claim 1, wherein two or more accelerator platforms
are mounted on the tower in a vertical stacking arrangement.
4. The tower of claim 3, wherein the two or more accelerator
platforms are linked in such a way that they always point in
substantially the same direction relative to rotation about the
vertical Z axis.
5. The tower of claim 3, wherein said linkage does not
substantially limit translation in the X, Y, or Z directions.
6. The tower of claim 3, wherein the two or more accelerator
platforms are linked in a compliant spring-like manner to enable
movement in the X and Y axes and wherein the force of the link acts
to return the accelerator platforms to an aligned
configuration.
7. The tower of claim 1, wherein the cross braces are angled.
8. The tower of claim 1, wherein at least one of power and
communication wires between the rotating platforms and a
non-rotating part of the facility traverses at least part of the
core of the tower vertically so said wires can twist a plurality of
turns in either direction as the platforms rotate.
9. The tower of claim 8, wherein said power and communication wires
come from two or more wind-turbine generators on said
platforms.
10. A tower for mounting wind turbines, comprising: a plurality of
corner posts forming the core of the tower; one or more cross
braces spanning the distance between pairs of corner posts; at
least one rotating support member mounted at the location of at
least one corner post; at least one accelerator platform attached
to the at least one rotating support member, wherein the
accelerator platform can rotate around the tower on the at least
one rotating support member; and at least two horizontal-axis wind
turbines mounted on opposite sides of the at least one accelerator
platform, wherein the rotating support member locations on the
corner posts are proximal to the intersection of the cross braces
and the corner posts.
11. The tower of claim 10, wherein the vertical location of the
rotating support member attachment points to the corner posts is
within a pre-defined distance of where the cross braces intersect
the corner posts, wherein the pre-defined distance is a percentage
of the spacing between intersection points between the cross braces
and the corner posts.
12. The tower of claim 11, wherein the percentage is +/-25%.
13. The tower of claim 10, wherein two or more accelerator
platforms are mounted on the tower in a vertical stacking
arrangement.
14. The tower of claim 13, wherein the two or more accelerator
platforms are linked in such a way that they always point in
substantially the same direction relative to rotation about the
vertical Z axis.
15. The tower of claim 8, wherein said linkage does not
substantially limit translation in the X, Y, or Z directions.
16. The tower of claim 13, wherein the two or more accelerator
platforms are linked in a compliant spring-like manner to enable
movement in the X and Y and wherein the force of the link acts to
return the accelerator platforms to an aligned configuration.
17. The tower of claim 8, wherein the cross braces are angled.
18-101. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of the following
U.S. patent applications, each of which is incorporated by
reference in its entirety: U.S. patent application Ser. No.
12/077,556, filed Mar. 20, 2008; U.S. patent application Ser. No.
12/315,943, filed Dec. 8, 2008; U.S. patent application Ser. No.
12/286,054, filed Sep. 26, 2008; U.S. patent application Ser. No.
12/929,000, filed Sep. 26, 2008; U.S. patent application Ser. No.
12/286,055, filed Sep. 26, 2008; U.S. patent application Ser. No.
12/454,526, filed May 19, 2009; U.S. patent application Ser. No.
12/454,527, filed May 19, 2009; U.S. patent application Ser. No.
12/454,823, filed May 21, 2009; U.S. patent application Ser. No.
12/586,998, filed Sep. 30, 2009; and U.S. patent application Ser.
No. 12/592,909, filed Dec. 5, 2009.
[0002] This application is also continuation-in-part of the
following U.S. patent applications, each of which is incorporated
by reference in its entirety: U.S. patent application Ser. No.
12/460,985, filed Jul. 27, 2009, which is a Continuation-in-Part of
U.S. patent application Ser. No. 12/217,916, filed Jul. 9, 2008,
U.S. patent application Ser. No. 12/006,024 filed Dec. 28, 2007,
and U.S. patent application Ser. No. 12/077,556, filed Mar. 28,
2008.
BACKGROUND
[0003] It is the general object of the present invention to provide
an improved wind turbine and tower for mounting wind turbines, as
well as improved methods for manufacturing thereof and associated
systems, components, methods, devices, and electronics.
SUMMARY
[0004] Disclosed herein is a structure for a wind turbine tower.
The structure includes a plurality of corner posts forming the core
of the tower, one or more cross braces spanning the distance
between at least one pair of corner posts, at least one rotating
support member mounted at the location of at least one corner post,
at least two accelerator platforms attached to the at least one
rotating support member, wherein each accelerator platform can
rotate on at least one rotating support member, and at least two
horizontal-axis wind turbines mounted on opposite sides of the at
least one accelerator platform. In some embodiments, the vertical
spacing between the rotating support member from the at least one
accelerator platform to an adjacent accelerator platform is
substantially an integer multiple of the vertical spacing between
the intersection points between the cross braces and the corner
posts. In other embodiments, the rotating support member locations
on the corner posts are proximal to the intersection of the cross
braces and the corner posts.
[0005] Two or more accelerator platforms may be mounted on the
tower in a vertical stacking arrangement, may be linked in such a
way that they always point in substantially the same direction
relative to rotation about the vertical Z axis, or may be linked by
a spring to enable movement in the X and Y axes and wherein the
force of the spring acts to return the accelerator platforms to an
aligned configuration. The cross braces may be angled. The power
and communication wires between the rotating platforms and a
non-rotating part of the facility may traverse at least part of the
core of the tower vertically so that the wires can twist a
plurality of turns in either direction as the platforms rotate. The
wires may come from two or more wind-turbine generators on the
platforms. The vertical location of the rotating support member
attachment points to the corner posts may be within a pre-defined
distance of where the cross braces intersect the corner posts,
wherein the pre-defined distance is a percentage of the spacing
between intersection points between the cross braces and the corner
posts. The percentage may be +/-25%.
[0006] Disclosed is a method of assembling a wind turbine blade and
impeller blade hub including injection molding an impeller blade
including a connection feature at the root end of the blade,
injection molding the impeller hub including a hub connection
feature that is complementary to the connection feature at the root
end of the blade, and mounting one or more impeller blades to the
impeller hub by mating the connection feature at the root end of
the blade with the complementary hub connection feature to form an
impeller blade assembly. At least one of the impeller blades and
the impeller hub is injection molded out of plastic, such as
glass-fiber filled or carbon-fiber filled plastic, and may utilize
a gas assist. The connection feature and hub connection feature may
enable fastening via at least one of an interference fit, a
friction fit, a ball and socket, a zipper, a snap fit, a threaded
fit, a hook and loop, an eyelet, and a clip. The injection molded
impeller blade may be hollow. The method may further include
mounting a nose cone to the impeller blade assembly, if a nose cone
feature is not already integrated into the impeller hub. The nose
cone may be injection molded. The method may further include
mounting the impeller blade assembly on a generator shaft of a wind
turbine. The method may further include first mounting the impeller
blade assembly on an adaptor hub before mounting to the generator
shaft or first mounting an adaptor hub to the generator shaft
before mounting the impeller blade assembly on the adaptor hub. The
wind turbine may be adapted to be mounted on an accelerator
platform that rotates around a tower on at least one rotating
support member. Closed-cell foam may be injected into air cavities
of the impeller blade assembly. The impeller blade assembly may be
balanced by adding a weight to the hub, such as by mounting through
an opening in the hub, optionally with bolts that self tap into
plastic features in the hub. The impeller blade assembly may be
disassembled and re-assembled without having to rebalance the
assembly.
[0007] Disclosed herein is a method of manufacturing a flange for
connecting structural members of a wind turbine tower. The method
may include hot rolling steel and forming it to an approximately
cylindrical shape or a flat sheet. The method may also include
heating and forging the approximately cylindrical steel shape to
form it into a flange shape. If the hot rolled steel is flat, the
method may include cutting the flat steel into an approximately
cylindrical steel shape before heating and forging to form it into
a flange shape. The method may conclude with cooling the flange and
machining the inside and outside surfaces of the flange to their
final shape. The flange material may include a carbon content less
than 0.3% or a carbon equivalent. The carbon equivalent is defined
by an equation, such as CE=% C+((% Mn+% Si)/6)+((% Cr+% Mo+%
V)/5)+((% Cu+% Ni)/15), less than 0.45%, or any other equation for
calculating carbon equivalency. The flange material may include an
element to retard grain growth during heating above an austentizing
temperature, such as 1000 degrees Fahrenheit. The flange material
may include at least one of titanium, niobium, ruthenium, vanadium,
zirconium, molybdenum, a rare earth element, a transition metal,
and a combination thereof. The flange material may include a grain
size (G) of 12 or smaller as measured using ASTM E112. The flange
material may include at least one of austenite dispersed in a
ferrite microstructure, pearlite dispersed in a ferrite
microstructure, carbide precipitates in a ferrite microstructure,
and nitride precipitates in a ferrite microstructure. The flange
may be welded to the tubular member, such as via a multipass metal
inert gas (MIG) weld or an inside tungsten inert gas (TIG) pass
weld. The assembly may be galvanized after welding. The flange may
define a circumaxially spaced series of small axially extending
openings for receiving bolts. The final shape of the flange may be
radial annular with at least a partial generally planar surface on
one side. The flange may be part of a flanged coupling unit for use
with a similar coupling unit in oppositely oriented interconnected
mating relationship for the endwise interconnection of the
structural members. The structural members may be axially aligned
similar elongated members.
[0008] The flanged coupling unit may include the radially extending
generally annular flange having at least a partially generally
planar radial surface on one side, a rigid connector for connecting
the flange with a mating flange of a similar coupling unit with the
planar surfaces of the two flanges engaged in face-to-face
relationship, and a boss formed integrally at its inner end portion
with the flange to form an external corner surface area therewith
on the side thereof opposite its planar surface and projecting
axially therefrom for connection with an end portion of a first
elongated member, the mating flange having a similar boss for
connecting a second elongated member in endwise axially aligned
relationship with the first member, and the external surfaces
oppositely adjacent to and through the corner area between the
flange and boss being substantially arcuate concave throughout
deriving from substantially continuously varying radii of curvature
between a first imaginary annular line spaced outwardly along and
extending around the boss and a second imaginary annular line
spaced outwardly along and extending around the flange, opposite
ends of the arcuate surface respectively adjacent the first and
second imaginary annular lines blending smoothly in transition to a
linear surface on the opposite side of the line, the largest radius
of curvature being adjacent the first imaginary annular line and
the smallest radius of curvature adjacent the second imaginary
annular line, and the first imaginary line being substantially
farther from the corner between the boss and flange than the second
imaginary line.
[0009] Disclosed herein is a wind power generating system that
includes at least two wind turbines comprising impeller blades,
wherein the turbines are mounted on a horizontally rotatable
support in spaced relationship with each other on opposite sides of
the axis of the support for rotation about horizontal axes, each
turbine being connected in driving relationship with an electrical
generator, which is in turn connected to an external load. The
system may also include at least two DC converters and power
switches respectively receiving the output of said generators, at
least two monitors each sensing at least one parameter of operation
of one generator, a controller connected with and receiving signals
from said monitors and including a reference in the form of a
performance curve for said generators, wherein said controller is
connected in controlling relationship with each of said generators
such that at least one generator follows the performance curve to
generate power, and at least one resistor in electrical
communication with at least one DC bus that transfer signals
between the DC converter and at least one inverter. The resistor
may dissipate the power when a monitor determines a
dissipation-requiring condition. The dissipation-requiring
condition may be at least one of: that at least one generator is
not following the performance curve, that power drawn by the
generator exceeds the capacity of the at least one inverter, that
the power drawn by the generator exceeds the capacity of a utility
grid connection, and that the utility grid fails. Substantially all
of the power may be dissipated in the at least one resistor while
the impeller blades are decelerated. The system may include various
combinations of resistors and inverters, such as two resistors and
two inverters, one resistor and one inverter, two resistors and one
inverter, one resistor and two inverters, and the like.
[0010] Disclosed herein is a method of braking in a wind turbine
generator including attaching at least one brake set to the rear of
a wind turbine generator, wherein the brake set is spring-applied,
pneumatically released, connecting at least one air pressure system
to the brake set, connecting a solenoid valve in line with the
brake set to control an air pressure from the at least one air
pressure system at the generator brake, pressurizing the brake to
release when the solenoid valve has voltage on its coil, and
venting the brake to engage when there is no voltage on its coil.
The at least one air pressure system comprises at least one
compressor. The at least one compressor may be located on a
non-rotating portion of a tower where the wind turbine generator is
mounted or a rotating portion of a tower where the wind turbine
generator is mounted. The single air pressure system may power a
plurality of brake sets. The plurality of air pressure systems may
power one or more brake sets.
[0011] In another method of braking in a wind turbine generator,
the method may include attaching at least one brake set to the rear
of at least one wind turbine generator, connecting at least one air
pressure system to the brake set, wherein the at least one air
pressure system is controlled by a solenoid valve, and applying an
air pressure through the air pressure system to the at least one
brake set to release and venting the air pressure at the least one
brake set to engage. The brake set may be spring-applied,
pneumatically released. 9. The method of claim 7, wherein the air
pressure system comprises at least one compressor. The at least one
air pressure system comprises at least one compressor. The at least
one compressor may be located on a non-rotating portion of a tower
where the wind turbine generator is mounted or a rotating portion
of a tower where the wind turbine generator is mounted. The single
air pressure system may power a plurality of brake sets. The
plurality of air pressure systems may power one or more brake
sets.
[0012] Disclosed herein is a large monolithic twin-sheet
thermoformed panel for use as a wind engaging arcuate convex
exterior covering on a generally cylindrical accelerator mounted at
an elevated position on a tower supports at least one pair of wind
turbines for generating electricity; said panel having a smooth
continuous exterior surface for engaging the wind and directing the
same in separate streams of air toward the turbines, an interior
surface comprising a multiplicity of small projections enhancing
the structural integrity of the panel and a structural foam
enhancing the strength of the panel, narrow elongated edge portions
on all sides of substantially reduced thickness overlapping like
edge portions of adjacent panels, at least one notch for receiving
and tightly fitting a structural mounting member and preventing
relative rotation of the panel, and a connector for fixedly
mounting the panel on the structural member so as to accommodate
full expansion and contraction of the panel. Second and third
notches may be provided respectively at opposite ends of the
interior surface of the panel each in spaced relationship with the
first notch, the second and third notches accommodating second and
third structural members with provision for panel expansion and
contraction and with resistance to panel stressing for firm
engagement with the structural member. At least three small spaced
apart projections may be provided with at least one on a first side
of the panel notch and with at least two on an opposite side for
firm engagement with the structural member and for prevention of
relative rotation of the panel. A bolt opening may be provided and
an annular flange may be provided to support the panel and to
recess the head of a bolt entered in the bolt opening so as to
provide a smooth uninterrupted wind flow surface on the exterior of
the panel. The small projections on the interior surface of the
panel may generally be cone shaped. The panel may be substantially
rectangular with approximately fifty (50) rows of projections in
one direction and approximately eighty two (82) rows in the other
direction.
[0013] Disclosed herein is a method of forming a large monolithic
lightweight thermoplastic panel including the steps of positioning
a pair of similar large blank sheets of thermoplastic in the shape
of the panel in parallel face-to-face relationship between first
and second thermal forming molds, vacuum drawing and thermoforming
the sheets so that a first sheet has a smooth continuous external
surface and a second sheet has a multiplicity of small spaced apart
projections substantially throughout the side opposite the first
sheet, the projections on the second sheet being simultaneously
fused with the first sheet to form an integral monolithic final
panel which is lightweight yet exhibits a high degree of structural
integrity; and injecting the interior of the panel with a
structural foam. The projections take substantially a cone shape.
There may be approximately sixty rows of cones in one direction and
approximately one hundred and four rows of cones in the other
direction. The plastic may be polyethylene. The plastic may be
high-density high molecular weight polyethylene. A central notch
may be formed in the second sheet with a through bolt hole
centrally located in both sheets. At least two spaced apart small
projections may be molded in each wall of the notch for a press fit
engagement with a structural member entered in the notch. Second
and third notches may be formed in the second sheet of plastic in
spaced relationship with the first notch. Each edge portion of the
panel may be formed with an elongated portion of reduced
thickness.
[0014] These and other systems, methods, objects, features, and
advantages of the present invention will be apparent to those
skilled in the art from the following detailed description of the
preferred embodiment and the drawings.
[0015] All documents mentioned herein are hereby incorporated in
their entirety by reference. References to items in the singular
should be understood to include items in the plural, and vice
versa, unless explicitly stated otherwise or clear from the text.
Grammatical conjunctions are intended to express any and all
disjunctive and conjunctive combinations of conjoined clauses,
sentences, words, and the like, unless otherwise stated or clear
from the context.
BRIEF DESCRIPTION OF THE FIGURES
[0016] The invention and the following detailed description of
certain embodiments thereof may be understood by reference to the
following figures:
[0017] FIG. 1 depicts a schematic perspective showing a tower, a
cylindrical accelerator and wind turbines mounted thereon;
[0018] FIG. 2 depicts a schematic top view showing a tower, a
cylindrical accelerator and a pair of wind turbines with three
hundred sixty (360) degree diffusers shown in section;
[0019] FIG. 3A depicts a block diagram illustrating twin turbines
and their associated generators and control system with a resistor
disposed in parallel with the DC bus;
[0020] FIG. 3B depicts a block diagram illustrating twin turbines
and their associated generators and an improved AC output
system;
[0021] FIG. 4 depicts a schematic illustration of Four Quadrant or
Regenerative Drive Circuitry monitored by the controller to
determine either generator or motor operation;
[0022] FIG. 5 depicts an enlarged schematic of a pair of vertically
adjacent accelerators with the skin members somewhat transparent to
show at least partially the support structures;
[0023] FIG. 6 depicts an enlarged view of a joint area between
vertically adjacent accelerators;
[0024] FIG. 7 depicts an enlarged perspective view of an
accelerator showing the support structure;
[0025] FIG. 8A depicts a schematic front view of a turbine with
forwardly swept blades in accordance with the invention;
[0026] FIG. 8B depicts a schematic side view of a turbine
illustrating blades with a rearward linear rake;
[0027] FIG. 8C depicts a schematic view of a turbine having blades
with a gradually curved rearward rake;
[0028] FIG. 8D depicts a schematic view of a turbine with blades
which have an outer portion with a rearward rake;
[0029] FIG. 9 depicts a schematic front view of a turbine with
unequal blade spacing;
[0030] FIG. 10A depicts an enlarged illustrative view of a wind
turbine, hub, shroud and completed vane assembly;
[0031] FIG. 10B depicts an enlarged view of an illustrative wind
turbine, hub, shroud and exposed structural member assembly;
[0032] FIG. 11A depicts an enlarged cross-sectional view of a
structural member and sheath forming a vane assembly;
[0033] FIG. 11B depicts a perspective view of a sheath;
[0034] FIG. 11C depicts a fragmentary view showing a sheath and
structural member of a vane assembly;
[0035] FIG. 12 depicts a somewhat schematic vertical section
through a wind turbine showing the relationship of an annular
shroud or blade tip ring and an adjacent stationary ring;
[0036] FIG. 13 depicts an enlarged view of a portion of FIG. 12
showing sealing means and the relationship thereto of the annular
ring about the blades and the associated stationary ring;
[0037] FIG. 14 depicts a plan view of a single panel of the
invention;
[0038] FIG. 15 depicts a fragmentary enlarged side view of the FIG.
14 panel;
[0039] Fig. depicts an exploded side view of a panel and associated
structural members prior to mounting the panel on the members;
[0040] Fig. depicts is a fragmentary exploded and enlarged side
view showing the panel and structural members of FIG. 15;
[0041] FIG. 18 depicts further enlarged view in perspective and
showing edge portions of a pair of panels;
[0042] FIG. 19 depicts a side view similar to FIG. 17 but showing a
panel partially attached to a structural member;
[0043] FIG. 20 depicts a fragmentary enlarged exploded side view
similar to FIGS. 16 and 17 showing a panel partially attached to a
structural member;
[0044] FIG. 21 depicts an enlarged vertical cross sectional view of
a panel taken through a central portion thereof;
[0045] FIG. 22 depicts a perspective view in cross section taken
through a central portion of a panel;
[0046] FIG. 23 depicts an enlarged cross sectional view through an
overlapping vertical joint between panels;
[0047] FIG. 24 depicts an enlarged sectional view and showing a
joint panel and its mounting means;
[0048] FIG. 25 depicts a cross sectional view through an open
thermoforming mold for the panels;
[0049] FIG. 26 depicts a fragmentary enlarged view through a
portion of the mold of FIG. 25;
[0050] FIG. 27 depicts a view similar to FIG. 25 but showing the
mold closed;
[0051] FIG. 28 depicts a somewhat schematic sectional view of a
joint construction of the present invention;
[0052] FIG. 29 depicts schematic sectional view taken generally as
indicated at 2-2 in FIG. 28;
[0053] FIG. 30 depicts a view of a small insert used between the
male member and an adjacent shoulder on the female member;
[0054] FIG. 31 depicts a view showing a locating pin employed as a
self-fixturing means;
[0055] FIG. 32 depicts a view showing a pair of locating pins
installed prior to the telescopic assembly of the male and female
members;
[0056] FIG. 33 depicts a view of a female member with integral ribs
employed as a centering means;
[0057] FIG. 34 depicts a schematic perspective showing an adhesive
distributing device mounted on an assembled male-female joint;
[0058] FIG. 35 depicts a fragmentary cross-sectional enlarged view
showing a notch and chamfer in an open end of a female member, the
locating pins thus being guided into an adjacent adhesive
chamber;
[0059] FIG. 36 depicts a fragmentary cross-sectional enlarged view
showing a notch and chamfer in an open end of a female member, the
locating pins thus being guided into an adjacent adhesive
chamber;
[0060] FIG. 37 depicts a fragmentary cross-sectional enlarged view
showing a short centering means formed integrally on the interior
surface of a female member in spaced relationship with the mouth of
the member, the centering means serving to center the free end of a
male member entered in the female member;
[0061] FIG. 38 depicts a sectional view through the adhesive
distributing device;
[0062] FIG. 39 depicts a side elevation in section of an improved
flanged coupling unit in accordance with the present invention;
[0063] FIG. 40 depicts a side elevation in section of a second
embodiment of an improved flanged coupling unit in accordance with
the present invention;
[0064] FIG. 41 depicts a side elevation of a `third embodiment of
an improved flanged coupling unit in accordance with the present
invention;
[0065] FIG. 42 depicts a schematic view of a tower employing a
number of improved flange coupling units interconnecting elongated
tubular structural Members;
[0066] FIG. 43 depicts an enlarged sectional view of an assembled
coupling employing a pair of similar units with flanges bolted
together to interconnect hollow tubular structural units as in FIG.
42;
[0067] FIG. 44 depicts a view similar to FIG. 43, but employing an
alternative means in the form of a clamp connecting the flanged
coupling units;
[0068] FIG. 45 depicts an enlarged elevational view in section
showing an improved coupling unit used individually in mounting an
elongated generally vertical support member for a wind tower or the
like;
[0069] FIG. 46 depicts an enlarged fragmentary perspective view
showing a manifold and lower end portions of an outrigger
comprising three (3) tubular members with a three member
foundation;
[0070] FIG. 47 depicts an enlarged fragmentary perspective showing
a manifold and a connecting bracket associated with a three member
foundation and main structural member of a tower;
[0071] FIG. 48 depicts a fragmentary sectional view showing a guide
and manifold with associated foundation members during drilling and
formation of the micro pile;
[0072] FIG. 49 depicts a view in elevation showing the tower, wind
turbines and supporting structures mounted thereon, outriggers in
place about the base of the tower with foundation members
supporting the tower and outriggers;
[0073] FIG. 50 depicts a fragmentary view in elevation showing a
lower portion of the tower and outriggers in greater detail;
[0074] FIG. 51 depicts a fragmentary illustration in perspective of
the erection apparatus of the present invention connected with a
tower to be erected;
[0075] FIG. 52 depicts a schematic side view of the apparatus and
tower of FIG. 50 demonstrating the erection procedure;
[0076] FIG. 53 depicts a further schematic view showing the tower
in a position of substantial erection where the cylinders commence
a resistive action;
[0077] FIGS. 54A and 54B depicts an enlarged view in section
showing a pivotal support for the tower and the connection of an
elongated member to the tower; and
[0078] FIG. 55 depicts a perspective view showing the apparatus of
the invention disconnected from the tower and in a preliminary
substantially horizontal attitude.
[0079] FIGS. 56A and B depict a top-down and section view,
respectively, of a tower for mounting a wind turbine and an
accelerator platform.
[0080] FIG. 57A depicts an impeller blade and FIG. 57B depicts an
enlarged view of the blade root.
[0081] FIG. 58 depicts an impeller hub.
[0082] FIG. 59A depicts an impeller blade assembly and FIG. 59B
depicts an enlarged view of the assembly.
DETAILED DESCRIPTION
[0083] Detailed embodiments of the present invention are disclosed
herein; however, it is to be understood that the disclosed
embodiments are merely exemplary of the invention, which may be
embodied in various forms. Therefore, specific structural and
functional details disclosed herein are not to be interpreted as
limiting, but merely as a basis for the claims and as a
representative basis for teaching one skilled in the art to
variously employ the present invention in virtually any
appropriately detailed structure. Further, the terms and phrases
used herein are not intended to be limiting, but rather to provide
an understandable description of the invention.
[0084] Referring to FIG. 1, a wind turbine installation may be
indicated generally at 100 with a tower 102, a cylindrical
accelerator 104, and six (6) pairs of wind turbines 108, 108
mounted in vertically stacked relationship on opposite sides of the
tower. The accelerator 104 may vary widely in construction and
configuration but is preferably cylindrical as shown and serves to
divide wind impinging thereon into a pair of discrete diverging and
accelerating streams of air for flow around opposite sides thereof
before entering the turbine. Further, the accelerator may be
preferably of sufficient vertical dimension to accommodate a
plurality of pairs of wind turbines, such as six shown in FIG.
1.
[0085] Wind turbines 108, 108 may be conventional and may be
mounted in vertically stacked relationship by means of spars 110,
110 projecting from accelerator 104. Various means of mounting the
wind turbines may be contemplated including cantilevered struts as
shown, multiple struts spaced angularly around the hub and other
arrangements common in fan design.
[0086] Disclosed herein are gaps between the wind turbine blades
and the accelerator platform surface. These gaps act to reduce the
downstream wake, which may result in a net increase in flow through
the turbine in spite of some air bypassing the turbine. In
combination with the gaps, a simple cylinder may be used as the
accelerator shape, stacking up multiple accelerators vertically,
and either blocking or using a mesh material in the gaps. In
combination with the gaps, diffuser shrouds may be disposed around
each turbine. Thus, any combination of accelerator shapes, gaps,
and shrouds in a twin-turbine wind power generating system may be
used. The accelerator may have a converging portion rearwardly of
the turbines. The front portion of the accelerator may have a
convex arcuate configuration.
[0087] Each wind turbine 108 may include means defining an
associated front to rear bypass opening. The openings may be formed
by naturally occurring gaps defined between a generally tangential
portion of an adjacent accelerator surface and the sweep formed by
tip portions of the turbine blades above and below the adjacent
accelerator surface portion. As illustrated in FIG. 1, gaps may be
shown at 112, 112 and take the configuration of upper and lower
triangles in reverse orientation. A wide variety of other bypass
opening designs may also be contemplated. Still referring to FIG. 1
the uppermost gaps 112, 112 may preferably open but, optionally,
may be provided with closing means 114, 114 and the gaps 112, 112
may also have a mesh-like material 118, 118 disposed therein as in
the turbines there below.
[0088] In embodiments, a diffuser shroud may be disposed about each
turbine which diverges rearward of the turbine. Shrouds 120, 120,
as depicted in FIG. 1, may extend about the outer 180.degree. of
the turbines with integral flat supporting spars 122, 122 extending
inwardly to the accelerator 104. The diffuser shrouds may continue
around on the side adjacent the accelerator, in which case, the
supporting spars will be structural only and not part of the
shrouds. The diffuser shrouds may be truncated along spaced upper
and lower horizontal planes adjacent turbine blade tips to permit
close spacing of the wind turbines.
[0089] Referring to FIG. 2 a schematic top view showing a tower, a
cylindrical accelerator and a pair of wind turbines 108, 108 is
illustrated. The diffusers 202, 202 (shown in section) may extend
through 360.degree. and completely surround a turbine 108,
diverging rearwardly of the turbine. Both diffuser designs as well
as other configurations may provide additional turbine performance
improvement as described herein.
[0090] Further, adjusting the accelerator and wind turbines carried
thereby angularly relative to wind direction may include using a
ring gear 124 mounted on the accelerator 104, a spur gear 128
driving the ring gear 124 and a small electric motor 130 rotating
the spur gear in one and an opposite direction. A controller 208
may respond to a wind direction sensor 210 and in turn monitor
operation of the motor 130.
[0091] The controller may also respond to signals from the sensor
and rotate the turbines to a safe angular position out of the wind
when dangerously high winds occur, as in the event of a
hurricane.
[0092] The aggregate effect of the cylindrical accelerator, the
bypass openings adjacent the turbines and the diffusers about the
turbines may result in a substantial improvement in performance
accompanied by significant savings in manufacturing cost. Angular
adjustment of the turbines in unison on the accelerator may also
result in substantial savings, such as for example in wiring costs
and in the costs associated with individual adjusting means for the
turbines.
[0093] Disclosed herein is a method for steering a wind power
generating system that has two turbines on opposite sides of a
vertical rotational axis by adjusting the load on at least one of
the generators so as to create a thrust imbalance between the two
sides, causing the entire system to rotate about its vertical
rotational axis to a new angular position. The implementation of
the method includes using a wind direction sensor as part of the
control system, using a permanent magnet AC generator, adjusting
the PWM duty cycle of the rectifier power electronics as the means
of adjusting the load, and the use of the method for turning the
system in or out of the wind based on power measurements, which is
a possible method of furling the twin turbine system.
[0094] Also disclosed is a power electronics architecture in
combination with the twin turbine system. Two architectures for the
boost converter and inverter are disclosed: the first is a
dedicated inverter for each boost converter in the system and the
second is a single inverter accepting power from a pair of boost
converters.
[0095] Also disclosed is the use of the power electronics to drive
at least one generator as a motor. Disclosed is the use of at least
one motor-driven impeller blade to generate thrust, much like the
prop of an airplane, that can rotate the wind generating system
about its vertical rotational axis. Using thrust from the turbines
to rotate a twin turbine wind generating system may be independent
of which direction the wind is coming from or if the wind is
blowing at all.
[0096] Referring now to FIG. 3, it will be obvious that all four
turbine generator control systems may be identical with A1 and B1
representing turbines in common on a first accelerator and A1 and
B1 representing turbines mounted in common on other accelerators.
The A1 system will be described as representative. Each turbine may
be connected in driving relationship with an electrical generator
in turn connected with an external load. Turbine 108 drives AC
generator 302 which may be conventional and of a variety of
different constructions, such as a three-phase or permanent magnet
type. In the three-phase type, the current and voltage of at least
one phase are sensed. DC boost converter 304 may be conventional
with variable pulse width capability and has at least one sensor
for monitoring parameters and preferably speed, voltage and current
sensors associated therewith and connected with the controller 308.
Speed may be measured by the controller by sensing the frequency of
the AC signal from the generator. A support position sensor is
included and advises the controller of the angular position of the
support. Controller 308, may be a conventional microprocessor type,
receives current and voltage signals from the sensors, calculates
power therefrom, and compares the calculated power with a desired
power reference in the form of a performance curve. An upper power
limit is established by the controller, the latter serving to
adjust the angular position of the support as required to reduce
power when said limit is exceeded. A lower power limit is
established by the controller, the latter serving to adjust the
angular position of the support as required to increase power when
said limit is exceeded. In some embodiments, the controller 308
receives meteorological data. A vertical series of supports each
carrying a pair of wind turbines are mounted on a vertical tower
having stationary sections, and wherein meteorological data
gathering devices are mounted on a stationary section and connected
with said controller 308. The data may include wind speed, wind
direction, and the like.
[0097] The controller 308 then adjusts the PWM duty cycle to adjust
generator output as required to bring the output into compliance
with the desired curve. The PWM of the converters may be selected
by comparing a function of voltage and current between the two
generators. The controller 308 may adjust the generator output by
adjusting the thrust of its associated turbine and thereby adjust
the angular position of the accelerator to maintain an optimum
angle of attack for the wind relative to the turbine blades. In
embodiments, the thrust may be adjusted until the horizontal
support stops moving. This may be accomplished by adjusting the
relative thrust until the accelerator stops rotating. In
embodiments with at least two turbines connected to a generator
each, at least one generator follows the performance curve and the
other generator adjusts the thrust of its turbine and thereby
adjusts the angular position of the horizontally rotatable
support.
[0098] From the boost converter 304, generator output may proceed
conventionally through DC bus 310, inverter 312 which serves the
generator 302 or both the generator 302 and a second generator 302a
in the system B1, and then in conventional AC form through
disconnect switch 314 to grid 318.
[0099] The reference performance curve is a current (or power) vs.
generator shaft speed curve that may be a target the controller is
trying to achieve as the wind speed changes. In accordance with the
performance curve, the speed of one or more of the turbines may be
reduced at high current (or power) to stall the blades when the
wind speed is too high such that the power on the generator shaft
is reduced. During fast wind speed increases (e.g. wind gusts), the
power drawn by the generator during the transient deceleration time
may temporarily exceed the power rating/capacity of the inverter or
the utility grid connection. During this time the excess power may
be dissipated in a resistor 320, which is shown in the block
diagram of FIG. 3A as a component in parallel electrical
communication with the DC bus 310. In embodiments, the resistor 320
may comprise more than one discrete resistor connected in series
and/or parallel combinations, such as for example, any resistor
network that is the Thevenin-equivalent of a single resistor.
[0100] Thus, the resistor 320 may be used to help return
performance to that dictated by the performance curve, which during
a wind gust, for example, would be the lower-speed higher-current
portion of the curve. A control algorithm may be programmed in
accordance with the performance curve to cause the turbine speed
reduction under various programmed conditions.
[0101] In the event of a grid failure, all of the power may be
dissipated in the resistor 320 while the blades are decelerated to
zero speed. Shutdown using the resistor 320 may be in place of or
in combination with a mechanical brake, which may be adapted
primarily to serve as a parking brake for maintenance or as a brake
in an emergency if the power electronics fail. In embodiments, the
resistor 320 may be the primary method of stopping the turbines
while the mechanical brakes may be the secondary method.
[0102] For example, if the utility grid fails while using the
generator as a motor to adjust the yaw angle of the turbines, the
kinetic energy in the blades can be dissipated in the resistor 320
until the blades stop.
[0103] In an embodiment, the back of the generator may connect to a
brake set, wherein the brakes may be used to stop the
turbine-driven generator from operating.
[0104] In an embodiment, two or more generators may be connected to
wind turbines on a tower. The brakes on each generator may be
spring-applied, pneumatically released, that is, the brakes may
need air pressure to release.
[0105] In an embodiment, a solenoid valve near each generator may
control the air pressure at each generator brake, pressurizing the
brake to release when it has voltage on its coil or venting the
brake to engage when there is no voltage on its coil. Thus, when
the solenoid valve is included in embodiments of the brakes, they
are fail-safe brakes, i.e., both air pressure and electrical power
are required for them to be released and allow the wind turbines to
spin.
[0106] In an embodiment, one or more compressors may power the
brakes. In embodiments, the compressors may not be located on the
rotating part of the tower. In embodiments, the compressors may be
located elsewhere on the tower and may have a flexible air hose
connection to the brakes that is threaded up the center of the
rotating part of the tower to allow it to twist. The compressors
may operate in conjunction with or without the solenoid valve in
embodiments.
[0107] In an embodiment, a single air pressure system may provide
air pressure to all brakes on the tower. In other embodiments, two
independent air systems may provide the air pressure to the brakes,
such as one supplying air to half the generator brakes and the
other supplying air to the other half of the generator brakes. In
other embodiments, three independent air systems may provide the
air pressure, each supplying air to a 1/3 of the generator brakes.
In embodiments, an air pressure system may be dedicated to each
pair of turbines on a single accelerator platform. It should be
understood that any number of independent air systems may be used
to provide air pressure to any number of brakes associated with
turbine-drive generators on the tower. In any event, the air
systems may include the compressors, as previously described
herein, located either on the rotating part or the non-rotating
part of the tower.
[0108] As described elsewhere herein, power cables carrying power
from the turbine-driven generator to the ground may be routed down
the center of the tower in a so-called twist section, enabling the
accelerator platforms to rotate at least a plurality of turns in
either direction. In embodiments, the twisting wires may not
traverse the complete length of tower. For example, the twist
section may be only .about.25% of the height of the tower while the
remainder comprises non-flexible wires that do not twist.
[0109] In an embodiment, the brakes may feature automatic pad wear
adjustment, torque adjustment, quick change pads, modular design
and easy maintenance.
[0110] The controller 308 may also operate to convert the operation
of one or both generators to operation in the mode of motors. This
is accomplished by the Four Quadrant or Regenerative Drive
Circuitry of FIG. 4 wherein the controller 308 may have two modes
of operation. In a first mode of operation the generator 302 may
operate as a generator and in the second mode of operation the
generator may operate as a motor. When the first bank of switches
314 are operated as a boost converter and the second and third
banks of switches 318, 402 as motor controls, the generators
operate as motors. In the alternative, when the first bank of
switches are operated as an inverter and the second and third bank
as boost converters, the generators may be operated as generators.
For example, the thrust from running at least one generator as a
motor may be employed to adjust the relative position of the
turbines. In another example, at least one turbine may be operated
as a motor when the wind is blowing predominately in a direction
perpendicular to the axis of rotation of the turbines.
[0111] Disclosed herein is a structure of the wind accelerating
platform in a twin-turbine wind power generating system that is a
cage-like structure of thin lightweight supporting members, e.g., a
truss, with at least one thin cover member attached to and forming
the skin of the structure. Also disclosed are methods of attachment
of the skin members that allow for differing thermal expansion
coefficients between the truss and the skin. Plastic, either
injection-molded or thermo-formed plastic, may be used as a
construction material for the skins. Galvanized steel, aluminum,
and carbon-fiber composites may be possible materials to build the
truss support structure with. Also disclosed is the use of
labyrinth seals between accelerator structures stacked vertically
on the same tower, which may be useful if the accelerator
structures rotated independently.
[0112] Referring to FIGS. 5 and 7, a support structure for the
accelerator is illustrated at 504, 504 and 508, 508. Generally
u-shaped thin support members may be provided in an annular series
arrangement to define the three-dimensional outline of the recess
502 which in turn defines an air passageway. Connected with the
u-shaped members may be thin annular members 508, 508 which
together with the members 504, 504 provide a lightweight but sturdy
support structure. The u-shaped members 504, 504 may take the form
of trusses as illustrated. Further, structural members may comprise
mounting plates 702, 702 which extend vertically and which support
the wind turbines 108, 108.
[0113] The support members 504, 504 and 508, 508 may be of
galvanized steel, aluminum, or a carbon composite. Supported on and
about the support members 504, 504 and 508, 508 may be a plurality
of cover member sections 512, or panels as elsewhere described
herein, as shown in FIG. 6 illustrating an enlarged view of a joint
area 510 between vertically adjacent accelerators. Each of the
cover member sections 512, 512 takes a generally u-shaped form and
the members are arranged in an adjacent relationship with edge
portions overlapping. Alternatively, a single large cover member
may be provided.
[0114] Attachment of the cover member to the support structure may
be a completely floating arrangement between the member and the
support structure. Alternatively, the cover member may be attached
to the support structure at a single area with the remaining
portion of the member in a floating relationship with the support
member. Annular connecting members 510 interconnect vertically
adjacent accelerators and joint areas between the members 510 and
512 are preferably provided with labyrinth seals 602, 602.
[0115] The cover member may be an injection-molded thermoplastic,
optionally with internal strengthening ribs, or it may be of
substantially uniform thickness throughout for production by a
thermo-forming process. In an embodiment, the member is formed of
polypropylene.
[0116] Disclosed herein are blade geometries used to improve the
structure of the blades and reduce audible noise when they are
spinning Some aspects include: varying the radial angles between
the blades which spreads the blade-pass frequency so it will not
sound like a pure tone which is easier for the ear to pick out than
white noise; adjusting the angle of the blade rake, which is an
angle back along the axis of rotation, and the weight of the tip
ring so that centrifugal forces balance wind thrust forces in the
wind direction to keep the rake constant without excessively stiff
and heavy blades; and blade sweep, which is a curve of the blade
from the hub to the tip in the plane of rotation.
[0117] Referring to FIG. 8A, a turbine may be indicated generally
therein at 108 with a hub 802, a plurality of circumaxially spaced
blades, shown at 804, 804 and an annular ring 808 interconnecting
the blade tips. The blades may be narrow, radially outwardly
elongated and configured to respond to wind pressure and provide a
torque in one direction. Each blade may have a root portion
connected with and supported by the hub 802 and a remote tip
portion connected with the ring 808. The blade tips may be
displaced forwardly as a result of centerlines 810, 810, which
curve gradually forwardly from their root portions to their tip
portions to provide a forward blade sweep. Alternatively, the
blades may have linear centerlines angularly arranged to provide a
forward sweep. Preferably, the blades may have arcuate centerlines
as shown with constant angles of curvature selected to cooperate
with centrifugal force to provide insignificant blade movement at
operating speeds. As shown, the blades 804, 804 may have tip
displacements of approximately nine degrees, although tip
displacements in the range one tenth of one degree to twenty
degrees are contemplated.
[0118] The annular tip ring 808 interconnecting the blade tips, in
addition to enhancing the generation of centrifugal force, tends to
minimize vortices adjacent the blade tips and as a result noise
generation is reduced and turbine performance enhanced. Twisting of
the long narrow blades about their centerlines may also be reduced
by the ring 808.
[0119] Referring to FIG. 8B, a turbine 108b that may have a hub
802b, blades 804b, 804b and an end ring 808b is illustrated. As
will be obvious from an inspection of the drawing, the blades 804b,
804b may have a rake profile with their tip portions displaced
rearwardly, or downwind, in relation to their root portions. The
blades may also have linear centerlines 804b, 804b in FIG. 8B but
gradually curved centerlines as at 810 in FIG. 8A may be
contemplated as well as blades having only portions 812, 812 near
their tips curved rearwardly as in FIG. 8D. In embodiments, the
longitudinal centerline of each blade may have a constant rate of
curvature from its root to its tip portion. Mass may be added at
the tips of the blades to increase the centrifugal force generated
during rotation and urge the blades radially in a direction
opposite the direction of rotation and toward a linear centerline
condition or urge the blades axially in a direction opposite the
direction of wind flow. For example, the annular ring 808 may add
mass. The longitudinal curvature of the blades and the tip mass may
be selected in relation to centrifugal force such that centrifugal
and wind generated forces balance and radial movement of the blade
tips relative to the hub is insignificant at operating speeds of
the turbine. In some embodiments, the angular displacement of each
blade tip portion from the hub center through the point of
attachment of the blade to the hub may fall in the range of one
tenth of one degree to twenty degrees or may be approximately nine
degrees.
[0120] Irrespective of the precise configuration, the displacement
of each blade tip portion relative to its root portion may fall in
the range of one degree to fifteen degrees and, preferably, the
displacement may be approximately five degrees.
[0121] Referring to FIG. 9 turbine 108b may have a hub 802b, blades
804b, 804b, and an end ring 808b. The blades 804b, 804b may have
any of the configurations described above but the circumaxial
spacing thereof may be unequal. As shown, the blades 804b, 804b may
have gradually curving centerlines 810, 810 in a forward sweep
configuration as described above and their tip portions are
unequally spaced circumaxially, spacing progressing from seventy
degrees to seventy four degrees for the five blades shown. The root
spacing may be equal in FIG. 9 but the tip spacing may be unequal,
but it will be obvious that unequal spacing may be provided at both
root and tip portions of the blades. Substantial reduction in noise
generation may be achieved with the configuration shown.
[0122] As is described hereinabove, the wind turbine may include an
impeller hub, which is mounted for rotation about an axis, and
which supports a plurality of radially-extending, wind-responsive
impeller blades. The blades may be connected with and supported by
the hub on a root end of the blade. The blades are configured such
that wind impinging thereon results in a substantial aggregate
torque rotating the blades and hub in one direction.
[0123] The impeller blades may be manufactured by injection
molding. In embodiments, the blades may be injection molded out of
plastic. The blade may be injection molded with connection features
at the blade root that enable mating with the impeller hub. For
example, the features may enable fastening via an interference fit,
a friction fit, a ball and socket, a zipper, a snap fit, a threaded
fit, a hook and loop, an eyelet, a clip, a slot fit, a tab fit, and
the like.
[0124] In embodiments, each impeller blade may be made in an
identical mold. However, it should be understood that not all
impeller blades mounted to a single impeller hub must be
identical.
[0125] In embodiments, the impeller hub may also be injection
molded. For example, the hub may be molded with a complementary
feature to enable impeller blade mating. The impeller hub may also
be injection molded to enable attachment to a generator shaft.
[0126] An imbalanced impeller would cause the tower to shake and
cause excessive wear on the generator rotating support members. In
an embodiment, weights may be added to the hub during or after
injection molding in order to balance the impeller assembly. For
example, the weights may be added during the final assembly. In an
embodiment, the hub may have a feature for mounting balancing
weights to balance the rotating masses about the rotational axis.
The impeller hub may have features 5808, as seen in FIG. 58,
through which a bolt may be mounted to serve as either the weight
itself or to bolt something heavier. In embodiments, the features
5808 may be formed from plastic. The bolts may be through bolts
with nuts on the opposite side or they may self tap into the
features 5808. The features 5808 may be blind cylindrical cavities
that do not go through. In an embodiment, the rotating support
member may be a pair of wheels on a yoke that is affixed to each
corner post. For embodiments of the tower with three corner posts,
there may be six total wheels. The platform may have a rail that
rests on the six wheels allowing the entire platform to rotate. In
some embodiments, one wheel at each corner post could be used, such
as if stronger wheel rotating support members were used.
[0127] Referring to FIGS. 57, 58, and 59, a plurality of injection
molded impeller blades 5708 may be attached to an impeller hub
5800, which may also be injection molded, to form the final
impeller blade assembly 5900. For example, a connection feature
5702 at the blade root (shown enlarged in FIG. 57B) may slide into
a mating slot 5802 or otherwise connect with a complementary hub
connection feature. FIG. 59B is an enlargement of an embodiment
where the blade root connection features 5802 are mated with the
mating slots 5802 of the impeller hub. The blade 5708 may then be
secured, such as by being bolted in place. In embodiments, the
blades may not be evenly spaced about the hub. In embodiments, the
blades may be disposed in an angular relationship to the hub.
[0128] The impeller blade assembly may be adapted to attach to the
generator shaft via the hub. In some embodiments, the impeller hub
mounts to an adaptor hub on the generator shaft. The impeller hub
may secure to the adaptor hub via a fastener, such as a nut, in an
opening 5804 of the impeller hub that aligns with an opening on the
adaptor hub.
[0129] Alternatively, the impeller hub may first be attached, and
then the impeller blades may be attached to the impeller hub
thereto. In some embodiments, the entire impeller blade assembly
may be injection molded as a single unit.
[0130] In an embodiment, a nose cone, or other cover for the upwind
side of the hub, may be injection molded. In an embodiment, the
cover may be a blunt-nose curved axisymmetric shape. In another
embodiment, the cover may be a dome-shaped nose cone that attaches
to the front of the hub, obscuring the blade attachment to the hub.
In yet another embodiment, the cover may be a bullet shaped nose
cone. In some embodiments, the nose cone feature may be integrated
into the hub, rather than being a separate part.
[0131] For example and without limitation, a sample process for
assembling the impeller blade assembly is described. In the
example, five blades made from the same blade mold are each
connected to a hub as described herein and secured. Continuing with
the example, the five-bladed impeller assembly is balanced. After
balancing, the blades are removed and the separate parts are
transported to the site of the wind turbine where the impeller
assembly is identically reassembled and installed on a generator
without changing the impeller balance that was performed
previously.
[0132] Still continuing with the example, a nose cone may be
attached. While many different attachment mechanisms may be
utilized such as any of the fit mechanisms described above for
impeller blade and impeller hub connection, the nose cone
attachment in this example is a single bolt through the center of
the nose cone to a tapped hole in the end of the generator shaft
and nose cone tabs that mate into the hub. In embodiments, a
sealant, epoxy or adhesive may be used to secure all bolts and
connections in the final assembly. For example, LOCTITE.RTM. may be
used.
[0133] In embodiments, assembly may include closed-cell foam being
injected into air cavities of the impeller blade assembly, such as
the nose cone, to prevent ice build up inside that would imbalance
the blade. Injection of the closed-cell foam is done in a way that
still allows the impeller to be disassembled for transport.
[0134] In an embodiment, the injection molded impeller blade may be
hollow. In other embodiments, the impeller blades are solid.
[0135] In embodiments, the material used for injection molding may
be glass-fiber filled plastic, such as glass-filled PPA,
glass-filled nylon, and the like. In embodiments, the plastic used
for injection molding may be carbon-fiber filled.
[0136] In an embodiment, the process for injection molding the wind
turbine impeller blades may be controlled by a computer. The
computer may receive sensor data from sensors mounted along the
injection molding line. The sensors may be configured to report
back a sensor output, such as any one of mold temperature, melt
temperature, injection pressure, packing pressure, warping, and the
like. The computer may modify the injection molding process based
on the feedback received from one or more sensors reporting one or
more sensor outputs.
[0137] In an embodiment, there may be three separate mold tools to
form the blade, hub and nose cone of the assembly. The blade mold
may include multiple plastic injection gates with hot runners,
movable baffles that direct the flow at specific times, and a gas
assist to make the root of the blade hollow to reduce warping and
bulk plastic cost. The process for timing of gate opening/closing
and baffle moving, temperatures at various places/times, and
pressures at various places/times may be controlled by the
computer.
[0138] Disclosed herein are stator vanes as airfoil-shaped
coverings over structural support struts that are shaped to
straighten the swirling airflow discharged downstream from the
turbine blades to increase performance. Also disclosed is the use
of steel as structural struts, struts as parallel offset metallic
members to fit within optimum airfoil shapes, thermoplastic as the
material for the airfoil-shaped coverings, cambered airfoils,
extruded airfoils, and a single hard attachment point or friction
attachment of the airfoil to the strut to accommodate differing
thermal expansion of the two materials.
[0139] FIGS. 10B, 11B, and 11C illustrate an elongated sheath 1008
in the shape of an airfoil which may form an air-directing vane. As
best illustrated in FIG. 11A the sheath 1008 has a number of
integral strengthening members which may extend throughout its
length within its interior cavity together with spaced apart
elongated and parallel cylindrical openings 1112, 1112 which may
slidably receive the aforementioned parallel tubular members 1012,
1012. An open channel 1114 extending between the two cylindrical
openings 1112, 1112 may receive the transverse truss members 1102,
1102 of the structural member 1108. The sheath may also be provided
with a camber, which together with the axial offset of the
structural members results in an optimum airfoil configuration.
[0140] As will be apparent, the sheaths 1008, 1008 and the
structural members 1108, 1108 may be readily assembled in a
relative sliding operation. The sheaths 1008, 1008 and structural
members 1108, 1108 may be maintained in their assembled
relationship merely with the aid of friction or, alternatively, a
single point of positive attachment may be provided as with a bolt
1118 in FIG. 11B. The bolt 1118 may penetrate the sheath and
connect with the structural member 1012. Thus, thermal expansion
and contraction of the sheath relative to the structural member is
accommodated. Further in accommodation of thermal expansion, the
sheath 1008 may be spaced slightly in a longitudinal direction from
the hub 802 as illustrated at 1120 in FIG. 11C.
[0141] The structural members 1108, 1108 may take the form of
trusses with a pair of elongated spaced apart parallel tubular
members 1012, 1012 extending longitudinally and connected by
transverse truss members 1102, 1102, FIGS. 10A, 11A, and 11C. The
tubular structural members 1012, 1012 may be spaced apart axially
as illustrated in FIG. 11A with the turbine axis depicted by broken
line 1104. The members 1012, 1012 may also be offset axially as
illustrated by the relationship between the axis line 1104 and the
broken centerline 1108 of the tubular members, the lines 1104 and
1108 being angularly displaced as illustrated at 1110 in FIG. 11A.
The structural members 1108, 1108 may be of metallic construction,
and the specific material may vary but is preferably galvanized
steel.
[0142] Disclosed herein is a sealing between independently rotating
accelerators that are vertically stacked. Also disclosed is a
horizontal-axis wind turbine with a ring connecting the blade tips
and a variety of sealing geometries between the blade tip ring and
a surrounding stationary ring (e.g., shroud), the primary sealing
method being a labyrinth seal on one or both axial sides of the
passageway between the blade ring and the stationary ring.
Referring to FIG. 12, a schematic vertical section through a wind
turbine is depicted. In an embodiment, the turbine blades 804 may
be provided with an annular shroud. A portion 1202 of the vertical
section may depict a sealing means. Details about the sealing means
and the relationship of the shroud and the annular ring 808 will be
described in conjunction with FIG. 13. The seal is provided for
restricting the flow of air between the blade tip ring and the
stationary ring thereabout and thereby directing maximum flow
through the blades.
[0143] Referring to FIG. 13, an enlarged view of the portion 1202
is depicted. In an embodiment, the annular ring 808 may be adjacent
to the annular shroud 120. Further, the annular ring 808 may be
stationary. It will be evident to a person skilled in the art that
enhanced blade performance may be achieved with a minimal loss of
airflow radially outwardly about the turbine as might occur between
the annular shroud 120 and the annular ring 808. Accordingly, a
sealing means may be provided and may take the form of labyrinth
seals at 602. The seals 602 may minimize the loss of airflow
between the annular shroud 120 and the annular ring 808 with the
air instead passing through or otherwise being directed to the
turbine blades 804 as desired. In an embodiment, the blade edges
may be at least partially enclosed through 360 degrees. The turbine
blades, the hub, and the annular ring about the blades may be
integrally molded in a one-piece plastic molded process, such as by
an injection molding process.
[0144] A vertically sectioned cylindrical accelerator for mounting
pairs of wind turbines respectively on opposite sides thereof may
have a covering of twin-sheet thermoformed plastic panels which are
smooth on the outside but carry a multiplicity of small cone-shaped
projections on their interior surface. The panels may be mounted on
a structural member to enable free expansion and contraction with
variation in ambient temperature. For example, the panels may be
secured using a single central bolt, a combination of a single
central bolt, a plurality of bolts, a mechanism that allows the
panel to move relative to the underlying truss structure to allow
for thermal expansion differences between the skin panel and the
truss structure, and a combination of one or more bolts and the
mechanism. The panels may be manufactured in a twin-sheet
thermoforming operation wherein one sheet is maintained with a
smooth surface and the second sheet is provided with the
cone-shaped projections, the two sheets being fused together to
form an integral panel of lightweight and high strength
characteristics.
[0145] Referring to FIG. 14, a plan view of a single panel 1402 is
depicted. The panel 1402 may be configured as a large monolithic
substantially rectangular panel. The panel 1402 may be
approximately eight and one half (8.5) feet long and five (5) feet
wide. Further, overall thickness of the panel 1402 may be
approximately one and one fourth (1.25) inches. In an embodiment,
an exterior surface 1404 of the panel 1402 may be smooth and
continuous for uninterrupted wind flow thereover.
[0146] Now referring to FIG. 15, a fragmentary enlarged side view
of the panel 1402 is depicted. In an embodiment, an interior
surface of the panel 1402 may include a multiplicity of small
strengthening projections 1508, 1508. The projections 1508, 1508
may take the form of a plurality of small cones. In an exemplary
embodiment, the panel 1402 may be manufactured with a slightly
greater curvature than in the installed condition.
[0147] Referring to FIG. 16, an exploded side view of the panel
1402 and associated structural members prior to mounting the panel
1402 on the members is depicted. The panel 1402 may be shown prior
to installation with a slight excess curvature. The panel 1402 may
receive a structural member 1602 by means of a notch 1608. Further,
at a central location, the panel 1402 may be provided with another
notch for receiving another structural member 1604 of the
accelerator 104. More details about the another notch and the
another structural member 1604 will be explained in conjunction
with FIG. 17.
[0148] Referring to FIG. 17, a fragmentary exploded and enlarged
side view illustrating the panel 1402 and structural members 1602,
1604 is depicted. Further, the panel 1402 may include a notch 1702.
Centrally located in the notch 1702 may be a single through opening
1704. The opening 1704 may be provided with a grommet 1708 for
receiving a bolt 1710. The bolt 1710 may be the only positive
connection between the panel 1402 and the structural members 1602,
1604 of the accelerator 104. Further, the notch 1702 may be
provided with a few projections 1712.
[0149] Now referring to FIG. 18, a further enlarged view in
perspective and showing edge portions of a pair of panels 1402 is
depicted. In an embodiment, six small spaced projections 1712 on
walls of the notch 1702 may provide for a press fit of the
structural member 1604 in the notch 1702. In a preferred
embodiment, notches 1714, 1608 may also be provided at opposite
ends of the panel 1402 for receiving structural members 1602, 1602.
Further, the structural members 1602, 1602 may position the ends of
the panel 1402 precisely against a flexing force of the latter, a
left hand edge portion of an adjacent panel being inserted between
the structural member 1602 and the base of the notch in the right
hand notch 1607 which may be substantially deeper than the left
hand notch 1714.
[0150] Referring to FIG. 19, a side view similar to FIG. 18 but
showing the panel 1402 partially attached to a structural member is
depicted. In an embodiment, the structure member 1602 of the panel
1402 may be received by the notch 1714.
[0151] Referring to FIG. 20, a fragmentary enlarged exploded side
view similar to FIGS. 16 and 19 showing the panel 1402 partially
attached to the structural member 1602 is depicted. As mentioned
herein, the notch 1702 may be single through the opening 1704.
Further, the panel 1402 may include the projections 1712.
[0152] Referring to FIG. 21, an enlarged vertical cross sectional
view of the panel 1402 taken through a central portion thereof is
depicted.
[0153] FIGS. 19, 20 and 21 show the panel 1402 in position on and
supported by the structural member 1604.
[0154] Now referring to FIG. 22, a perspective view in cross
section taken through a central portion of the panel 1402 is
depicted. Further, FIG. 23 depicts an enlarged cross sectional view
through an overlapping vertical joint between panels. As
illustrated in FIGS. 22 and 23, the overlapping vertical edge
portions 2302 of the panel 1402 may be shown with the edge portion
2302 provided with a small boss 128 on its interior surface. The
boss 128 may be engaged by an anti-rattle spring clip 2304 at a
central portion of the latter with end portions of the clip entered
in openings 2308, 2310 respectively in end portions of the panels
adjacent the edge portions 2302. Further, the spring clip 2304 may
be maintained in a slightly flexed condition to ensure a tight fit
between the panel edge portions 2302 and may thus prevent
intermittent airflow inwardly and resulting rattle.
[0155] Referring to FIG. 24, an enlarged sectional view of the
panel 1402 and its mounting means are illustrated. In an
embodiment, a panel 2402 may extend between panel edge portions
2402a and 2302a, overlapping the edge portion 2302a and in turn may
be overlapped by the edge portion 2402a. Further, a rivet 2404 or
other connector may be employed to connect the panel 2402 to the
edge portion 2402a and to one end of a spring clip 2404; the latter
may have its opposite end connected to the panel 2402 at a central
portion by a bolt 2410 and a nut 2412. As will be apparent, the
bolt 2410 may be tightened to draw the panel 2402 and the clip 2404
toward engagement and to urge the end portion of the panel 2402
against the edge portion 2302a thus completing a tight closure of
all joints between the panel 2402 and vertically adjacent panels
1402a, 1402a.
[0156] Disclosed herein is a twin thermoforming process used to
fabricate the skin panels of the accelerator platform. Aspects of
the panel geometry may be adapted to enhance strength, prevent
rotation, allow for thermal expansion, and generate overlap regions
between panels that allow for minimal disruption of the air flowing
over the surface and the shedding of rainwater. Now referring to
FIG. 25, a cross sectional view through an open thermoforming mold
for the panels is depicted. Further, FIG. 26 depicts a fragmentary
enlarged view through a portion of the mold of FIG. 25. Also, FIG.
27 depicts a portion of the mold with the mold closed. FIGS. 25-27
will be described herein together. In an embodiment, the mold may
be employed in the manufacture of the panels 1402, 1402 and it will
be noted that an upper mold half 2502 may have a gradually arcuate
smooth lower surface 2504 for forming the exterior surface of a
first sheet of thermoplastic 2508 which may be extruded or
otherwise prepared. A lower mold half 2510 may have a multiplicity
of small projections 2512, 2512 for forming cones on the lower
surface of a second sheet of plastic 2514 and for fusing and
forming the two sheets of plastic into a single integral panel 1402
of large monolithic unitary construction in a rectangular or other
configuration. This method of molding may be known as "twin-sheet
thermoforming" and may result in a panel 1402 of the highest
possible strength to weight ratio. The presently preferred plastic
may be high-density high-molecular weight polyethylene. In some
embodiments, the inside of the twin-thermoformed skin panel
structure may be filled with structural foam after the
twin-thermoforming process to make it at least one of stiffer and
stronger.
[0157] Disclosed herein is a method of forming a structural
adhesive joint between two tubular members. Gluing with a
structural adhesive, like bolting, is a method of joining steel
components that can be done in the field without compromising
corrosion protection already applied to the members to be joined.
Properly engineered adhesive joints take advantage of the
compliance of the adhesive to reduce stress concentrations in the
joint and use less material than bolted flange couplings, reducing
weight and cost of a structure with many joints such as a truss.
This disclosure provides methods of achieving good adhesive joints
between telescoped tubular components using a centering means to
maintain the proper adhesive thickness and an adhesive injection
means that is fast for field installation and results in complete
filling of the adhesive chamber.
[0158] Referring to FIGS. 28 and 29, an adhesive joint construction
indicated generally at 2800 may include telescopically assembled
male and female members 2802 and 2804, which may be similar in
cross sectional configuration but which are different in size so as
to cooperatively define a narrow continuous open-end adhesive
chamber 2808. The members 2802 and 2804 may be both tubular with
circular cross sections as shown, but as mentioned above, a wide
variety of types of tubular and other male and female members may
benefit from the teaching of the present disclosure. As mentioned
above, it may be most important to maintain uniform thickness of
the adhesive throughout the chamber 2808 without pockets or voids
in order to provide an efficient and low cost joint of high
structural integrity and light weight.
[0159] The male and female members may be designed to provide
adhesive chamber 2808 of uniform width throughout when the members
may be telescopically assembled and small locating pins 2810, 2810
may thereafter be employed to fix the relative positions of the
members and precisely establish the width of the adhesive chamber
2808. At least one pin 2810 may be provided and as shown, four (4)
equally circumaxially spaced pins 2810, 2810 may be inserted into
the adhesive chamber 2808 through its open end to positively fix
the position of the members and the width of the chamber 2808. The
pins 2810, 2810 may be inserted under pressure as with a pneumatic
gun and may thus serve as a self-fixturing function for the
joint.
[0160] Referring to FIGS. 29 and 36, a series of small notches
2902, 2902 may be provided in equally circumaxial spaced
relationship around the mouth of the female member 2804. Each notch
2902 may have a shallow chamber 3602 at its inner end which may be
adapted to direct a locating pin 2810 into an adhesive chamber in
pressure engagement with the contiguous surfaces of the male and
female members 2802, 2804.
[0161] Alternatively, locating pins such as 3202, 3202 shown in
FIG. 32 may be employed as centering means and may be positioned in
the mouth of the female member 2804 prior to assembly of the same
with the male member 2802. A connecting loop 3204 may facilitate
handling the pair of the locating pins 3202, 3202.
[0162] Referring to FIG. 33, a second alternative embodiment of
centering means is shown with integral ribs 3302, 3302 formed in
circumaxially spaced relationship on the interior surface of a
rectangular tubular member 3304 with two (2) ribs 3302, 3302 on one
side of the member 3304.
[0163] Still further, short centering means 3702 may include a
single annular element or a number of individual ribs on the
interior surface of the female member 2804 spaced inwardly from the
mouth of the member as shown in FIG. 37. The annular element or
ribs 3702 may serve as auxiliary centering means and may engage and
center the free end of a male member 2802 as it may reach the end
of its travel during assembly of the male and female members. The
annular element or ribs 3702 may be employed with any of the
foregoing centering means.
[0164] With the adhesive chamber 2808 properly sized and the
members 2802 and 2804 secured in fixed positions by the pins 2810,
2810, a distributing device 2814 may be positioned about open end
2812 of the adhesive chamber 2808, and as shown in FIGS. 34 and 38
encloses and may have an inlet port 2902 which may communicate with
the same for the introduction of an adhesive under pressure.
Various adhesives may be employed but LOCTITE H8600 may be
preferred in an illustrative embodiment for joining the galvanized
structural steel employed in wind turbine tower construction. A
relatively low viscosity adhesive may be preferred for rapid
insertion in a high production environment. A uniform adhesive
thickness less than fifty thousandths of an inch may be found to
provide the high strength low weight results desired with
galvanized structural steel.
[0165] As mentioned above, the use of open cell foam seals may
accommodate an adhesive filling procedure based on pressure control
and termination resulting in a completely filled adhesive chamber.
It should also be noted that the distributing device 2814 may serve
independently as a centering means avoiding the need for
substantially all other centering means.
[0166] As mentioned, the prevention of voids in the adhesive may
also be important and a small open cell foam insert 2818, FIGS. 30
and 37, captured and compressed between an annular shoulder 2820 on
the interior wall of the female member 2804, and the inner end of
the male member 2802 may prevent the entrapment of air and
resulting pockets or voids. The insert may be perforate to air and
may readily allow the same to pass but may serve as an effective
barrier to adhesive.
[0167] Referring now to FIG. 35, it may be observed that three (3)
elongated structural members 3502, 3502 form a closed loop
subassembly indicated generally at 3504, which may be a part of a
truss type wind turbine tower. Employing the teaching of the
present method, the members 3502, 3502 may be assembled as shown
with their end portions entered loosely in cups 3508, 3508, which
form a part of connecting or joint members 3510, 3510. Locating
pins such as 2810, 2810, not shown, may then be inserted
circumaxially about the ends of the members 3502, 3502 into
adhesive chambers within the cups 3508, 3508 in a self-fixturing
operation. This may be followed by positioning of adhesive
distributing devices about the joints and the introduction of
adhesive to fill the adhesive chambers thus completing the
subassembly.
[0168] Disclosed are flange geometries for welding to the end of
tubes that result in the best strength per weight of the flange
plus tube system. By morphing from a thin-walled tube to a flange
in a roughly elliptical manner, stress concentrations may be
reduced resulting in at least one of thinner tubes, lighter
flanges, or a combination thereof. Because galvanizing steel cannot
be done in the field, it is necessary to have another joining means
such as bolted flanges for final construction at the site of the
wind turbine. Thus, for a given strength of tower, the use of steel
may be economized. Referring to FIG. 39, a first embodiment of the
present invention is indicated generally at 3900 and may include a
radial flange 3902 and an axial boss 3904 projecting axially there
from. A corner area at the junction of the flange and boss may be
indicated generally at C with adjacent area B extending from the
corner region along the neck and toward the free end of the boss. A
second and substantially smaller area D adjacent the corner area
(on its opposite side) may extend along the flange 3902 toward its
free end. A through opening or axial bore 3912 may extend from the
free end of the boss to a planar surface 3914 on the flange which
may reside in a radial plane. The corner or junction E between the
planar surface 3914 and internal annular surface 3912 of the boss
3904 may be defined by a convex curve E also on a relatively small
radius.
[0169] As mentioned above, the external surfaces of the unit at B,
C and D may be bounded by two points or imaginary annular lines
3908, 3910 respectively on the axial surface of the boss and the
radial surface of the flange. The former line may be substantially
farther from the corner than the latter as indicated by the
dimensions F, G. As will be apparent on inspection, the external
surface 3912 may curve gradually adjacent the boundary line 3908
and substantially more rapidly adjacent the boundary line 3910 on
the flange. At each end, however, the arcuate surface may blend
smoothly in transition to a linear surface on the opposite side of
the boundary line. As stated above, the curve may also be regarded
as having a gently changing slope adjacent the boss and a more
sharply changing slope adjacent the flange. Still further, the
external surface 3912 may be viewed as defined by at least three,
and preferably an infinite number of discrete radii. In any event,
the portions of the surface may blend together to form a
continuously varying smooth arcuate surface with the surface of the
smallest radius on the flange 3902. Preferably the surfaces B, C
and D taken in the aggregate, at least approximately follow the
contour of the external surface of a quadrant of an ellipse, shown
in broken line at 3916.
[0170] As mentioned above, the enhanced thickness of the wall of
the coupling unit may be a second important feature of the present
invention. As will be obvious from inspection of the drawings, the
wall thickness of the unit may proceed along the neck of the boss
toward the flange increasing through the regions B and (and
remaining substantially constant in outward progression along the
flange from C to the outer end of the flange.
[0171] FIG. 40 shows a second embodiment of the invention in the
form of a coupling unit 4002 having a flange 4004 and an axial boss
4008. The external surface of the unit at its corner region and
adjacent areas may be identical with those of the coupling of FIG.
39. The internal surface of the unit, however, may vary
substantially from that of the FIG. 39 coupling and instead may be
substantially identical with the external surface. As will be
obvious, this may result in a slight reduction of the thickness of
the coupling wall but the unit may nevertheless be found to have
excellent strength characteristics and may be a lightweight
construction. A third embodiment of the coupling unit of the
present invention may be indicated generally at 4100 in FIG. 41.
The unit may include a flange 4108 and a boss 4102 with an external
corner area C with a relatively small radius of curvature similar
to that of conventional coupling units. The internal surface of the
unit at 4104, however, may be substantially identical with the
external surface B, C, and D in FIG. 39 and with the internal and
external surfaces in FIG. 40. This may entail a substantial radial
inward bulge of the inner surface, which may be acceptable in
certain applications. Wall thickness may be superior in this
embodiment to both the FIG. 39 and FIG. 40 embodiments.
[0172] FIG. 42 illustrates a structural use of the improved
coupling of the present invention in a wind turbine tower or the
like having a plurality of elongated tubular structural members
4204, 4204 interconnected by coupling units 3900, 3900 shown in
enlarged fragmentary section in FIG. 43. As illustrated in FIG. 43,
each of the flanges 3902, 3902 of mating coupling units 3900, 3900
may be provided with an annular series of axial openings 4010, 4010
which receive bolts 4302, 4302 connecting the units together.
[0173] Referring to FIG. 44, an alternative means of connection is
provided in the form of a clamp member 4402, which may surround the
flanges 3902, 3902 and may in turn be interconnected by bolts 4404,
4404 whereby to clamp and firmly hold the flanges in
engagement.
[0174] FIG. 45 illustrates the use of a single coupling unit as a
mounting support for a large generally vertical elongated base
member of a wind turbine tower or the like. The unit may have a
configuration substantially identical with the FIG. 39 unit and may
be attached to a foundation by a plurality of bolts as illustrated.
From the foregoing, it will be apparent that design improvements
have been made which may initially seem to be minor in nature, but
which in the aggregate are nevertheless found to substantially
enhance the strength and integrity of the units while
simultaneously reducing the weight and the amount of material
consumed in manufacture of the improved coupling units.
[0175] FIG. 46 illustrates an alternative embodiment of the
invention with improved foundation systems providing a higher
degree of structural integrity and superior stability for the tower
and its wind turbines even in hurricane conditions. Referring
particularly to FIG. 46, lower end portions 4602, 4602 of three (3)
elongated tubular members forming an outrigger may be shown
connected by flanges 4604, 4604 with short tubular connecting tubes
4608, 4608. The connecting tubes may open at their lower ends and
may receive upper end portions of tubular metallic inner members
4610, 4610 of micro piles 4612, 4612. Further, external nuts 4614,
4614, one shown, may cooperate with nuts internally of the
connecting tubes together with rotating support member plates in
affecting connections between the outriggers 4602, 4602 and the
tubular inner members 4610, 4610 of the micro piles.
[0176] A manifold 4618, which may preferably be of precast
concrete, may have three (3) openings 4620, 4620 for receiving the
inner members 4610, 4610 of the micro piles. A hardenable medium
4622 may fill the gaps between the walls of the openings 4620, 4620
and the tubular micro pile members 4610, 4610, the former being
somewhat larger in diameter than the latter.
[0177] As will be apparent from the forgoing, the upper end
portions of the tubular members 4610, 4610 of the micro piles may
be maintained in desired predetermined positions by means of the
manifold 4618, and as will be described herein below, the manifold
4618 may also serve as a guide during the formation of the micro
piles whereby to establish desired predetermined angular
relationships of the micro piles.
[0178] Referring to FIG. 47, a manifold 4700 is shown for
establishing connection of tubular upper end portions 4702, 4702 of
micro piles 4704, 4704. The manifold 4700 may also be constructed
of precast concrete and may have three through openings 4708, 4708,
two shown, for receiving the tubular inner members 4702, 4702 of
the micro piles. A hardenable medium 4710, 4710 may fill gaps
between the tubular members 4702, 4702 and the walls of the
openings 4708, 4708. At upper end portions, the members 4702, 4702
may be connected with a manifold type bracket 4712, which has three
(3) flanges 4714, 4714, two shown. The flanges 4714, 4714 may have
openings for receiving the members 4702, 4702 and may be associated
with upper and lower nuts 4718, 4720 that secure the members 4702,
4702 in the openings in the flanges 4714, 4714. At its upper end,
the manifold type bracket 4712 may carry a large flange 4722 for
connection with a main vertical structural member of a wind turbine
tower. An associated truss member may be connected with the bracket
4724.
[0179] The micro piles 4612, 4612 and 4704, 4704 may extend a
substantial distance downwardly into the earth and may be between
20 and 50 feet in length, preferably approximately 30 feet long for
both the outriggers and the main structural members of the tower.
Further, the micro piles may extend in a "splayed" relationship
with each other, FIG. 48, for maximum effectiveness in both
compression and tension. The angular relationship of the micro
piles with respect to the centerlines of their supported members
may vary, but it is preferred to maintain a displacement of
approximately 3 degrees from the centerlines of the outriggers and
a displacement of approximately 10 degrees from the centerlines of
the structural members of the towers.
[0180] Referring now to FIG. 48, the template function of the
manifolds 4618, 4700 is illustrated subsequent to the drilling
operation and the injection of concrete through a tube such as
4702a. The tube 4702a may be entered in an opening 4620a and may be
maintained in position on completion of drilling and concrete
injection by means of one or more small inserts 4802, 4802
positioned in the opening 4620a. A first insert 4802 is shown in
the opening 4620a in FIG. 48, and a second insert 4802 is shown
above the upper end of the tube 4702a. As will be apparent, the
inserts 4802, 4802 may serve to maintain the tubular member 4702a
in a desired angular position when drilling and formation of the
micro pile is complete with the concrete remaining in an unhardened
condition. The inserts 4802, 4602 may be retained in the opening
4620a during grouting of the opening 4620a with hardenable medium
and may insure precise final positioning of the upper ends of the
members 4702a, 4702a for connection with their respective supported
members.
[0181] Disclosed herein is a method of manufacturing the flange of
the coupling unit described above. As described previously herein,
the coupling unit includes a radial flange and an axial boss with
an axial bore, and is adapted to couple tubular members that form
the structural components of the tower for mounting wind
turbines.
[0182] Alloyed steels may be used to manufacture the flange. The
flange may then be welded to a tube without becoming brittle in the
heat-affected zone. The alloyed steel may be compatible with the
galvanizing process without any other treatment (e.g.
annealing).
[0183] The flange material may begin as hot rolled bar stock or a
high-strength, low-alloy (HSLA) steel plate that may be hot-formed
to a near net shape resembling the finished flange, and then
machine-finished to the final size. The flange raw material may be
steel utilizing alloying elements rather than carbon to attain the
desired grain size and structure in the final product. Grain
structure and size may affect the mechanical properties of the
flange, and may be controlled in part by the alloying elements and
in part by the manufacturing process. Using the alloyed steel
enables welding of the flange to a tube without heat treatment of
the weld zone. In embodiments, alloying elements of steel may be
selected to reduce grain growth during reheating, restrict zinc
alloy growth during galvanizing, and to have high strength without
heat treatment.
[0184] In an embodiment, the hot rolled bar may be a fine grain
hot-rolled bar that may be cut to a pre-determined length and
heated to form a slug. The slug may then be moved to a die which
may close around the hot bar forming it into a shape resembling the
finished flange. The formed slug may then be cooled and machined to
the net shape.
[0185] In an embodiment, the HSLA plate may be cut to a
pre-determined size and placed into a die which draws the steel to
a shape resembling the finished flange. The formed steel may then
be cooled and machined to net shape.
[0186] In an embodiment of the process, a steel slug may be hot
rolled into an approximate cylindrical shape, heated, and forged
with one or more steps to form it into a shape approximating the
shape of the flange as described herein. Forging may include
striking the material while it is hot. In another embodiment of the
process, a steel slug may be hot rolled into a flat piece of steel,
cut into an approximate cylindrical shape, heated, and forged with
one or more steps to form it into a shape approximating the shape
of a flange as described herein.
[0187] In any event, the material may then be cooled and the inside
and outside surfaces of the flange may be machined to their final
shape. The flange may then be welded to the tubular member.
[0188] The flange material may comprise a carbon content less than
0.3%. The flange material may comprise a carbon equivalent defined
by an equation, such as the American Welding Society (AWS) equation
or any other applicable equation. For example, the AWS equation is
as follows: CE=% C+((% Mn+% Si)/6)+((% Cr+% Mo+% V)/5)+((% Cu+%
Ni)/15), less than 0.45%. The flange material may comprise an
element to retard grain growth during heating above the
austentizing temperature, such as a temperature of about 1000
degrees Fahrenheit. The flange material may comprise at least one
of titanium, niobium, ruthenium, vanadium, zirconium, molybdenum,
or other rare earth elements, metals, transition metals, or
combinations thereof.
[0189] The flange material may be of a fine grain with a grain size
(G) of 12 or smaller, as measured using ASTM E112. In embodiments,
the grain size is substantially about 7. It should be understood
that the flange material is not limited to a particular grain
size.
[0190] The flange material may include austenite dispersed in a
ferrite microstructure, pearlite dispersed in a ferrite
microstructure, carbide precipitates in a ferrite microstructure,
nitride precipitates in a ferrite microstructure, or the like.
[0191] The weld may be a multipass metal inert gas (MIG) weld. The
weld may be an inside tungsten inert gas (TIG) pass weld. After
welding, the assembly may be galvanized.
[0192] Disclosed herein is a tower and wind turbine supporting
structure which at least partially envelops the tower at an
elevated position for enhanced wind velocity. The tower includes a
plurality of horizontally spaced apart vertically extending narrow
elongated and lightweight members and a plurality of shorter narrow
lightweight interconnecting cross members extending between the
vertical members and cooperating therewith to form a massive
monolithic structure having a vertical dimension of at least thirty
five (35) feet. The exterior cross sectional configuration and
dimensions of the tower from its base to the area of attachment of
the wind turbine supporting structure may be less than that of the
adjacent interior cross sectional surfaces of the wind turbine
supporting structure. At least one power operated lifting device
may be mounted substantially at the top of the tower and have at
least one lift line extending downwardly therefrom. A plurality of
diagonally extending outriggers may be adapted to be attached to
the tower after the turbine and supporting structure has been
positioned at the base of the tower, raised to its respective
operating position by said lifting device and secured in place. The
outriggers may be spaced apart horizontally about the base of the
tower and may each be of narrow elongated and lightweight but
longitudinally rigid construction, each outrigger having its upper
end portion connected to the tower in supporting relationship
therewith and its lower end portion disposed in horizontally spaced
relationship with the tower at least approximately at ground level.
The supporting structure may include a foundation system supporting
each vertical structural member of the tower and each outrigger at
its lower end portion. The wind turbines and their supporting
structures may be substantially completely manufactured on site
about the base of the tower. Alternatively, the wind turbines and
their supporting structures may be manufactured off-site in
sections, and the sections may be transported to the site and
assembled sequentially about the tower base and thereafter raised
and secured in position. The sections may be no larger than that
allowed for truck transport.
[0193] Referring to FIG. 49, a tower for mounting wind turbines and
their supporting structures is indicated generally at 4900 with the
tower proper at 4902, supporting structures at 504, 504 and
turbines at 108,108. The illustrative tower 4902 shown may have a
height A of two hundred (200) feet. As illustrated in FIG. 50, the
tower 4902 may include a plurality of narrow elongated and
lightweight vertically extending longitudinal members 4904, 4904,
preferably tubular, and a plurality of shorter narrow lightweight
interconnecting cross members 5012, 5012. The cross members 5012,
5012 may be tubular or triangular in cross section in a truss
structure. The members 5012, 5012 may extend between the members
4904, 4904 and may cooperate therewith to form a massive monolithic
structure having a vertical dimension of at least fifty (50) feet.
The cross section and other structural characteristics of the tower
may vary but in all cases the cross sectional dimensions and
configuration of the tower may from its base to the area of
connection with the wind turbine supporting structures be at least
partially uniform to permit raising of the wind turbines and their
supporting structures thereabout. Tower 4902 may be a preferred
triangular vertically uniform cross sectional configuration the
short cross members 5012, 5012 extending diagonally between the
vertical members 4904, 4904.
[0194] Mounted at or near the top of the tower or at its base may
be a power operated lifting device 4908, which may be shown with a
pair of depending lift lines 4912, 4912 respectively on opposite
sides of the tower 4902 and may be connected with a wind turbine
supporting structure 504 at the base of the tower.
[0195] The wind turbines 108, 108 and their supporting structures
504, 504 may vary widely in construction and may completely
surround the tower 4902. It should also be noted that the
supporting structures may be mounted for incremental rotation about
the tower in adjusting the position of the turbines for optimum
performance in response to change in the direction of wind
flow.
[0196] Referring now to FIG. 56, a tower for mounting wind turbines
and accelerator platforms is depicted. In this embodiment, the
tower is a double-lattice, or truss-type, tower with diagonal
support beams attached to the corner posts at the exact same
vertical spacing as the spacing between the accelerators (also
known as accelerator platforms) and wind turbines. The rotating
support member attachment points that hold the rotating accelerator
platforms to the tower may be located substantially at the same
locations as the support brace intersections for maximum
strength.
[0197] FIG. 56A depicts a top view of the tower. FIG. 56B depicts a
section view where the section goes through a blade, along the
inner diameter of an accelerator platform to a rotating support
member on one corner post, straight to another corner post to
another rotating support member, and along the inner diameter of
the platform until it can go straight through the other turbine.
FIG. 56 also depicts the wind turbines 5620 with an impeller 5618
that defines a swept area 5614.
[0198] The vertical spacing between rotating support member
attachment points from one accelerator platform 5602 to the other
may be the same as the spacing between the wind turbine impeller
hubs 5604 and is shown as dimension h. The vertical spacing between
the intersections of the cross braces 5612 and corner posts 5610 is
shown as dimension d. The relationship between these vertical
spacings may be described by the equation h=n*d where n is an
integer. The cross bracing structure on the tower depicted in FIG.
56 is a so-called double lattice architecture where each cross
brace 5612 in one direction crosses three cross braces 5612 in the
other direction. In the case depicted in FIG. 56, the vertical
spacing of the tower would be described by the equation h=2*d. It
should be understood that not all towers will be of a double
lattice architecture. For example, in a single-lattice tower the
cross braces 5612 would be a series of X's going up the tower where
each cross brace 5612 intersects a single cross brace 5612 in the
other direction. In this case, the vertical spacings of the tower
would be described by the equation h=d.
[0199] In an embodiment, a lattice (truss-type) tower for wind
turbine 5620 mounting may have two or more accelerator platforms
5602 attached to the tower such that they can rotate around the
tower on rotating support members 5608 mounted on each corner post
5610. Each accelerator platform 5602 may have two horizontal-axis
wind turbines 5620 on opposite sides and the accelerator platforms
5602 may be mounted on the tower in a vertical stacking
arrangement. The lattice tower may have three or more corner posts
5610 with angled cross bracing 5612 between the corner posts 5610.
The vertical spacing between the rotating support members from one
platform 5602 to an adjacent platform 5602 may be an exact multiple
of the vertical spacing between the intersection points between the
cross braces 5612 and the corner posts 5610.
[0200] Each rotating support member 5608 may be located on the
corner posts 5610 at substantially the same location as where the
cross braces 5612 intersect the corner posts 5610. In the tower,
the rotating support member location mounts may be substantially
close to where the center line of a cross brace 5612 may intersect
the outside of the corner post 5610. In an embodiment, at an
intersection point there may be cross braces 5612 that go downwards
and cross braces 5612 that go upwards. The downwards and upwards
cross braces 5612 would not intersect the outside of the corner
post 5610 at the same place. The rotating support members 5608 may
be located at the higher of the two locations, i.e., the
intersection of the centerline of the cross brace 5612 that goes
downward from the intersection point.
[0201] The vertical location of the rotating support member
attachment points may be within a pre-defined distance of where the
cross braces 5612 intersect the corner posts 5610, where the
pre-defined distance may be a percentage of the spacing between
intersection points between the cross braces 5612 and the corner
posts 5610.
[0202] In embodiment, each platform may be mounted to the tower on
its own rotating support member 5608. The vertical spacing of
rotating support members 5608 between adjacent accelerator
platforms 5602 may be aligned with cross braces spacing. The
rotating support members are aligned at cross brace intersection
points.
[0203] In an embodiment, the vertical spacing between turbine axes
may be greater than 1.25 the diameter of the turbines. The
accelerators carrying the turbines may each define a passageway
designed to capture and direct a stream of wind through an arcuate
horizontal path to its associated wind turbine, each said
passageway having an interior forwardly facing concave central
portion viewed in cross-section which is generally parti-circular
for wind impact, redirection horizontally and transfer to the
turbine. There may be forwardly facing convex exposed opposite end
portions at the mouth of the passageway viewed in cross-section
each having a sharp substantially pointed radius of curvature for
entry of the wind and direction of the same rearwardly toward the
central portion of the passageway. The radii of said end portions
may fall in the range of zero (0) to 0.25 the diameter of the
turbines. Smooth transition portions may converge toward the
central portion from the front end portions of each passageway. The
radius of curvature of the end portions of the passageways falls in
the neighborhood of zero (0) to 0.1 or approximately zero. The
transition portions of said passageway may be linear. A unitary
wind passageway may extend continuously in opposite directions and
in a generally diverging arcuate path from a front portion of the
accelerator to each of the turbines. Each wind passageway may
extend arcuately from the front of the accelerator through
approximately one hundred eighty degrees (180 degrees) in each
direction to the wind turbines. Each of said wind passageways may
generally be parti-circular viewed vertically and open radially
outwardly substantially throughout its length between the wind
turbines. The turbine inlets may provide a funnel like
configuration transitioning air into the turbines. Each turbine may
have a funnel like shape at its outlet to diffuse air from the
turbine.
[0204] In embodiments, a winch at the bottom of the tower with
cables running up over pulleys at the top of the tower may be used
to lift the accelerator platforms 5602 to the mounting positions
along the tower.
[0205] In an embodiment, when two or more accelerator platforms
5602 are mounted on a tower, each accelerator platform 5602 is
mounted to the tower on its own rotating support members. The
platforms 5602 may be connected together in a way that forces them
to rotate together about a vertical Z axis, i.e., the platforms
5602 are linked together in such a way that they always point in
substantially the same direction relative to rotation about the
vertical Z axis (give or take a few degrees for tolerance), but all
other degrees of freedom remain (translation in X, Y, and Z and
rotation about X and Y). Thus, if one accelerator platform 5602
tries to rotate, it will cause all of the other accelerator
platforms 5602 to rotate with it, however, no other significant
forces other than rotation about the Z axis may act between the
platforms. In this way, each platform 5602 carries its own weight
on its own rotating support members 5608, and the platforms 5602
can translate in the horizontal plane relative to each other to
allow for tolerances in how each platform 5602 rotates on its
rotating support members 5608. In some embodiments, the rotating
support members 5608 on each platform 5602 may allow movement, such
as movement in the horizontal plane, to account for tolerances in
the roundness of the platform.
[0206] In some embodiments, the freedom for accelerator platforms
5602 to move in the X-Y plane relative to each other may be
restricted by a compliant spring-like means. The restriction is
such that horizontal translation and angular misalignment (rotation
about the Z axis) between adjacent platforms is possible but the
further the platforms translate/rotate from the nominal relative
position between platforms, the more force there is trying to pull
them back to the nominal relative position/angle between platforms.
In these embodiments there may be no substantial mechanical
coupling that resists relative motion in the Z direction between
platforms.
[0207] In an embodiment, the power cables carrying power from the
generators attached to the wind turbines to the ground come up to
the top of the tower and drop down the middle of the tower in the
so-called twist section. The twist section enables the accelerator
platforms to rotate at least a plurality of turns in either
direction. In some embodiments, a plurality of generators for the
tower may have their cables running down the center of the tower in
the twist section. In embodiments, both power and communication
wires to instrumentation and actuators on the rotating accelerator
platforms may run down the center of the tower so they may also
twist.
[0208] Disclosed herein is a lattice tower with substantially
uniform cross section and outriggers that can be attached after the
wind accelerating platforms have been raised into place, such as by
using power operated lifting devices rigged to the tower,
alleviating the need for a crane to install the parts of the wind
turbine mounted up on the tower. Different truss geometries for the
tower and outriggers may be possible. Also disclosed is the use of
foundation members only where the vertical tower members reach the
ground, and the use of micropile foundations as the discrete
foundation members. The use of micropiles greatly reduces the
amount of concrete use compared to pedestal-type foundations for
conventional wind turbines.
[0209] Referring to FIG. 50, a plurality of longitudinally rigid
outriggers may provide support in both tension and compression. As
shown, three (3) outriggers 4910, 4910 may be provided and each
outrigger 4910 may be of tubular metallic construction with three
(3) longitudinally extending elongated members 5014, 5014 in a
triangular configuration and a plurality of shorter tubular members
5018, 5018 interconnecting the longitudinal members. The outriggers
4910, 4910 may have their upper end portions connected in
supporting relationship with the vertical longitudinally members of
the tower; three (3) outriggers may be provided for the triangular
tower 4902. Preferably, the connection of the outriggers with the
tower may be effected at the point where at least one cross member
5012 may connect with a vertical member 4904. Further, the
outriggers may have a length B in the range twenty (20} to one
hundred (100) feet and, in the illustrative embodiment shown, the
outriggers may have a length B of approximately fifty (50) feet.
The outriggers may be at an angle with the vertical in the range of
thirty (30) to eighty (80) degrees, the preferred angle may be
approximately sixty (60) degrees.
[0210] At lower end portions, the outriggers 4910, 4910 may be
provided with separate foundation members in the form of elongated
members 4918, 4918 of composite metallic and concrete construction.
As shown, the foundation members 4918, 4918 may take the form of
micro piles of the type sold and installed by CON-TECH SYSTEMS LTD.
of 8150 River Road, Delta, B.C. Canada V4G 1B5 under the trademarks
SCHEBECK and TITAN and may extend downwardly into the earth at
angles substantially the same as that of the members which they
support. The length of the micro pile members may be in the range
of twenty (20) to fifty (50) feet and in the illustrative
embodiment shown, the outrigger foundation members 4918, 4918 may
be approximately thirty (30) feet long.
[0211] When bedrock may be reasonably close to the surface, the
foundation members 4918, 4918 may be supported by anchors 4914
embedded in the bedrock, one shown on the right hand member 4918 in
FIG. 49. Foundation members 4920, 4920 for the vertical members
4904, 4904 of the tower 4902 may be preferably the same as those
for the outriggers with the length of the members falling in the
range of twenty (20) to fifty (50) feet. In the illustrative
embodiment shown, the length of the members 4920, 4920 may be
approximately thirty (30) feet and the members extend vertically,
downwardly from the vertical members which they support.
[0212] Referring to FIG. 51 a fragmentary illustration in
perspective of an erection apparatus connected with a tower to be
erected is depicted. In an embodiment, a wind turbine tower or the
like may be indicated at 5100 in position on the ground ready for
erection. The apparatus and method of the invention may be
particularly well suited to the erection of relatively lightweight
lattice type towers of the type shown but are not so limited. It
may be contemplated that a wide variety of tower types and
configurations may benefit from the apparatus and method of the
invention.
[0213] The erection apparatus may be indicated at 5102 and may
include a pair of rigid elongated members 5104, 5104 in generally
triangular configuration straddling a base portion of the tower
with the apex 5108 of the triangle spaced substantially above the
tower and with the elongated members arranged laterally with
respect to the arc of tower erection. At least one rigid elongated
lift member 5110 may be provided and may have one end attached to
the elongated members 5104, 5104 at their apex 5108 and an opposite
end attached to the tower at 5112 in remotely spaced relationship
with the apex 5108 of the elongated members 5104, 5104. Further, a
pair of fluid pressure operated cylinders 5114, 5114 may also be
provided and may be arranged in a triangular configuration
laterally straddling the tower 5100 each with an upper end secured
to the elongated members 5104, 5104 at their apex 5108 and with
their lower ends supported in laterally spaced relationship with
the tower 5100. In an embodiment, the elongated members 5104, 5104
may be pivotally supported at their lower end portions and a
representative mounting device shown at 5118 may be employed for
each of said members.
[0214] Referring to FIG. 52, a schematic side view of the apparatus
5102 and the tower 5100 demonstrating the erection procedure is
depicted. A pivot pin may be connected with and supports an
elongated member 5104 and may be mounted in housing for rotation
through an arc of approximately ninety degrees as required during
tower erection. The housing may be secured to a foundation by bolts
and the pivot pins for the two elongated members may be maintained
in axial alignment.
[0215] In an alternative and preferred embodiment of the pivotal
support for the elongated members 5104, 5104 are shown in FIG. 54A.
FIGS. 54A and 54B depict an enlarged view in section showing a
pivotal support for the tower 5100 and the connection of an
elongated member to the tower 5100. In an embodiment, a pivot pin
5402 may be mounted in a boss 5424 on a member 5404. The member
5404 may in turn be secured to a foundation 5408 by bolts 5410,
5410. Further, the pivot pin 5402 may be connected with a generally
L-shaped member 5410 that may be connected with and may support the
lower end portion of a main corner member 5412 forming an integral
part of the tower 5100. Also connected with the lower end portion
of the member 5412 may be a lower end portion of an elongated
member 5104 by means of bolts 5414, 5414. Thus, the elongated
member 5104 may pivot with the member 5412 and the tower 5100
during erection of the latter. The pivot pin 5402 may rotate
through approximately 90 degrees during erection of the tower 5100
and a stop 5420 on the member 5404 may serve to position the tower
5100 precisely in its vertical attitude on engagement of the member
5420 with a co-operating stop 5422 on the base of the tower member
5412. Thus, both the tower member 5412 and the elongated member
5104 may move together through an angle of approximately 90 degrees
in an erection operation.
[0216] Further, a pair of fluid pressure cylinders and their
extensions may also pivot through an angle of approximately 90
degrees during erection. In an embodiment, due to increase in
length during the erection procedure a slight degree of freedom in
the lateral direction may also be required. Accordingly, a two
dimensional pivot capability may be provided at both ends of the
cylinders and their extensions by means of conventional ball joint
connections, not shown.
[0217] Referring to FIG. 53, a schematic view showing the tower
5100 in a position of substantial erection where cylinders commence
a resistive action is depicted. The method of the present invention
may be apparent in conjunction with FIGS. 52 and 53. The
aforementioned elongated members 5104, 5104, lift member 5110, and
fluid pressure cylinders may be positioned as shown in FIG. 52 on
the pivotal supports of 54A, the elongated members and fluid
pressure cylinders at approximately 11 o'clock in FIG. 52 and the
tower 5100 in a substantially horizontal position. The fluid
pressure cylinders may then be operated in a pushing mode to urge
the pistons of the cylinders upwardly and to cause the elongated
members and the lift member 5110 to swing arcuately upwardly and
rightwardly to the position shown in FIG. 53. During this operation
the elongated members and the cylinders swing through an arc in a
clockwise direction. When the tower 5100 may have swung upwardly
through an arc bringing its center of gravity 5302 into vertical
alignment above the pivot point 5304 of the tower 5100 as shown in
FIG. 53, the tendency of the tower 5100 may be to continue in its
clockwise movement, accelerating as it moves. Accordingly, at
approximately eighty degrees in the illustrative embodiment shown,
the fluid pressure cylinders may be reversed and assume a resistive
or pulling mode controlling the movement of the tower so that it
may gradually come to rest in a vertical position with the stop
members 5420 and 5422 of FIG. 54A in engagement.
[0218] Disclosed herein is the use of hydraulic cylinders, such as
in the erection apparatus, to tip up the tower after it has been
constructed horizontally on the ground, eliminating the need for a
crane on site which would add considerable expense. The hydraulic
cylinders may be attached to the discrete foundations members for
the outriggers that are spaced apart from the main tower
foundations. Referring to FIG. 55, a perspective view showing the
erection apparatus disconnected from the tower 5100 and in a
preliminary substantially horizontal attitude is depicted. Further,
the erection apparatus, which may be preferably detachably
connected to the tower 5100 and its pivot supports, may then be
removed from the tower 5100 and employed in the erection of the
next succeeding tower. At this point, it may be noted that the
pivot supports and foundations for the fluid pressure cylinders may
be positioned so as to be employed subsequently in the installation
of diagonal outriggers supporting the tower.
[0219] Finally, the erection apparatus may be transported to the
tower site, such as in a relatively small truck even in the most
difficult terrain; ]the problems with access encountered with large
cranes are overcome. On arrival at the site, the erection apparatus
may be attached with its elongated members secured to independent
pivot supports, the fluid pressure operated cylinders similarly
mounted on their ball joint supports, and the apparatus arranged in
a preliminary prone position as shown in FIG. 55. That is, the
apparatus may extend rightwardly away from the tower and may be
substantially horizontal but may be elevated slightly at its end
remote from the tower. The fluid cylinders may then be operated in
a retractive or pulling mode to cause the apparatus to swing
upwardly and leftwardly in a counter-clockwise direction to its
broken-line operating position. The lift member may then be
attached and a simple and efficient method of installation of the
erection apparatus completed.
[0220] The methods and systems described herein may be deployed in
part or in whole through a machine that executes computer software,
program codes, and/or instructions on a processor. The processor
may be part of a server, cloud server, client, network
infrastructure, mobile computing platform, stationary computing
platform, or other computing platform. A processor may be any kind
of computational or processing device capable of executing program
instructions, codes, binary instructions and the like. The
processor may be or include a signal processor, digital processor,
embedded processor, microprocessor or any variant such as a
co-processor (math co-processor, graphic co-processor,
communication co-processor and the like) and the like that may
directly or indirectly facilitate execution of program code or
program instructions stored thereon. In addition, the processor may
enable execution of multiple programs, threads, and codes. The
threads may be executed simultaneously to enhance the performance
of the processor and to facilitate simultaneous operations of the
application. By way of implementation, methods, program codes,
program instructions and the like described herein may be
implemented in one or more thread. The thread may spawn other
threads that may have assigned priorities associated with them; the
processor may execute these threads based on priority or any other
order based on instructions provided in the program code. The
processor may include memory that stores methods, codes,
instructions and programs as described herein and elsewhere. The
processor may access a storage medium through an interface that may
store methods, codes, and instructions as described herein and
elsewhere. The storage medium associated with the processor for
storing methods, programs, codes, program instructions or other
type of instructions capable of being executed by the computing or
processing device may include but may not be limited to one or more
of a CD-ROM, DVD, memory, hard disk, flash drive, RAM, ROM, cache
and the like.
[0221] A processor may include one or more cores that may enhance
speed and performance of a multiprocessor. In embodiments, the
process may be a dual core processor, quad core processors, other
chip-level multiprocessor and the like that combine two or more
independent cores (called a die).
[0222] The methods and systems described herein may be deployed in
part or in whole through a machine that executes computer software
on a server, client, firewall, gateway, hub, router, or other such
computer and/or networking hardware. The software program may be
associated with a server that may include a file server, print
server, domain server, internet server, intranet server and other
variants such as secondary server, host server, distributed server
and the like. The server may include one or more of memories,
processors, computer readable media, storage media, ports (physical
and virtual), communication devices, and interfaces capable of
accessing other servers, clients, machines, and devices through a
wired or a wireless medium, and the like. The methods, programs or
codes as described herein and elsewhere may be executed by the
server. In addition, other devices required for execution of
methods as described in this application may be considered as a
part of the infrastructure associated with the server.
[0223] The server may provide an interface to other devices
including, without limitation, clients, other servers, printers,
database servers, print servers, file servers, communication
servers, distributed servers, social networks, and the like.
Additionally, this coupling and/or connection may facilitate remote
execution of program across the network. The networking of some or
all of these devices may facilitate parallel processing of a
program or method at one or more location without deviating from
the scope of the invention. In addition, any of the devices
attached to the server through an interface may include at least
one storage medium capable of storing methods, programs, code
and/or instructions. A central repository may provide program
instructions to be executed on different devices. In this
implementation, the remote repository may act as a storage medium
for program code, instructions, and programs.
[0224] The software program may be associated with a client that
may include a file client, print client, domain client, internet
client, intranet client and other variants such as secondary
client, host client, distributed client and the like. The client
may include one or more of memories, processors, computer readable
media, storage media, ports (physical and virtual), communication
devices, and interfaces capable of accessing other clients,
servers, machines, and devices through a wired or a wireless
medium, and the like. The methods, programs or codes as described
herein and elsewhere may be executed by the client. In addition,
other devices required for execution of methods as described in
this application may be considered as a part of the infrastructure
associated with the client.
[0225] The client may provide an interface to other devices
including, without limitation, servers, cloud servers, other
clients, printers, database servers, print servers, file servers,
communication servers, distributed servers and the like.
Additionally, this coupling and/or connection may facilitate remote
execution of program across the network. The networking of some or
all of these devices may facilitate parallel processing of a
program or method at one or more location without deviating from
the scope of the invention. In addition, any of the devices
attached to the client through an interface may include at least
one storage medium capable of storing methods, programs,
applications, code and/or instructions. A central repository may
provide program instructions to be executed on different devices.
In this implementation, the remote repository may act as a storage
medium for program code, instructions, and programs.
[0226] The methods and systems described herein may be deployed in
part or in whole through network infrastructures. The network
infrastructure may include elements such as computing devices,
servers, cloud servers, routers, hubs, firewalls, clients, personal
computers, communication devices, routing devices and other active
and passive devices, modules and/or components as known in the art.
The computing and/or non-computing device(s) associated with the
network infrastructure may include, apart from other components, a
storage medium such as flash memory, buffer, stack, RAM, ROM and
the like. The processes, methods, program codes, instructions
described herein and elsewhere may be executed by one or more of
the network infrastructural elements.
[0227] The methods, program codes, and instructions described
herein and elsewhere may be implemented on a cellular network
having multiple cells. The cellular network may either be frequency
division multiple access (FDMA) network or code division multiple
access (CDMA) network. The cellular network may include mobile
devices, cell sites, base stations, repeaters, antennas, towers,
and the like. The cell network may be a GSM, GPRS, 3G, EVDO, mesh,
or other networks types.
[0228] The methods, programs codes, and instructions described
herein and elsewhere may be implemented on or through mobile
devices. The mobile devices may include navigation devices, cell
phones, mobile phones, mobile personal digital assistants, laptops,
palmtops, netbooks, pagers, electronic books readers, music players
and the like. These devices may include, apart from other
components, a storage medium such as a flash memory, buffer, RAM,
ROM and one or more computing devices. The computing devices
associated with mobile devices may be enabled to execute program
codes, methods, and instructions stored thereon. Alternatively, the
mobile devices may be configured to execute instructions in
collaboration with other devices. The mobile devices may
communicate with base stations interfaced with servers and
configured to execute program codes. The mobile devices may
communicate on a peer to peer network, mesh network, or other
communications network. The program code may be stored on the
storage medium associated with the server and executed by a
computing device embedded within the server. The base station may
include a computing device and a storage medium. The storage device
may store program codes and instructions executed by the computing
devices associated with the base station.
[0229] The computer software, program codes, and/or instructions
may be stored and/or accessed on machine readable media that may
include: computer components, devices, and recording media that
retain digital data used for computing for some interval of time;
semiconductor storage known as random access memory (RAM); mass
storage typically for more permanent storage, such as optical
discs, forms of magnetic storage like hard disks, tapes, drums,
cards and other types; processor registers, cache memory, volatile
memory, non-volatile memory; optical storage such as CD, DVD;
removable media such as flash memory (e.g. USB sticks or keys),
floppy disks, magnetic tape, paper tape, punch cards, standalone
RAM disks, Zip drives, removable mass storage, off-line, and the
like; other computer memory such as dynamic memory, static memory,
read/write storage, mutable storage, read only, random access,
sequential access, location addressable, file addressable, content
addressable, network attached storage, storage area network, bar
codes, magnetic ink, and the like.
[0230] The methods and systems described herein may transform
physical and/or or intangible items from one state to another. The
methods and systems described herein may also transform data
representing physical and/or intangible items from one state to
another.
[0231] The elements described and depicted herein, including in
flow charts and block diagrams throughout the figures, imply
logical boundaries between the elements. However, according to
software or hardware engineering practices, the depicted elements
and the functions thereof may be implemented on machines through
computer executable media having a processor capable of executing
program instructions stored thereon as a monolithic software
structure, as standalone software modules, or as modules that
employ external routines, code, services, and so forth, or any
combination of these, and all such implementations may be within
the scope of the present disclosure. Examples of such machines may
include, but may not be limited to, personal digital assistants,
laptops, personal computers, mobile phones, other handheld
computing devices, medical equipment, wired or wireless
communication devices, transducers, chips, calculators, satellites,
tablet PCs, electronic books, gadgets, electronic devices, devices
having artificial intelligence, computing devices, networking
equipments, servers, routers and the like. Furthermore, the
elements depicted in the flow chart and block diagrams or any other
logical component may be implemented on a machine capable of
executing program instructions. Thus, while the foregoing drawings
and descriptions set forth functional aspects of the disclosed
systems, no particular arrangement of software for implementing
these functional aspects should be inferred from these descriptions
unless explicitly stated or otherwise clear from the context.
Similarly, it will be appreciated that the various steps identified
and described above may be varied, and that the order of steps may
be adapted to particular applications of the techniques disclosed
herein. All such variations and modifications are intended to fall
within the scope of this disclosure. As such, the depiction and/or
description of an order for various steps should not be understood
to require a particular order of execution for those steps, unless
required by a particular application, or explicitly stated or
otherwise clear from the context.
[0232] The methods and/or processes described above, and steps
thereof, may be realized in hardware, software or any combination
of hardware and software suitable for a particular application. The
hardware may include a general purpose computer and/or dedicated
computing device or specific computing device or particular aspect
or component of a specific computing device. The processes may be
realized in one or more microprocessors, microcontrollers, embedded
microcontrollers, programmable digital signal processors or other
programmable device, along with internal and/or external memory.
The processes may also, or instead, be embodied in an application
specific integrated circuit, a programmable gate array,
programmable array logic, or any other device or combination of
devices that may be configured to process electronic signals. It
will further be appreciated that one or more of the processes may
be realized as a computer executable code capable of being executed
on a machine readable medium.
[0233] The computer executable code may be created using a
structured programming language such as C, an object oriented
programming language such as C++, or any other high-level or
low-level programming language (including assembly languages,
hardware description languages, and database programming languages
and technologies) that may be stored, compiled or interpreted to
run on one of the above devices, as well as heterogeneous
combinations of processors, processor architectures, or
combinations of different hardware and software, or any other
machine capable of executing program instructions.
[0234] Thus, in one aspect, each method described above and
combinations thereof may be embodied in computer executable code
that, when executing on one or more computing devices, performs the
steps thereof. In another aspect, the methods may be embodied in
systems that perform the steps thereof, and may be distributed
across devices in a number of ways, or all of the functionality may
be integrated into a dedicated, standalone device or other
hardware. In another aspect, the means for performing the steps
associated with the processes described above may include any of
the hardware and/or software described above. All such permutations
and combinations are intended to fall within the scope of the
present disclosure.
[0235] While the invention has been disclosed in connection with
the preferred embodiments shown and described in detail, various
modifications and improvements thereon will become readily apparent
to those skilled in the art. Accordingly, the spirit and scope of
the present invention is not to be limited by the foregoing
examples, but is to be understood in the broadest sense allowable
by law.
[0236] All documents referenced herein are hereby incorporated by
reference.
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