Wind turbine and method of manufacture

• US 20070013194A1
• Filed: 07/17/2006
• Published: 01/18/2007
• Est. Priority Date: 07/15/2005
• Status: Active Grant

• Current Assignee: Southwest Windpower, Wind Resource LLC
• Original Assignee: Southwest Windpower Incorporated (XZERES Corp.)
• Inventors: Calley, David
• Granted Patent: US 8,018,081 B2
• Time in Patent Office: Days
• US Class Current: 290/44
• CPC Class Codes: F03D 1/00 Wind motors with rotation axis substantially parallel to the air flow entering the rotor controlling thereof F03D7/02
• CPC Class Codes: F03D 1/0608 characterised by their aerodynamic shape
• CPC Class Codes: F03D 7/047 characterised by the controller architecture, e.g. multiple processors or data communications
• CPC Class Codes: F03D 80/00 Details, components or accessories not provided for in groups F03D1/00 - F03D17/00
• CPC Class Codes: F03D 9/11 storing electrical energy
• CPC Class Codes: F03D 9/25 the apparatus being an electrical generator F03D9/22 takes precedence
• CPC Class Codes: F05B 2240/2213 and with the rotor downwind from the yaw pivot axis
• CPC Class Codes: H02K 21/14 with magnets rotating within the armatures
• CPC Class Codes: H02K 7/1838 Generators mounted in a nacelle or similar structure of a horizontal axis wind turbine
• CPC Class Codes: Y02E 10/72 Wind turbines with rotation axis in wind direction
• CPC Class Codes: Y02E 70/30 Systems combining energy storage with energy generation of non-fossil origin
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A variable voltage and frequency output wind turbine. Variations of the wind turbine include use of a slotless alternator to reduce alternator noise, a high power AC output to facilitate transmission of the output over extended distances, AC to DC converters and DC to AC converters, and sensors for systems and devices to receive the wind turbine output and to allow matching of the output to the receiving devices and system. Other features include a removable hatchcover for dissipating heat from components contained in the turbine or attached to the hatchcover, a swept blade design to reduce blade-produced noise, and power storage components for storing and intermittently using energy stored as a result of wind turbine power generation.

Claims

1. A wind turbine, comprising:

an electrical output device;

at least one wind driven blade operatively coupled to the electrical output device, wherein movement of the at least one wind driven blade produces output from the coupled electrical output device; and

a bi-directional inverter coupled to the electrical output device, the bi-directional inverter being coupled to a DC load.

2. The wind turbine of claim 1, wherein the electrical output device is an alternator.

3. The wind turbine of claim 1, wherein the DC load is selected from a group consisting of a battery, a pump, a compressor, a heater, a cathodic protection device, a DC to DC converter, and an electrolizer.

4. The wind turbine of claim 1, further comprising:

a controller coupled to the bi-directional inverter.

5. The wind turbine of claim 4, further comprising:

a sensor coupled to the DC load, wherein the controller controls operation of the wind turbine as a function of input received by the sensor.

6. The wind turbine of claim 1, wherein the power output device is usable over a range of power requirements of the DC load.

7. The wind turbine of claim 1, wherein the electrical output device has an output in a range of between about 0 volts and 420 volts.

8. The wind turbine of claim 4, wherein the controller is wirelessly coupled to the bi-directional inverter.

9. The wind turbine of claim 5, wherein the controller is wirelessly coupled to the sensor.

10. The wind turbine of claim 4, wherein the controller controls output of the electrical output device.

11. The wind turbine of claim 10, wherein the controller controls output of the electrical output device via stall regulation.

12. The wind turbine of claim 11, wherein the electrical output device includes a plurality of winding portions, and wherein the stall regulation is controlled via shorting of at least one of the plurality of winding portions.

13. The wind turbine of claim 1, further comprising:

an inverter coupled to the electrical output device and to the bi-directional inverter.

14. The wind turbine of claim 13, further comprising:

a sensor coupled to the DC load, wherein the controller controls operation of the wind turbine as a function of input received by the sensor;

15. The wind turbine of claim 13, wherein the controller is coupled to the inverter.

16. The wind turbine of claim 13, wherein the controller is wirelessly coupled to the inverter.

17. The wind turbine of claim 13, further comprising:

a housing, wherein the inverter is contained within the housing.

18. The wind turbine of claim 1, further comprising:

a housing that houses the electrical output device.

19. The wind turbine of claim 1, wherein the bi-directional inverter is further coupled to an AC load.

20. The wind turbine of claim 19, wherein the AC load is selected from a group consisting of a pump, a compressor, a heater, and a transformer.

21. The wind turbine of claim 4, further comprising:

a housing that houses the electrical output device and the controller.

22. The wind turbine of claim 5, further comprising:

a housing that houses the electrical output device, the controller, and the sensor.

23. The wind turbine of claim 19, further comprising:

a first sensor for sensing the DC load; and

a second sensor for sensing the AC load;

wherein the controller controls operation of the wind turbine as a function of input received by the first and second sensors.

24. The wind turbine of claim 4, wherein the bi-directional inverter is further coupled to an AC load, wherein the DC load and the AC load are each variable, and wherein the controller controls output of the electrical output device as a function of the variable DC load and the variable AC load.

25. The wind turbine of claim 4, wherein the controller is coupled to a second wind turbine.

26. The wind turbine of claim 25, wherein the DC load is variable, wherein the second wind turbine has a variable second wind turbine load, the variable second wind turbine load be selected from at least one of a variable second wind turbine AC load and a variable second wind turbine DC load, and wherein the controller controls output of the wind turbine and the second wind turbine as a function of the variable DC load and as a function of the variable second wind turbine load.

27. The wind turbine of claim 1, wherein the wind turbine is stall regulated.

28. The wind turbine of claim 27, wherein the wind turbine is stall regulated under a predetermined condition.

29. The wind turbine of claim 28, wherein the predetermined condition is selected from a group consisting of a predetermined blade movement speed, a power output limit, and a startup condition.

30. The wind turbine of claim 4, further comprising:

a wind turbine sensor coupled to the controller, wherein the controller controls operation of the wind turbine as function of input received by the sensor.

31. The wind turbine of claim 30, wherein the electrical output device has a velocity, and wherein the wind turbine sensor senses at least one selected from a group consisting of velocity of that at least one wind driven blade, velocity of the electrical output device, velocity of the wind, and the output of the electrical output device.

32. An active variable frequency wind turbine for providing outputs to variable frequency loads, the wind turbine comprising:

an electrical output device, the electrical output device producing a variable frequency AC output depending on device speed;

at least one wind driven blade operatively coupled to the electrical output device, wherein variable movement of the at least one wind driven blade produces AC output from the coupled electrical output device;

an AC to DC converter coupled to the electrical output device;

a DC to AC converter coupled to the DC to AC converter, the AC to DC converter being coupled to a load; and

a controller coupled to the DC to AC converter, the controller being capable of controlling the DC to AC converter to vary output from the DC to AC converter depending on an output selection for the load coupled to the DC to AC converter.

33. The wind turbine of claim 32, wherein the load is variable, the wind turbine further comprising:

a sensor for sensing the load;

wherein the output from the DC to AC converter varies with the varied load.

34. The wind turbine of claim 33, wherein the load comprises a transformer.

35. The wind turbine of claim 34, wherein the AC to DC converter is a rectifier.

36. The wind turbine of claim 35, wherein the load is a battery.

37. The wind turbine of claim 32, wherein the electrical output device is an alternator.

38. The wind turbine of claim 32, wherein the electrical output device is single phase.

39. The wind turbine of claim 32, wherein the electrical output device is poly phase.

40. The wind turbine of claim 39, wherein the wind turbine is stall regulated.

41. The wind turbine of claim 40, wherein the wind turbine is stall regulated under a predetermined condition.

42. The wind turbine of claim 41, wherein the predetermined condition is selected from a group consisting of a predetermined blade movement speed, a power output limit, and a startup condition.

43. An electric power output device, comprising:

a slotless winding portion, the slotless winding portion including windings encompassing a core comprising magnetic flux conducting material; and

a rotor portion having a rim and a plurality of magnetic elements attached to the rim, wherein the rim comprises a magnetic flux conducting material;

wherein the slotless winding portion and the rotor portion are rotatably moveable relative to one another.

44. The device of claim 43, wherein the core is low loss.

45. The device of claim 44, wherein the core is laminated.

46. The device of claim 44, wherein the core comprises an eddy current reducing material.

47. The device of claim 46, wherein the eddy current reducing material comprises a ferrous material.

48. The device of claim 43, wherein the plurality of magnetic elements include a plurality of permanent magnates.

49. The device of claim 43, further comprising:

an AC to DC converter coupled to the electrical output device.

50. The device of claim 49, wherein the AC to DC converter is a rectifier.

51. The device of claim 49, wherein the AC to DC converter is coupled to a DC to AC converter.

52. The device of claim 51, wherein the DC to AC converter is coupled to an output power receiving device, the turbine further comprising:

a control device coupled to the DC to AC converter for controlling output from the electrical output device as appropriate for electrical characteristics of the output power receiving device.

53. The device of claim 52, further comprising:

a monitoring device for monitoring electrical characteristics of the output power receiving device.

54. The device of claim 43, further comprising:

a radio-frequency filter coupled to the electrical output device.

55. The device of claim 43, further comprising:

a housing for housing the electrical output device.

56. The device of claim 55, wherein the slotless winding portion is fixed relative to the housing.

57. The device of claim 55, wherein the housing includes:

a hatch cover.

58. The device of claim 57, wherein the control device is attached to the hatch cover.

59. The device of claim 58, wherein the hatch cover is located so as to be cooled by the air flow.

60. The device of claim 55, further comprising:

a tower, wherein the housing is attached to the tower.

61. The device of claim 43, wherein the device is a generator.

62. The device of claim 43, wherein the device is an alternator.

63. The device of claim 43, wherein the slotless winding portion has a generally circular cross-sectionally shape, the slotless winding portion being sectioned into a plurality of sections radially about the circular cross-sectional shape, each of the sections of the slotless winding portion including a plurality of emplaced winding sets and having connectors to enable connection among the sections of the slotless winding portion.

64. The device of claim 63, wherein the core is sectioned into a plurality of sections, and wherein each of the sections of the sectioned winding portion includes one of the plurality of core sections.

65. The device of claim 64, wherein each of the plurality of core sections is contained with a molded section.

66. The device of claim 65, wherein the molded section comprises plastic.

67. The device of claim 63, wherein the sections of the sectioned winding portion are connected via at least one coupling component.

68. The device of claim 67, wherein the at least one coupling component is a circuit board.

69. The device of claim 67, wherein one of the at least one coupling component includes at least one lead for providing electrical power output from the winding portion.

70. The device of claim 63, wherein the device has a number of phases, and wherein each of the plurality of emplaced winding sets corresponds to one of the plurality of phases.

71. The device of claim 70, wherein each of the plurality of emplaced winding sets include at least two emplaced winding sets correspond to the same one of the plurality of phases.

72. The device of claim 71, wherein each sequential pair of the at least two emplaced winding sets corresponding to the same one of the plurality of phases are connected in series.

73. The device of claim 72, wherein a first emplaced winding set of each sequential pair of the at least two winding sets connected in series has opposite polarity to a second emplaced winding set of each sequential pair of the at least two winding sets connected in series.

74. The device of claim 72, wherein a first emplaced winding set of each sequential pair of the at least two winding sets connected in series has the same polarity as a second emplaced winding set of each sequential pair of the at least two winding sets connected in series.

75. The device of claim 63, wherein each of the plurality of winding sets is essentially identical.

76. The device of claim 43, wherein the windings comprise flat wire.

77. The device of claim 43, wherein the windings include a plurality of winding portions and a plurality of winding portion connection points connecting pairs of winding portions.

78. The device of claim 43, wherein the device is incorporated in a wind turbine.

79. The device of claim 43, wherein the device is incorporated in a vehicle.

80. The device of claim 79, wherein the wind turbine includes:

at least one blade attached to a hub, each of the at least one blade being rotatable with the hub responsive to an air flow against each of the at least one blade;

wherein the electrical output device is operatively coupled to the hub and capable of generating electrical output upon rotation of the hub.

81. The device of claim 80, wherein each of the at least one blade has a swept design.

82. The device of claim 80, wherein the hub is coupled to an axle.

83. A wind turbine, comprising:

an electrical output device;

at least one wind driven blade operatively coupled to the electrical output device, wherein movement of the at least one wind driven blade produces output from the coupled electrical output device; and

an inverter coupled to the electrical output device;

wherein the wind turbine provides an AC output;

wherein the at least one wind driven blade has kinetic energy proportional to the movement of the at least one wind driven blade;

wherein the wind turbine converts the kinetic energy of the at least one wind driven blade into electrical energy; and

wherein the inverter incorporates into the AC output the converted electrical energy.

84. The wind turbine of claim 83, wherein the inverter is a bi-directional inverter.

85. The wind turbine of claim 84, wherein the converted electrical energy is used to correct power factor.

86. The wind turbine of claim 83, wherein the wind turbine converts the kinetic energy of the at least one wind driven blade into electrical energy via reducing the movement of the at least one wind driven blade.

87. The wind turbine of claim 83, wherein the wind turbine is stall regulated.

88. The wind turbine of claim 87, wherein the wind turbine is stall regulated under a predetermined condition.

89. The wind turbine of claim 88, wherein the predetermined condition is selected from a group consisting of a predetermined blade movement speed, a power output limit, and a startup condition.

90. The wind turbine of claim 83, wherein the inverter is located in close proximity to the electrical output device.

91. The wind turbine of claim 90, the wind turbine further comprising:

a housing, wherein the electrical output device and the inverter are located within the housing.

92. A wind generator blade for reducing wind noise, the blade being usable upon rotation via a hub point in a downwind direction from an interfering body, the interfering body producing a cross-sectional area of interference, the blade comprising:

a root portion in proximity to the hub point; and

a swept body portion extending to a tip;

wherein, during rotation of the blade, the root portion enters the cross-sectional area of interference while the swept body portion and the tip remain outside the cross-sectional area of interference, and wherein the root portion exits the cross-sectional area of interference prior to the tip portion completely entering the cross-sectional area of interference.

93. The blade of claim 92, wherein the blade comprises a flexible material.

94. The blade of claim 92, wherein the blade is formed of glass reinforced polyester.

95. The blade of claim 92, wherein the blade is formed from at least two blade sections.

96. The blade of claim 95, wherein the at least two blade sections are joined in the direction of the extending body portion.

97. The blade of claim 92, wherein each of the at least two blade sections includes reinforcing ribbing.

98. The blade of claim 92, wherein the blade is formed using a multi-part injection mold.

99. A wind generator blade, comprising:

a first blade portion, the first blade portion having a first blade wall portion encompassing a generally concave first blade area; and

a second blade portion the second blade portion having a second blade wall portion encompassing a generally concave second blade area, the second blade portion being abuttably assembleable with the first blade portion such that at least one chamber is formed therebetween.

100. The wind generator blade of claim 99, wherein each of the first blade portion and the second blade portion are formed using injection molding.

101. The wind generator blade of claim 99, wherein each of the first blade portion and the second blade portion are formed using compression molding.

102. The wind generator blade of claim 99, wherein each of the first blade portion and the second blade portion include reinforcing ribbing, the reinforcing ribbing being located within at least one of the generally concave first blade area and the generally concave second blade area.

103. A yaw assembly for maintaining an electrical coupling between an electrical device, having an electrical device housing, and an attached device moveable relative thereto, the yaw assembly including:

a yaw;

a slidable engagement feature engaged with the yaw, slidable engagement of the slidable engagement feature allowing slidable movement of the electrical device housing relative to the attached device;

slip connection features coupled to the electrical device;

a variably coupleable mechanism connected to the attached device and engageable with the slip connection features, such that the electrical device is coupleable to the variable coupleable mechanism via the slip connection features; and

flexibly operating features engaged with the yaw to dampen transmission of vibration with the yaw.

104. The yaw assembly of claim 103, wherein the yaw is attached to the attached device.

105. The yaw assembly of claim 103, wherein the attached device is a tower.

106. The yaw assembly of claim 103, wherein the electrical device is an alternator.

107. The yaw assembly of claim 103, wherein the electrical device is a wind turbine.

108. the yaw assembly of claim 103, wherein the electrical device moves rotationally relative to the attached device.

109. The yaw assembly of claim 103, wherein the slidable engagement feature includes a bearing.

110. The yaw assembly of claim 103, wherein the slip connection feature includes a slip ring.

111. The yaw assembly of claim 103, wherein the slip connection feature includes a separator adjacent the slip ring.

112. The yaw assembly of claim 103, wherein the electrical device includes a circuitry device.

113. The yaw assembly of claim 112, wherein the circuitry device includes a printed circuit board.

114. The yaw assembly of claim 112, wherein the slip connection feature is attached to the circuitry device.

115. The yaw assembly of claim 103, wherein the variably coupleable mechanism includes a brush.

116. The yaw assembly of claim 103, wherein the variably coupleable mechanism includes a holding feature.

117. The yaw assembly of claim 103, further comprising:

a biasing mechanism for biasing the variably coupleable mechanism in contact with the slip connection feature.

118. The yaw assembly of claim 117, wherein the biasing mechanism includes a spring.

119. The yaw assembly of claim 103, wherein the variably coupleable mechanism is coupled to an output line.

120. The yaw assembly of claim 119, wherein the variably coupleable mechanism is coupled to the output line via at least one rigid coupling device.

121. The yaw assembly of claim 103, further comprising:

a shield for shielding the yaw assembly.

122. The yaw assembly of claim 103, wherein the flexibly operating features include at least one bushing.

123. The yaw assembly of claim 122, wherein the at least one bushing is comprised of a flexible material.