Power conversion and energy storage device

• US 8,963,356 B2
• Filed: 01/23/2012
• Issued: 02/24/2015
• Est. Priority Date: 01/21/2010
• Status: Active Grant

• Current Assignee: American Hydro Jet Corporation
• Original Assignee: America Hydro Jet Corporation
• Inventors: Roos, Paul W.
• Primary Examiner(s): ZARROLI, MICHAEL C
• Application Number:
  US13/356,288
• Publication Number:
  US 20120169054A1
• Time in Patent Office: 1,128 Days
• US Class Current: 290/52
• CPC Class Codes: F03B 13/083 The generator rotor being mounted as turbine rotor rim
• CPC Class Codes: F03B 3/04 with substantially axial flow throughout rotors, e.g. propeller turbines rotors per se F03B3/126
• CPC Class Codes: F03B 3/18 Stator blades; Guide conduits or vanes, e.g. adjustable conduits in dams or the like F03B13/08; arrangement of valves F03B11/004
• CPC Class Codes: H02K 1/148 Sectional cores H02K1/141 takes precedence
• CPC Class Codes: H02K 1/278 Surface mounted magnets; Inset magnets
• CPC Class Codes: H02K 11/0094 Structural association with other electrical or electronic devices
• CPC Class Codes: H02K 11/05 Rectifiers associated with casings, enclosures or brackets
• CPC Class Codes: H02K 11/33 Drive circuits, e.g. power electronics H02K11/38 takes precedence
• CPC Class Codes: H02K 2213/12 Machines characterised by the modularity of some components
• CPC Class Codes: H02K 5/08 Insulating casings
• CPC Class Codes: H02K 5/12 specially adapted for operating in liquid or gas combined with cooling arrangements H02K9/00
• CPC Class Codes: H02K 5/1285 of the submersible type
• CPC Class Codes: H02K 5/203 specially adapted for liquids, e.g. cooling jackets
• CPC Class Codes: H02K 7/086 radially supporting the rotor around a fixed spindle; radially supporting the rotor directly H02K7/09 takes precedence
• CPC Class Codes: H02K 7/088 radially supporting the rotor directly
• CPC Class Codes: H02K 7/14 Structural association with mechanical loads, e.g. with hand-held machine tools or fans with fan or impeller for cooling the machine H02K9/06
• CPC Class Codes: H02K 7/1823 structurally associated with turbines or similar engines
• CPC Class Codes: H02K 9/19 for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
• CPC Class Codes: Y02E 10/20 Hydro energy

Abstract

Power conversion device including: a first fluid conduit; a diffuser attached thereto with at least one vane supporting a diffuser hub; a rotor supported by the diffuser hub and having a rotor blade, hub, and shroud at the periphery thereof with at least one magnet thereon; a housing surrounding the shroud and attached to the diffuser, and having a stator including laminations forming poles and at least one coil therearound, the stator encapsulated in a non-metallic compound to prevent fluid contact with laminations and coil(s); a commutation control connected to the coil(s) and having external leads; and a second fluid conduit attached to the housing so fluid flow causes a torque load on the blades, rotating the rotor and inducing a magnetic field in the poles to generate current in the coil, converting hydraulic power to electric power. The device operates as a turbine/generator and as a motor/pump.

Claims

1. A power conversion device comprising:

a first fluid conduit;

a diffuser attached to the first fluid conduit and having at least one vane supporting a hub of the diffuser;

a rotor rotatably supported by the hub of the diffuser and having at least one rotor blade, a rotor hub, and a shroud at the periphery of the rotor, the shroud having at least one magnet mounted thereto;

a housing surrounding the shroud and attached to the diffuser, the housing having a stator including laminations forming poles and at least one electric coil around the poles, the stator being encapsulated in a non-metallic compound such that fluid is prevented from contacting the laminations and the at least one electric coil;

a fluid-lubricated bearing integral with the stator and supporting the rotor and having lubrication slots located between the poles;

at least one commutation control device connected to the at least one electric coil and having external power leads; and

a second fluid conduit attached to the housing,

whereby a flow of fluid through the power conversion device causes a torque load on the rotor blades, rotating the rotor and inducing a magnetic field in the poles, generating an electric current in the at least one electric coil, converting hydraulic power to electric power.

2. The power conversion device of claim 1 wherein the diffuser is removably attached to the housing.

3. The power conversion device of claim 1 wherein the stator is removably attached to the housing.

4. The power conversion device of claim 1 wherein the stator includes at least two stator segments, each segment having at least one pole and at least one electric coil.

5. The power conversion device of claim 4 wherein each stator segment is removably attached to the housing.

6. The power conversion device of claim 4 wherein the stator segments are isolated from fluid by encapsulation with a non-metallic compound.

7. The power conversion device of claim 1 further including a circumferential band holding the at least one magnet to the rotor.

8. The power conversion device of claim 1 wherein the at least one magnet is encapsulated with a non-metallic compound.

9. The power conversion device of claim 1 wherein the rotor includes rotor segments and each rotor segment has at least one rotor blade and a shroud segment.

10. The power conversion device of claim 9 wherein the shroud segments each have at least one magnet.

11. The power conversion device of claim 1 including at least one cooling duct.

12. The power conversion device of claim 11 whereby the cooling fluid flowing through the at least one cooling duct is at least one of the fluid flowing through the power conversion device and an alternate fluid from a separate source.

13. The power conversion device of claim 11 whereby the at least one cooling duct is in the housing.

14. The power conversion device of claim 11 further including a cooling insert which includes the at least one cooling duct and surrounds the stator.

15. The power conversion device of claim 14 wherein the at least one commutation control device is attached to the cooling insert, and the cooling insert, the stator and the at least one commutation control device are isolated from the fluid by encapsulation with a non-metallic compound.

16. The power conversion device of claim 14 wherein the stator and the at least one cooling insert are isolated from the fluid flowing through the power conversion device by encapsulation with a non-metallic compound.

17. The power conversion device of claim 14 wherein (i) the stator includes at least two stator segments, (ii) each cooling insert includes at least one cooling insert segment attached to each stator segment, (iii) each stator segment has at least one pole and at least one electric coil, and (iv) each cooling insert segment has at least one cooling duct.

18. The power conversion device of claim 17 wherein the at least one commutation control device is attached to the at least one cooling insert segment, and each stator segment and the at least one commutation control device are isolated from the fluid by encapsulation with a non-metallic compound.

19. The power conversion device of claim 17 wherein the at least two stator segments and the cooling insert segments are isolated from the fluid flowing through the power conversion device by encapsulation with a non-metallic compound.

20. The power conversion device of claim 1 wherein the at least one commutation control device links the electric coils directly to the external power leads.

21. The power conversion device of claim 1 wherein the at least one commutation control device controls the torque between the rotor and the stator by controlling the electric current through the at least one electric coil.

22. The power conversion device of claim 1 wherein the at least one commutation control device is configured to control fluid flow rate by controlling rotor rotational speed.

23. The power conversion device of claim 1 wherein the at least one commutation control device is configured to substantially maximize the product of torque and rotor rotational speed as the fluid flow rate varies.

24. The power conversion device of claim 1 further including an electric load bank and the commutation control device is configured to control the electric current to the external power leads and the load bank to keep the torque load on the rotor substantially constant as the load on the external power leads varies.

25. The power conversion device of claim 24 wherein the load bank is located in the at least one stator vane.

26. The power conversion device of claim 1 wherein the at least one commutation control device is cooled by at least one of the housing and the diffuser.

27. The power conversion device of claim 1 including a track and hoist configured to transport the power conversion device between an operating position and a service position.

28. The power conversion device of claim 27 wherein the track and hoist are configured to rotate the power conversion device about an axis perpendicular to the rotational axis of the rotor.

29. The power conversion device of claim 27 further including at least one quick-release fluid-conduit connecting clamp configured to facilitate the transfer of the power conversion device between the operating position and the service position.

30. The power conversion device of claim 1 including a track and carriage configured to transport the power conversion device from an operating position to a service position.

31. The power conversion device of claim 1 further including a penstock connected to the first fluid conduit to direct fluid to the device from an upstream fluid reservoir through the power conversion device and the second fluid conduit to a downstream fluid reservoir.

32. The power conversion device of claim 31 also including an electric current source, the current source and the at least one commutation control device being configured to operate the power conversion device in a pump mode and a power generating mode, the pump mode including the application of electric current to the external power leads, causing a magnetic field to drive the rotor and pump fluid up the penstock to the upstream fluid reservoir, thereby converting electrical energy to stored hydraulic energy which is later converted back to electrical energy when the power conversion device operates in power generation mode.

33. The power conversion device of claim 31 wherein the penstock is configured to operate as a siphon to connect the upper reservoir to the first fluid conduit.

34. The power conversion device of claim 33 also including an electric current source, the current source and the at least one commutation control device being configured to operate the power conversion device in a pump mode and a power generating mode, the pump mode including the application of electric current to the external power leads, causing a magnetic field to drive the rotor and pump fluid up the penstock to prime the siphon.

35. The power conversion device of claim 33 further including a shut-off valve placed between the first fluid conduit and the penstock and a fluid supply valve placed in the penstock such that when the shut-off valve is closed and fluid is supplied through the fluid supply valve, the penstock fills with fluid until the siphon is primed, and when the shut-off valve opens, the power conversion device operates in power generation mode.

36. The power conversion device of claim 33 further including a vacuum pump to prime the siphon by drawing a vacuum at substantially the highest point of the penstock.

37. The power conversion device of claim 1 wherein the device is placed over an opening in a weir.

38. The power conversion device of claim 1 further including at least one auxiliary turbine in at least one of upstream and downstream positions in relation to the power conversion device and having at least one drive shaft rotatably connecting the power conversion device rotor to an at least one rotor of the at least one auxiliary turbine, whereby the at least one auxiliary turbine drives the rotor of the power conversion device.

39. The power conversion device of claim 1 also including an electric current source, the current source and the at least one commutation control device being configured to operate the power conversion device in a pump mode and a power generating mode, the pump mode including the application of electric current to the external power leads, causing a magnetic field to drive the rotor and pump fluid from the second fluid conduit, through the housing, diffuser and first fluid conduit, thereby converting electric power to hydraulic power while operating in pump mode.

40. A power conversion device comprising:

a first fluid inlet;

a diffuser with (a) at least one vane supporting a hub of the diffuser and (b) a rotor rotatably supported by the hub of the diffuser and having (i) rotor blades, (ii) a rotor hub, and (iii) a shroud at the periphery of the rotor, the shroud including at least one magnet mounted thereto;

a housing surrounding the shroud and having a rigidly-attached stator including laminations, a plurality of poles, and at least one electric coil;

a fluid-lubricated bearing integral with the stator and supporting the rotor and having lubrication slots located between the poles; and

a source of electric current connected to the at least one electric coil,

whereby the electric current generates a magnetic field producing a torque on the at least one magnet, rotating the rotor and causing the rotor blades to pump fluid through the housing, the diffuser and the fluid inlet, thereby converting electric power to hydraulic power.

41. The power conversion device of claim 40 including a track and hoist configured to transport the power conversion device between an operating position and a service position.

42. The power conversion device of claim 41 wherein the track and hoist are configured to rotate the power conversion device about an axis perpendicular to the rotational axis of the rotor.

43. The power conversion device of claim 41 further including at least one quick-release fluid-conduit connecting clamp configured to facilitate the transfer of the power conversion device between the operating position and the service position.

44. The power conversion device of claim 40 including a track and carriage configured to transport the power conversion device from an operating position to a service position.

45. The power conversion device of claim 40 wherein the diffuser is removably attached to the housing.

46. The power conversion device of claim 40 wherein the stator is removably attached to the housing.

47. The power conversion device of claim 40 wherein the stator includes at least two stator segments, each segment having at least one pole and at least one electric coil.

48. The power conversion device of claim 47 wherein each stator segment is removably attached to the housing.

49. The power conversion device of claim 47 wherein the stator segments are isolated from fluid by encapsulation with a non-metallic compound.

50. The power conversion device of claim 40 further including a circumferential band holding the at least one magnet to the rotor.

51. The power conversion device of claim 40 wherein the at least one magnet is encapsulated with a non-metallic compound.

52. The power conversion device of claim 40 wherein the rotor includes rotor segments and each rotor segment has at least one rotor blade and a shroud segment.

53. The power conversion device of claim 52 wherein the shroud segments each have at least one magnet.

54. The power conversion device of claim 40 including at least one cooling duct.

55. The power conversion device of claim 54 whereby the cooling fluid flowing through the at least one cooling duct is at least one of the fluid flowing through the power conversion device and an alternate fluid from a separate source.

56. The power conversion device of claim 54 whereby the at least one cooling duct is in the housing.

57. The power conversion device of claim 54 further including a cooling insert which includes the at least one cooling duct and surrounds the stator.

58. The power conversion device of claim 57 wherein the stator and the at least one cooling insert are isolated from the fluid flowing through the power conversion device by encapsulation with a non-metallic compound.

59. The power conversion device of claim 57 wherein (i) the stator includes at least two stator segments, (ii) the cooling insert includes at least one cooling insert segment attached to each stator segment, (iii) each stator segment has at least one pole and at least one electric coil, and (iv) each cooling insert segment has at least one cooling duct.

60. The power conversion device of claim 59 wherein the at least two stator segments and the cooling insert segments are isolated from the fluid flowing through the power conversion device by encapsulation with a non-metallic compound.

61. A power conversion device comprising:

a first fluid conduit;

a diffuser attached to the first fluid conduit and having at least one vane supporting a hub of the diffuser;

a rotor rotatably supported by the hub of the diffuser and having at least one rotor blade, a rotor hub, and a shroud at the periphery of the rotor, the shroud having at least one magnet mounted thereto;

a housing surrounding the shroud and attached to the diffuser, the housing having a stator including laminations forming poles and at least one electric coil around the poles, the stator being encapsulated in a non-metallic compound such that fluid is prevented from contacting the laminations and the at least one electric coil;

at least one commutation control device connected to the at least one electric coil and having external power leads;

a fluid-lubricated bearing integral with the stator and having lubrication slots located between the poles;

a second fluid conduit attached to the housing; and

an electric power source,

whereby the application of electric current from the electric power source to the external power leads causes a magnetic field to drive the rotor and pump fluid from the second fluid conduit, through the housing, diffuser and first fluid conduit, thereby converting electric power to hydraulic power.

62. The power conversion device of claim 61 wherein the at least one commutation control device links the electric coils directly to the external power leads.

63. The power conversion device of claim 61 wherein the at least one commutation control device controls the torque between the rotor and the stator by controlling the electric current through the at least one electric coil.

64. The power conversion device of claim 61 wherein the at least one commutation control device is configured to control fluid flow rate to control rotor rotational speed.

65. The power conversion device of claim 61 wherein the at least one commutation control device is cooled by at least one of the housing and the diffuser.

66. The power conversion device of claim 61 wherein the at least one commutation control device is attached to a cooling insert, and the cooling insert, the stator and the at least one commutation control device are isolated from the fluid by encapsulation with a non-metallic compound.

67. The power conversion device of claim 66 wherein the at least one commutation control device is attached to at least one cooling insert segment, and each stator segment and the at least one commutation control device are isolated from the fluid by encapsulation with a non-metallic compound.

68. A power conversion system providing electric power to at least one external load, the system having a plurality of power conversion devices in fluid series and a system controller, each power conversion device comprising:

a first fluid conduit;

a diffuser attached to the first fluid conduit and having at least one vane supporting a hub of the diffuser;

a rotor rotatably supported by the hub of the diffuser and having at least one rotor blade, a rotor hub, and a shroud at the periphery of the rotor, the shroud having at least one magnet mounted thereto;

a housing surrounding the shroud and attached to the diffuser, the housing having a stator including laminations forming poles and at least one electric coil around the poles, the stator being encapsulated in a non-metallic compound such that fluid is prevented from contacting the laminations and the at least one electric coil;

at least one commutation control device connected to the at least one electric coil and having external power leads connected to at least one external load; and

a second fluid conduit attached to the housing,

and the system controller is configured to apportion the electric power to the at least one external load among the plural power conversion devices.

69. The power conversion system of claim 68 whereby the rotors are connected by at least one drive shaft, rotatably coupling the rotors.