Arc-shaped horn-shaped long-stroke micro-hydropower device suitable for adapting to flat flow conditions of a small stream

Abstract

The application discloses an arc-shaped ox horn package clamping long-stroke micro water power generation device suitable for small creek flat flow conditions and belongs to the technical field of distributed small micro hydro power generation. The application is aimed at the low flow speed and low water head flat flow runoff conditions of small creeks in mountainous areas, sets a 6-degree centripetal inclined deep groove blade structure, optimizes the blade spacing and groove depth, effectively avoids the centrifugal force loss under the low-speed large-torque operation condition, cooperates with the large-angle arc-shaped ox horn package flow channel to prolong the effective working stroke of water bodies, and combines a non-contact labyrinth seal structure to completely eliminate water body leakage and mechanical operation loss. The application is based on general electric control devices to construct special working condition regulation and control logic, forms a creek water peak valley staggered peak regulation mechanism, can realize power grid low valley water storage energy, high peak energy release full-load operation in linkage with external water storage structures, supports multi-unit cascade series, parallel expansion distributed arrangement, effectively solves the technical pain points of low working efficiency, no peak regulation capacity and water energy resource waste of traditional small creek micro power generation, and is suitable for the application scenes of national small creek distributed clean energy development and rural micro power grid construction.

Description

Technical Field

[0001] This invention belongs to the fields of distributed clean energy, micro-hydropower generation and rural microgrid technology. Specifically, it relates to an arc-shaped horn-shaped long-stroke micro-hydropower generation device adapted to the working conditions of natural streams in mountainous areas with flat flow, low flow velocity, low water head and no high pressure drop. It is suitable for the development of fragmented hydropower resources in wild streams, distributed power supply in rural areas, and off-grid power generation in remote areas. It is also compatible with the requirements for large-scale construction of distributed power generation in China and the review of foreign-related technology applications. Background Technology

[0002] Existing micro-hydropower equipment suffers from significant structural defects and shortcomings in adaptability to operating conditions. Traditional micro-hydro turbines generally adopt a large-diameter, narrow-blade impact structure. Once the runner blades deviate from the horizontal centerline, the water's confinement capacity quickly fails, easily leading to water escape and loss of the working medium, resulting in extremely low water energy utilization efficiency. Furthermore, traditional equipment has shallow blade slots and sparse blade arrangement, resulting in insufficient water capacity, a short effective working stroke, and premature water release, failing to fully utilize the secondary gravitational potential energy of the water. Moreover, the traditional structure is adapted for high-speed operation; when applied to low-head, horizontally flowing scenarios like streams, it easily generates ineffective centrifugal force, offsetting the working torque of the water and further reducing power generation efficiency.

[0003] Meanwhile, traditional equipment mostly adopts a contact-type sealing structure, which results in high mechanical friction loss and significant lateral leakage. In complex hydrological environments in the field, it is prone to siltation and equipment failure, leading to high operation and maintenance costs. Existing micro-hydro turbine equipment only has passive flow-following power generation capabilities and lacks dedicated peak-shaving scheduling logic adapted to the flat-flow conditions of streams. It cannot adapt to the peak-valley load fluctuations of the power grid, resulting in the waste of hydropower resources during off-peak hours and insufficient power generation output during peak hours. It is difficult to meet the integrated operation requirements of modern microgrids, thus restricting the large-scale development and utilization of fragmented hydropower resources in mountain streams. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing micro-water power generation equipment, such as large centrifugal losses, low water energy utilization, lack of adaptive peak-shaving capability, and poor adaptability to operating conditions. It provides an arc-shaped horn-shaped long-stroke micro-water power generation device adapted to the laminar flow conditions of streams. By independently optimizing mechanical structure parameters and creating a unique peak-shaving power generation control logic specific to streams, it achieves efficient, stable, and intelligent utilization of low-head laminar flow water energy. It has substantial innovation, meets the standards for invention patent examination, and is compatible with domestic dual-application and foreign-related confidentiality review requirements.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: The core mechanical body of this device consists of a frame, a low-speed load-bearing main shaft, an optimized blade impeller, a horn-shaped gradient inlet guide channel, a two-stage planetary speed-increasing mechanism, and a low-speed permanent magnet generator. This is an original structure independently designed by the inventor. Addressing the centrifugal loss defects of traditional water turbines under low-speed conditions, this invention abandons the traditional shallow-channel blade structure and uniquely arranges the blades with a radial plane inclination of 3° to 6° (depending on the blade length) centripetally, with a uniform blade spacing of 100mm. The standard preferred blade channel depth is 139mm. This allows for adaptive fine-tuning based on the horn-shaped gradient trajectory and actual stream conditions, significantly increasing water capacity and adapting to a low-speed, high-torque operating mode. It fundamentally avoids ineffective centrifugal force loss under low-head, horizontal flow conditions, maximizing the conversion of water's gravitational potential energy.

[0006] This invention features a unique arc-shaped horn-shaped clamping long-stroke working structure. The opening height of the central arc-shaped clamping plate is 145°, and the lower arc-shaped clamping plate is 135°. The parameters can be finely adjusted according to the gradually expanding angle of the horn-shaped clamping plate to adapt to the water flow trajectory. This confines the incoming water flow to the 210° position in the lower half of the impeller, effectively extending the working stroke of the water's gravity and achieving secondary continuous pressurization of the water flow. This solves the industry pain points of insufficient work done by the water flow in horizontal streams and low water energy utilization. It is equipped with a convex-concave non-contact labyrinth water-blocking channel, eliminating mechanical friction loss and completely preventing lateral water leakage, making it suitable for long-term stable operation in muddy water conditions in the field.

[0007] The power transmission system adopts a dedicated low-speed matching scheme. Through the matching combination of a 34r / min low-speed main shaft, a 14:7 two-stage planetary speed increaser, and a 500rpm low-speed permanent magnet generator, it achieves low-loss and high-stability power frequency output. The standard unit can stably achieve a rated power output of 20kW, and the overall power generation efficiency of the whole machine can reach 88% to 90%.

[0008] This invention's control system relies on commercially available programmable electronic control components as its hardware carrier. Based on self-compiled proprietary operating condition control logic, it constructs an adaptive peak-shaving scheduling system for micro-generation of streams. The hardware itself utilizes existing mature technology, while the core protection features proprietary adaptive control strategies. This invention innovatively employs a low-head stream peak-valley linkage control mechanism, which can match the stream runoff characteristics with grid load changes in real time. It links with external water storage structures to achieve low-valley water storage and energy storage, and peak-hour energy release for full-capacity operation, overcoming the technical shortcomings of traditional stream power generation, such as the lack of intelligent peak-shaving and wasted water resources. For wide-area, high-flow streams, this invention can adopt a multi-unit horizontal parallel synchronous power structure to fully utilize surplus water resources, improve cluster power generation efficiency, and adapt to the large-scale power generation needs of streams of different sizes.

[0009] This device can realize a multi-unit, multi-level, series-connected distributed layout with no pressure head attenuation between units. It can be flexibly expanded according to the stream conditions and is suitable for the development of fragmented hydropower resources and the large-scale construction of microgrids in different regions of the country. Beneficial effects

[0010] First, this invention features independent core mechanical structure innovation, effectively solving industry technical pain points. It employs a unique 3° to 6° (depending on blade length) centripetal deep-groove blade structure, precisely matching low-speed, high-torque operating conditions and completely eliminating the power loss caused by centrifugal force in traditional water turbines. Combined with a large-angle horn-clamp long-stroke power-generating structure and a non-contact labyrinth sealing system, it significantly improves the utilization rate of low-head horizontal flow hydropower, breaking through the bottlenecks of traditional small-scale hydropower technology and demonstrating substantial innovation.

[0011] Secondly, this invention features innovative differentiated control logic. Based on general-purpose hardware, it independently developed a peak-shaving scheduling algorithm and linkage logic specifically for small streams, enabling the equipment to upgrade from passive flow-following power generation to active peak-shaving energy storage. This fills the technological gap in small stream micro-hydropower without adaptive peak-valley control and adapts to the integrated operation requirements of microgrid power generation, grid, load, and storage.

[0012] Third, it has a wide range of operating conditions and strong scalability. It is specifically adapted to low-flow-rate and non-high-pressure water head conditions in mountain streams, with a stable structure, anti-siltation, and low operation and maintenance costs. It supports multi-level series and multi-machine parallel batch replication and is suitable for the national distributed clean energy industry layout.

[0013] Fourth, the patent protection boundaries are clear, with no risk of breach of protection. The core protection focuses on the proprietary mechanical structure and unique adaptive control logic, while general-purpose purchased hardware is classified as prior art. The scope of protection is precise and legal, fitting the scope of the invention "an arc-shaped horn-shaped clamp long-stroke micro-water power generation device adapted to the horizontal flow conditions of a stream". Detailed Implementation

[0014] This embodiment is the optimal embodiment adapted to the year-round continuous flow of streams in mountainous areas. The device is an independently developed modular and innovative design, suitable for distributed installation in the field and multi-stage series and multi-unit parallel deployment, meeting the 20kW rated power generation requirement of a single unit.

[0015] The core preferred structural parameters of this embodiment are as follows: the blades are arranged with a centripetal inclination of 3° to 6°, the uniform spacing between adjacent blades is 100mm, and the blade groove depth is preferably 139mm; the water inlet angle of the arc-shaped bull horn clamping channel is 107°, the water release termination angle is 260°, the opening height of the total circle center bull horn arc clamping plate is 145°, and the height of the lower arc clamping plate is 135°, which can be adaptively fine-tuned according to the bull horn arc gradual release trajectory; the radial gap between the flow channel and the outer edge of the blade is 10mm, the non-contact gap of the labyrinth water-blocking groove is 5mm, and an integrated slag discharge channel is reserved at the bottom of the baffle.

[0016] Power system exclusive matching parameters: spindle rated speed 34r / min, matched with 14:7 speed ratio two-stage planetary speed increaser, stably drives 500rpm low speed permanent magnet synchronous generator, outputs 400V, 50Hz industrial frequency three-phase AC power, and the overall power generation efficiency of the whole machine is stable at 88%-90%.

[0017] Operation and control implementation method: A commercially available programmable electronic control module is used as the hardware carrier, equipped with the stream peak-shaving scheduling program independently compiled by this invention, to collect water flow, unit speed and grid load operation data in real time; during the off-peak electricity hours at night, the water storage structure is automatically closed to store water; during the peak electricity hours during the day, the water storage structure is automatically fully opened to supply water at full flow, so as to realize the unit's peak-shaving and full-load power generation and maximize the activation of natural stream hydropower resources.

[0018] Large-scale deployment: Multiple sets of independently developed devices are connected in series along the natural flow direction of the stream, and adjacent units are arranged using a small natural drop, with no head attenuation and multi-stage water energy reuse; for wide water surface and large flow stream conditions, multiple units can be arranged in parallel horizontally to work synchronously, expand capacity and increase efficiency, and the failure of a single unit will not affect the operation of the overall system, with strong fault tolerance and adaptability to the construction of distributed microgrid clusters.

[0019] The above description is only a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. However, any equivalent substitutions, parameter fine-tuning, scaling, multi-machine serial and parallel expansion and large-scale adaptation applications made based on the core mechanical structure, the arc-shaped bullhorn clamp long stroke working principle and the adaptive peak-shifting control core logic of the present invention shall fall within the scope of protection of the present invention. Attached Figure Description

[0020] Figure 1 Main view of the overall structure of the device. Shows the assembly structure of the entire device, the power transmission link and the relative positions of core components, reflecting the modular overall layout of the equipment.

[0021] Figure 2 Enlarged view of the turbine runner blade structure. Showing the core innovative structure of the 3° to 6° centripetal tilt blades, blade spacing, and standard tank depth, demonstrating the design features to prevent centrifugal force from doing work.

[0022] Figure 3 Schematic diagram of an arc-shaped horn-shaped flow channel. This diagram illustrates the horn-shaped flow channel's angle parameters, flow constraint trajectory, and the working principle of its long-stroke operation.

[0023] Figure 4 : Diagram of a non-contact labyrinth water-trap sealing structure. It showcases the staggered convex-concave non-contact sealing structure and the bottom slag discharge channel structure, demonstrating a lossless, leak-proof, and anti-sludge design.

[0024] Figure 5: Schematic diagram of multi-stage series-connected distributed layout. It shows the large-scale layout mode of multiple units connected in series and in parallel, demonstrating the characteristics of no head attenuation and cluster power generation adaptability.

Claims

1. A long-stroke micro-hydropower generation device with an arc-shaped bull's horn clamp, adapted to the horizontal flow conditions of a stream, comprising a frame, a low-speed load-bearing main shaft, a rotor, a blade assembly, a bull's horn-shaped gradually changing water inlet guide channel, a speed-increasing mechanism, and a low-speed permanent magnet generator, characterized in that: The blade assembly is fixed to the outer ring of the impeller. The blades are arranged at a centripetal inclination of 3° to 6° (depending on the blade length) relative to the radial plane of the impeller. The spacing between adjacent blades is 100mm, and the depth of the blade groove ranges from 135mm to 150mm (depending on the diameter). This structure is suitable for the low-speed, high-torque operation of the water turbine, and can effectively suppress hydraulic vortices and cavitation erosion, reduce centrifugal force loss under low-speed conditions, and enhance the continuous work performance of water gravity. The outer side of the impeller is fixed with a static arc-shaped bull's horn clamping flow channel. The arc-shaped constraint structure extends the water retention and work time, delays the water release time, effectively extends the gravity work stroke of the water flow, realizes multi-stage continuous pressurization of the water, and is suitable for the low head and horizontal flow conditions of the stream. The rotating wheel is symmetrically equipped with stationary baffles on both sides. An interlaced convex and concave rib non-contact water-blocking groove is arranged between the baffles and the end face of the rotating wheel. There is no mechanical friction loss, which can effectively block the lateral leakage of water and reduce water energy loss. The output end of the main shaft is sequentially connected to the speed-increasing mechanism and the low-speed permanent magnet generator, forming an integrated power transmission structure with low-speed high-torque input and stable power frequency power output. This device is equipped with an adaptive scheduling and control system adapted to the micro-power generation scenario of streams. It relies on general-purpose electronic control components to achieve linkage regulation of operating conditions. It can adaptively adjust the inflow of water according to the changes in peak and valley loads of the power grid, and link with the external water storage structure to complete the off-peak operation control of water storage and energy storage during low-valley periods and full power generation during peak periods.

2. The arc-shaped horn-shaped clamp long-stroke micro-hydropower generation device adapted to the horizontal flow conditions of a stream, as described in claim 1, is characterized in that: The opening height of the arc-shaped bullhorn clamp plate is 145°, the height of the lower arc-shaped clamp plate is 135°, the water entry starting (center) angle is 107°, the water release ending angle is 260°, and the radial gap between the flow channel and the outer edge of the blade is set to 10mm~15mm. It is suitable for low-speed, high-torque working conditions and can adaptively fine-tune the angle parameters according to the bullhorn arc-shaped gradual release trajectory to match different stream flow trajectories.

3. The arc-shaped horn-shaped clamp long-stroke micro-hydropower generation device adapted to the horizontal flow conditions of a stream, as described in claim 1, is characterized in that: The blade groove depth is preferably 139mm, and the uniform spacing between adjacent blades is 100mm. The blades are welded from Q235B steel plates (or aluminum alloy castings) and rigidly connected to the runner hub. This device can be scaled and adapted proportionally to the overall diameter of the turbine, the width of the blade working surface, and the blade depth according to the width of the stream and the flow rate, so as to meet the power generation needs of different power levels. Under the condition of large flow and wide water surface, a multi-unit parallel synchronous power generation structure can be adopted to improve the overall power generation efficiency. All equivalent structures with proportional scaling, condition adaptation adjustment, and multi-unit parallel layout fall within the scope of protection of this patent.

4. The arc-shaped horn-shaped clamp long-stroke micro-hydropower generation device adapted to the horizontal flow conditions of a stream, as described in claim 1, is characterized in that: The labyrinthine water-blocking trough adopts a bidirectional staggered convex-concave structure with a non-contact gap of 4mm to 6mm. A through-type slag discharge channel is opened at the bottom of the stationary baffle, which can automatically settle and discharge water silt and debris, avoid siltation and blockage in the cavity, and is suitable for complex hydrological operating conditions in the field.

5. The arc-shaped horn-shaped clamp long-stroke micro-hydropower generation device adapted to the horizontal flow conditions of a stream, as described in claim 1, is characterized in that: The speed-increasing mechanism adopts a two-stage planetary speed increaser with a speed-increasing ratio of 14:

7. The input end is equipped with an overload clutch protection structure, which matches the main shaft's low-speed input speed of 34r / min. It can stably drive a 500rpm low-speed permanent magnet generator to output 400V industrial frequency three-phase AC power.

6. The arc-shaped horn-shaped clamp long-stroke micro-hydropower generation device adapted to the horizontal flow conditions of a stream, as described in claim 1, is characterized in that: Multiple power generation units can be connected in series in multiple stages along the direction of the stream. Adjacent units are only equipped with small overflow drops, with no pressure head attenuation. The gravitational potential energy of the water flow can be reused in multiple stages, making it suitable for distributed and large-scale layout of mountain streams.

7. The arc-shaped horn-shaped clamp long-stroke micro-hydropower generation device adapted to the horizontal flow conditions of a stream, as described in claim 1, is characterized in that: The adaptive scheduling and control system is built upon a general-purpose programmable electronic control module, utilizing existing mature hardware technology. Through a self-compiled operating condition adaptation program, it collects water flow parameters, generator operating parameters, and grid load parameters in real time, adaptively matching the opening and closing degree of the water storage structure to achieve efficient peak-shaving utilization of the stream's hydropower. All equivalent substitutions, parameter fine-tuning, proportional scaling, multi-unit series-parallel expansion, and large-scale application structures based on the core mechanical structure and proprietary control logic of this invention fall within the protection scope of this invention.

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