Dynamic Ratio Speed Increaser for Windmills
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Solution Overview
Problem
Fluid driven rotary prime movers, such as windmills, face inefficiencies due to a mismatch in performance characteristics between turbines and generators, leading to unstable operation and the need for variable frequency drive control systems, which increase costs and reduce efficiency.
Innovation Solution
A speed increaser assembly featuring paired epicyclical gear systems with a two-generator design, allowing for optimal matching of turbine and generator performance over a wider operating range, minimizing the need for VFD control by distributing torque between two generators during high wind speeds and utilizing one generator as a motor during low wind speeds to optimize energy production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single generator is used with a traditional speed increaser, then the structure is simple, but the turbine and generator performance characteristics mismatch leading to unstable operation
Solution Approach 1:
The patent divides the single generator system into two separate generators, each connected to its own epicyclic gear set. This segmentation allows each generator to operate independently within its optimal performance range, improving operational stability and reliability while distributing the torque load across two separate drive paths.
Solution Approach 2:
The patent implements a dynamic speed increaser where the reduction ratio can vary based on operating conditions. The two epicyclic gear sets with different reduction ratios allow the system to dynamically adapt to varying wind speeds and torque conditions, enabling stable operation across a wider range of conditions without requiring complex active control systems.
2Reliability
If variable frequency drive control systems are added to match turbine and generator performance, then operational stability improves, but system cost and complexity increase
Solution Approach 1:
The patent replaces the need for electronic variable frequency drive control systems with a purely mechanical solution. The two epicyclic gear sets with different reduction ratios provide passive performance matching through their inherent mechanical characteristics, eliminating the need for complex electronic control while achieving the same goal of optimizing turbine-generator performance matching.
3Loss of energy
If the operating range is limited to maintain generator efficiency, then generator performance is optimized, but the window of opportunity for electricity generation decreases
Solution Approach 1:
By segmenting the power generation into two separate generators, each can operate within its own efficient range. The first generator handles high-torque low-speed conditions while the second generator handles lower-torque higher-speed conditions, effectively expanding the overall operating range without sacrificing efficiency in either regime.
Solution Approach 2:
The patent changes the reduction ratio parameter through the two different epicyclic gear sets. The first epicyclic gear set provides a first reduction ratio optimized for high-torque conditions, while the second provides a second reduction ratio optimized for lower-torque conditions, allowing the system to adapt to varying wind speeds and expand the effective operating range.
4Adaptability or versatility
If a two-generator design with paired epicyclic gear systems is implemented, then flexibility and operating range improve, but device complexity increases
Solution Approach 1:
The patent employs nested epicyclic gear systems where planets are meshed with both sun gears and annuli. This nested configuration allows compact arrangement of the two-generator system, reducing overall size and complexity while maintaining the benefits of dual generators with different reduction ratios. The shared annulus structure further integrates the two gear systems.
Solution Approach 2:
The patent merges two separate epicyclic gear systems into a unified structure where components are shared. The second annulus is rotationally connected to the first annulus, and both epicyclic systems share common structural elements, reducing the overall complexity compared to having completely separate systems while still providing independent torque paths to each generator.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances flexibility and efficiency by allowing generators to operate within stable conditions across varying wind speeds, increasing the 'window of opportunity' for electricity generation and reducing the reliance on VFD control systems, thereby improving overall energy production and reducing operational costs.
Implementation Method 1
The speed increaser includes a first epicyclic and a second epicyclic. The first epicyclic includes a first carrier rotationally connected to the turbine, a first sun rotationally connected to the first generator, a first annulus, and a first planet in meshing engagement with the first sun and the first annulus.
Data Source
AI summary
A fluid driven rotary prime mover assembly including a turbine, a first generator, a second generator and a speed increaser is provided. The gear assembly includes a first epicyclic and a second epicyclic. The first epicyclic includes a first carrier rotationally connected to the turbine, a first sun rotationally connected to the first generator, a first annulus, and a first planet in meshing engagement with the first sun and the first annulus. The second epicyclic includes a second carrier rotationally grounded, a second sun rotationally connected to the second generator, a second annulus connected to the first annulus, and a second planet in meshing engagement with the second sun and the second annulus.