"PROGRESSIVE HYDROKINETIC ENERGY CONVERTER"
FIELD OF THE INVENTION
The present invention refers to a mechanical device for progressive hydrokinetic energy conversion to be used both in mobile and stationary drive units in order to provide significant increase of the system overall yielding, thus resulting a better performance without higher fuel consumption.
BACKGROUND OF THE INVENTION
Energy conversion devices are more and more used due to growing environmental concerns about the consumption of fossil fuels. There is an ever-growing demand for energy conversion systems having optimized yielding, in order to obtain the best possible performance with the lowest energy consumption.
The U.S. Patent 4,777,846, having the same author, discloses one said energy conversion device. Basically, the energy conversion device is a torque conversion device wherein a shaft provided with straight teeth is coupled to a shaft provided with helicoidal teeth by means of an external rotating sleeve. The power inlet is made through the shaft with straight teeth, which transfers the energy to the external rotating sleeve that in turn transfers the energy to the shaft with helicoidal teeth. In this first stage, the whole set comprising the sleeve, the shaft with straight teeth, and the shaft with helicoidal teeth has the same rotation, and the power in the device inlet is the same power in the device outlet.
An energy increase is obtained in the device outlet by means of linear movement of a non-rotating piston externally coupled to said rotating sleeve. This effect is reached because the force exerted over the external rotating sleeve is transferred to the shaft with helicoidal teeth. As it is clear for those skilled in the Art, the linear force exerted over the helicoidal teeth
generates a vector force component crosswise the shaft, thus resulting in a torque increase in the device outlet. The rotation in the device outlet also increases, thus resulting a general power increase and consequently better yielding. As shown in this patent, there is a duplicated device to guarantee continuous power gain in the outlet. Furthermore, a turbine driven by the shaft with helicoidal teeth provides storage of kinetic energy, thus allowing the device to work some time without external energy supply.
However, the device as described in said patent has several deficiencies. Firstly, spherical pins are used to couple the external sleeve to the shafts. The use of said spherical pins causes the early wear of shafts. Since the force applied to the sleeve is high and the pins are fixed towards the sleeve, the existing friction between the shaft and pins is very high. Therefore, the device does not present a long working life, and its industrial application becomes unviable. Furthermore, the sleeve is mechanically driven by means of a piston rod coupled to a gear set. This design causes two problems: (i) high wear of mechanical components due the high system rotation and force exerted on the pistons; and (ii) since the linear speed of the sleeve depends on the rotation of the inlet shaft of the device, the sleeve and the piston rod tend to a self-acceleration, which makes them reach very high speeds, causing vibrations and early wear of parts.
Furthermore, external sleeves are duplicated in a single body.
Since they have two sections, i.e. one section with straight teeth to be coupled to the shaft with straight teeth and another section with helicoidal teeth to be coupled to the shaft with helicoidal teeth, its industrial manufacturing is highly complex. It is impossible to manufacture it in commercial scale machines, but only with highly specialized tools, making it becomes expensive and commercial unviable.
Therefore, it is the object of the present invention to solve the problems found in the previous Art.
It is also an object of the present invention to provide a hydrokinetic energy converter having a low mechanical wearing rate of its parts, in order to grant a longer work life.
Another object of the present invention is to provide a progressive hydrokinetic energy converter wherein the linear movement of the rotating sleeve does not depend on the rotation of the shafts.
Another object of the present invention is to provide a progressive hydrokinetic energy converter that solves the vibration problems as found in the previous Art.
Another object of the present invention is to provide a progressive hydrokinetic energy converter wherein its external rotating sleeve can be manufacture in commercial scale. BRIEF DESCRIPTION OF THE INVENTION
The progressive hydrokinetic energy converter of the present invention comprises a power inlet shaft having a section provided with straight teeth, a power outlet shaft having a section provided with helicoidal teeth, and an external rotating sleeve coupling said power inlet shaft to said power outlet shaft in the corresponding toothed sections. Therefore, the sleeve has a section internally provided with straight teeth, which is coupled to the straight teeth section of the power inlet shaft, and a section internally provided with helicoidal teeth, which is coupled to the helicoidal teeth section of the power outlet shaft. Re-circulating spheres are provided between the sleeve and the shafts, in order to guarantee low friction between the parts.
The power inlet shaft also comprises a gear provided with a ratchet on the opposite end of the straight teeth section. Similarly, the power outlet shaft is provided with a gear, but with no ratchet, on the opposite end of
the helicoidal teeth section, near the converter outlet.
Furthermore, the progressive hydrokinetic energy converter comprises a non-rotating piston externally coupled to said external rotating sleeve. The piston is coupled to the sleeve by means of axial load ball or roller bearings and radial load ball or roller bearings. The piston is contained inside a shell forming two hermetical chambers separated by the center of the piston. The coupling also allows the linear movement of the piston inside the shell.
The progressive hydrokinetic energy converter also comprises a flywheel for kinetic energy storage, a hydraulic pump, and a hydraulic turbine provided with an external housing and internal vanes. A drive pulley is coupled to the power inlet shaft by means of a sleeve, being also coupled to the external housing of the hydraulic turbine. The progressive hydrokinetic energy converter of the invention additionally comprises a hydraulic and lubricating circuit and a flow-directing valve. By means of belts, said drive pulley drives the hydraulic pump and the flywheel. The flywheel in turn is driven by means of a transmission comprising a shaft supported by bearings, one pulley on one end of the shaft, and a conical gear on the opposite end of said shaft. The pulley on the shaft of the transmission is coupled to the drive pulley by means of a belt, and the conical gear is coupled to a conical gear on the flywheel shaft. The flywheel shaft is also supported by bearings and forms an angle difference of 90° between the shaft of the transmission and the shaft of the flywheel shaft. The transmission multiplies the rotation of the flywheel; therefore, the rotation of the flywheel is higher than the rotation of the drive pulley. The hydraulic pump feeds the hydraulic and lubricating circuit, in conjugation with said flow-directing valve.
The power outlet shaft prolongs concentrically through said power inlet shaft and said sleeve, reaching the hydraulic turbine. The power outlet
shaft couples to the vanes of said hydraulic turbine.
The power inlet shaft, the power outlet shaft, the external rotating sleeve, the shell and the flow-directing valve are integers that comprise the main system of the invention. According to a preferred embodiment herein described and illustrated, the main system is juxtaposed to a secondary system, forming a duplicated system. However, the power outlet shaft of the secondary system does not prolong concentrically through the power inlet shaft and through the sleeve, being specifically coupled to the main system. Therefore, the coupling of the main system to the secondary system is made by the power inlet shaft gear of the main system, which is coupled to an intermediate gear, which is in turn coupled to the inlet shaft gear of the secondary system. Similarly, the power outlet shaft gear of the secondary system is coupled to an intermediate gear, which is in turn coupled to the power outlet shaft gear of the main system. An external drive force drives the progressive hydrokinetic energy converter of the present inventions by means of the drive pulley. A drive unit, e.g. an electrical motor, internal combustion motors, vapor, turbine motors or any other appropriate type, may generate the external drive force.
BRIEF DESCRIPTION OF THE DRAWINGS The progressive hydrokinetic energy converter of the invention, its objects, enhancements and effects will be evident for those skilled in the Art from the detailed description presented below, with references to the attached Figures, given only as illustrations of specific embodiments of the invention. Said Figures are schematic and their dimensions and proportions may not correspond to reality, since they only aim to illustrate the invention didactically, not imposing any other limitations than those of the claims as presented further below.
Figure 1 is a cross section view of the progressive hydrokinetic
energy converter of a preferred embodiment of the invention;
Figure 2 is a detailed cross section view of the main system of a preferred embodiment of the invention;
Figure 3 is a transversal section view of the duplicated system of a preferred embodiment of the invention;
Figures 4a and 4b are exploded views of the rotating sleeve of a preferred embodiment of the invention; and
Figure 5 is a scheme of the hydraulic and lubrication circuit of a preferred embodiment of the invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Figure 1 shows the progressive hydrokinetic energy converter (100) comprising a housing (101) inside which is disposed a drive pulley (102) provided with grooves (104), (105). The drive pulley is coupled to the power inlet shaft (301) by means of a sleeve (107), and couples the external housing (109) of the hydraulic turbine (108). By means of a belt (not shown), the drive pulley (102) is coupled to the transmission pulley (201) of the flywheel (208). The groove (104) is coupled to the pulley (501) of the drive unit (500), as shown in Figure 5, by means of a belt (not shown). The groove (105) is coupled to the pulley (503) of the hydraulic pump (502), shown in Figure 5, by means of a belt (not shown).
Despite the progressive hydrokinetic energy converter uses pulleys with belts in its preferred embodiment, other mechanical couplings, such as gears, may be used, not changing the scope of the present invention.
Still referencing to Figure 1 , the flywheel (208) transmission comprises a shaft (202) supported by bearings (203), (204), a pulley (201) on one end of said shaft (202) and a conical gear (205) on the opposite end. The conical gear (205) is coupled to the conical gear (206) of the flywheel (208) shaft (207), also supported by bearings (209), (210). The transmission shaft
(202) and the flywheel shaft (207) form an angle difference of 90° between each other. The transmission multiplies the rotation; therefore, the rotation the flywheel (208) is higher than the rotation of the drive pulley (102).
Still on Figure 1 , the hydraulic turbine (108) comprises an external housing (109) coupled to the drive pulley (102). The hydraulic turbine is provided with internal vanes (110) coupled to the power outlet shaft (302). The power outlet shaft is not coupled to the power inlet shaft (301) and one of its end prolongs concentric internally through the power inlet shaft (301 ) to the internal vanes (110) of the hydraulic turbine (108) and the other end prolongs to the outlet (312) of the converter. Therefore, the power outlet shaft (302) and the power inlet shaft (301) rotate independently.
Figure 2 shows that the main system (300) comprises a power inlet shaft (301) provided with a straight teeth section (303), a power outlet shaft (302) provided with a helicoidal teeth section (304). As mentioned above, one end of the power outlet shaft (302) prolongs concentric internally through the power inlet shaft (301) and the sleeve (107) to the internal vanes (110) of the hydraulic turbine (108), and the other end prolongs to the outlet (312) of the converter. The main system (300) also comprises an external rotating sleeve (305) coupling the power inlet shaft to the power outlet shaft on the toothed sections. Said sleeve (305) comprises an internal straight teeth section (307), which is coupled to the straight teeth section (303) of the power inlet shaft (301), and a helicoidal teeth section (306) which is coupled to the helicoidal teeth section (304) of the power outlet shaft (302). Re-circulating spheres (308) are provided between the sleeve (305) and the shafts (301), (302), thus guaranteeing low friction between components.
The power inlet shaft (301) also comprises a gear (309) provided with a ratchet (311) on the opposite end of the straight teeth section. Similarly, the power outlet shaft (302) comprises a gear (310), but with no ratchet, on the
opposite end of the helicoidal teeth section (304), previously located towards the progressive hydrokinetic energy converter outlet (312).
Furthermore, the main system (300) comprises a non-rotating hydraulic piston (313) externally coupled to said external rotating sleeve (305). The piston is coupled to the sleeve by means of axial load ball or roller bearings (314) and radial load ball or roller bearings (315). The piston (313) is contained within a shell (316) forming two hermetic chambers (317), (318) separated by the center (319) of said piston. The coupling also allows the linear movement of the piston (313) inside the shell (316). The chambers (317), (318) are provided with conduit passages (320), (321) respectively, each one in communication with the hydraulic and lubricating circuit as shown in Figure 5. The hydraulic piston (313), at the end of its forward course, touches the first bascule (322) which in turn activates the flow-directing valve (506), shown on Figure 5. The valve (506) directs the oil flow through the chamber (317) of the hydraulic piston (313). Similarly, the piston, at the end of its return movement, touches a second bascule (323) which in turn activates said flow-directing valve (506). The valve (506) directs the oil flow through the chamber (318), thus moving the piston forward again.
The main system (300), as better shown on Figures 3 and 5, is coupled to a secondary system (300') forming the duplicated system protected by a housing (325). The power outlet shaft (302') of the secondary system (300') does no concentrically prolong through the power inlet shaft, since the secondary system is solely coupled to the main system. The coupling is made by the gear (309) of the power inlet shaft (301) of the main system, which is coupled to an intermediate gear (326), which is in turn coupled to the gear (309') of the inlet shaft of the secondary system (300'). Similarly, the gear (310) of the power outlet shaft (302) of the main system is coupled to an intermediate gear (327), which is in turn coupled to the gear (310') of the power outlet shaft
(302') of the secondary system (300').
The drive unit (500) shown by Figure 5 generates the external drive force, activating the progressive hydrokinetic energy converter by means of the drive pulley (102). The drive unit may be any appropriate drive mean, such as an electric motor, internal combustion motors, vapor motors or turbines or any other appropriate type.
Now referring to Figures 4a and 4b, the rotating sleeve (305), according to a preferred embodiment of the invention, comprises two separated sections (401 ), (402). The first section (401) is internally provided with helicoidal teeth (403) and the second section (402) is internally provided with straight teeth (404). The sections (401), (402) are joined together by means of vertical teeth (405), (406) prolonging themselves through flanges (407), (408) of each section and fitting among each other. The junction has an external finishing ring (409). Figure 5 shows the hydraulic and lubrication circuit (504) according to a preferred embodiment of the invention. The hydraulic pump has two pressure lines (505), (513). The first pressure line (505) activates the piston (313) of the main system (300) and the second pressure line (513) activates the piston (313') of the secondary system (300'). The pump (502) pressurizes the oil, which passes through the conduit (505) and through the flow-directing valve (506) which in turn directs the oil flow to the conduit (507), (321) filling in the first chamber (318) of the hydraulic piston (313). The oil coming out from the second chamber (317) of the hydraulic piston (313) passes through the conduit (320), shown in Figure 2, and through the conduit (508) reaching the flow-directing valve (506) which in turn directs the oil flow to the conduit (509), lubricating the progressive hydrokinetic energy converter through the holes (323), as shown in Figure 2. The oil falls on a tray and is collected by the return conduit (510), passes through a heat exchanger (511) and returns afterwards through the
conduit (512) to the hydraulic pump. Similarly, the pump (502) pressurizes the oil, which passes through the conduit (513) and through the flow-directing valve (506) which in turn directs the oil flow to the conduit (514), filling in the second chamber of the piston (313'). The oil coming out from the first chamber of the piston (313') passes through the conduit (515) reaching the flow directing valve (506) which in turn directs the oil to the conduit (516), lubricating the secondary system (300'). The oil falls on a tray and is collected by the return conduit (510) passing through a heat exchanger (511) and returning by the conduit (512) to the hydraulic pump. According to the description above, it must be considered that the hydraulic circuit activates the main system piston in a forward movement and the secondary system piston in a return movement. When the piston touches the flow-directing valve, the oil flow direction, except for the pressure lines (505), (513), is inverted, moving the main system piston in a return movement and the secondary system piston in a forward movement. The hydraulic and lubrication circuit is also provided with a filter
(518) to clean the oil impurities and a tank (not shown) providing oil flow to the hydraulic pump through the conduit (517).
The operation of the progressive hydrokinetic energy converter in its preferred embodiment will be better understood with the following description.
The drive unit (500) drives the pulley (102) which in turn subsequently drives the power inlet shaft (301), the external housing (109) of the hydraulic turbine (108), the hydraulic pump (502) and the flywheel transmission. The flywheel transmission drives the flywheel (208). The power inlet shaft (301) transfers the rotating movement to the external rotating sleeve (306), which in turn transfers the movement to the power outlet shaft (302). Similarly, the gear (309) of the power inlet shaft (301) provides rotating movement to the secondary system (300'). The power outlet shaft (302) of the
main system (300) transfers the rotating movement to the internal vanes (110) of the hydraulic turbine (108). In this first stage, all rotating parts of the progressive hydrokinetic energy converter, with the exception of the flywheel and its transmission, have the same rotation. The drive pulley (102), sleeve (107), power inlet shaft (301), external rotating sleeve (305), power outlet shaft (302), both of the main system (300) and the secondary system (300'), the external housing (109) and the internal vanes (110) of the hydraulic turbine (108) have the same rotation, being the system balanced. As previously mentioned, the transmission of the flywheel (208) multiplies the rotation, and the flywheel (208) has a higher rotation then the drive pulley (102).
In a second stage, the hydraulic pump (502) is activated, and a small portion of the energy from the drive unit (500) is sent to the hydraulic pump, which feeds the hydraulic and lubrication circuit (504) with pressurized oil. Through the conduit (321), the pressurized oil is injected into the first chamber (318) of the hydraulic piston (313), displacing it linearly forward. The piston (313) moves with it the external rotating sleeve (305). Therefore, the pressure force as exerted by the oil is transferred to the sleeve (305) which in turn transfers it to the re-circulating spheres (308), which finally transfer the force to the helicoidal teeth (304) of the power outlet shaft (302) of the main system. As it is known form physics, the force exerted over the helicoids (304) can be decomposed into two components, one horizontal and the other vertical, depending on the helix (304) angle. The horizontal component does not have any influence in the result as provided by the progressive hydrokinetic energy converter of the invention. However, the vertical component increases significantly the torque in the outlet shaft (302) of the progressive hydrokinetic energy converter. It is also remarkable that the linear movement of the piston (313) increases the rotation of said power outlet shaft (302). Because of the conjunction of torque and rotation increase, the power in the outlet (312) also
increases.
The vertical component of the force exerted over the helicoids (304) depends on inclination angle. The inclination angle should be between 0° and 90°, preferably between 5° and 40° and, more preferably, about 15°. By the end of its forward course, the piston (313) touches a bascule (322) that activates the flow-directing valve (506), which in turn inverts the direction of the oil pressure. Pressurized oil starts to be injected into the second chamber (317) of the piston (313) through the conduit (320), and the pressurized oil is no longer injected into the first chamber (318). Therefore, the piston (313) is no longer in a forward movement, but in a return movement. Oil contained in the first chamber (318) exits through the same conduit (321) through which it entered. The return movement of the piston (313) then increases the rotation of the power inlet shaft (301 ). In order to avoid the increasing rotation of the power inlet shaft (301) from increasing the rotation of the drive pulley (102), the gear (309) ratchet (311) on the power inlet shaft provides a free wheel effect to said power shaft. Therefore, during the return movement of the piston (313), the power inlet shaft does not meet any resistance against the movement, and the energy coming from the drive pulley (102) is fully transferred to the secondary system (300') through the gear (309) of the power inlet shaft (301) of the main system (300). Similarly, the outlet power from the secondary system (300') is fully transferred to the gear (310) of the power outlet shaft of the main system.
As clearly shown, the power increase effect is only reached when the piston (313) is moving forward. Therefore, the main system and the secondary system work cooperatively. When the main system piston is moving forward, the secondary system piston is returning and vice versa. The outlet power increment (312) from the progressive hydrokinetic energy converter of the invention will be therefore always constant.
The forward movement speed of the piston no longer depends on the rotation of the progressive hydrokinetic energy converter shafts, and the piston can be moved very slowly independently from the shafts. The vibration problems of the previous device do not exist anymore. Furthermore, the force applied to the piston can vary according to the pressure exerted by the hydraulic pump, no longer depending on the converter speed, as occurs with the device of the prior Art. In addition, re-circulating spheres provide less friction and consequently lower wear of mechanical components.
As described above, the rotation of the power outlet shaft (302), when the piston is working, is higher than the rotation of the power inlet shaft (301) and consequently higher than the speed of the drive pulley (102) and the external housing (109) of the hydraulic turbine (108). Being the power outlet shaft coupled to the internal vanes (110) of the hydraulic turbine (108), the internal vanes tend to accelerate the external housing (109). Consequently, the drive pulley (102) is also accelerated, thus increasing its rotation and the rotation of all components coupled to it, like the power inlet shaft (301), the flywheel (208), the hydraulic pump (502) and the drive unit (500), thus tending the progressive hydrokinetic energy converter to a self-acceleration.
The drive unit (500) is provided with a ratchet (not shown) on its pulley (501). When the drive pulley (102) speed is increased, the ratchet decouples the drive unit (500) form the progressive hydrokinetic energy converter. Consequently, the progressive hydrokinetic energy converter is no longer driven by the drive unit, but only by the kinetic energy of the flywheel (208), thus allowing its operation for long periods of time without any external power supply. As the energy stored on the flywheel (208) is consumed, the progressive hydrokinetic energy converter starts to loose speed, including the drive pulley (102) that reaches again the rotation of the drive unit. The ratchet re-couples the drive unit (500) to the pulley (102) and the progressive hydrokinetic energy
converter is then driven again by the drive unit (500), re-starting the above- described cycle.
Therefore, there is a lower energy consumption by the drive unit, less pollution and higher yielding, among other advantages. It should be recognized that, although the invention has been described with relation to its preferred embodiment, those skilled in the Art can develop a wide variation of structural and operational details and expand the invention to other types of applications, but not deviating from the principles of the invention. The flywheel may be e.g. in vertical or horizontal position, requiring few adjustments in its transmission, or the pulley and belts may be substituted by gears with no change to the scope of the invention. Attached claims should therefore be understood as covering all equivalents included within the coverage and character of the invention.