AU2015100513A4

AU2015100513A4 - Flexible Roof Mounting System for Small Wind Turbine Generators

Info

Publication number: AU2015100513A4
Application number: AU2015100513A
Authority: AU
Inventors: Weixin Yuan
Original assignee: J LIU & W YUAN
Current assignee: J LIU & W YUAN
Priority date: 2015-04-18
Filing date: 2015-04-18
Publication date: 2015-05-21
Anticipated expiration: 2023-04-18

Abstract

The invention provides a flexible roof mounting system for mounting various types of small wind turbine generators above the ridge or a surface of tiled or metal roofs. The system comprises: a tubular mast (2) for mounting a small wind turbine generator thereon; the mast (2) is to be inserted on a mast seat (14) welded on the mast base assembly (3); the mast is fixed by inner and outer reinforcing plates (12, 13) and two supporting rod assemblies (5); the mast base assembly (3) is supported above the roof by six telescopic support members (4); the length of the telescopic support member (4) can be adjusted to reach battens of different spacing; the opening angle between the telescopic support members (4) on both sides of the mast base assembly can be adjusted to fit a wide range of roof pitch angles; j [W3[~ ir-it- <A / lot. Figi

Description

1 FLEXIBLE ROOF MOUNTING SYSTEM FOR SMALL WIND TURBINE GENERATORS FIELD [0001] The present invention relates to a system for mounting a small wind turbine generator above the ridge or a surface of a tiled or metal roof. BACKGROUND [0002] Conventionally, a small wind turbine generator can only be mounted on the ground with the turbine mast to be fitted on embedded bolts of a concrete foundation. The ground installation of a small wind turbine generator involves soil testing, trenching, concreting and lifting of a wind turbine mast and turbine components. These ground construction works contribute to a considerable amount of the cost of a small wind turbine generator project and in many cases making a small wind project not financially viable. [0003] In the current small wind industry in Australia, there have been small wind turbine projects using antenna roof mounting structures for micro wind turbine installations on a roof top. One known example is to use a tripod structure. Such tripod structures are commonly used in mounting antenna to a roof. In this tripod structure a mast is used to support a small wind turbine above the roof; two supporting rods are used to support the wind turbine mast on the roof. This tripod structure is originally designed for light weighted antenna mounting on the roof top and therefore not suitable for a 2 small wind turbine that is much heavier than an antenna. Tripod structures as these have problems coping with the complex loading from the wind turbine structure and transferring such loading to the roof structure in a balanced manner. [0004] Another similar known example is to use steel guy wires to support the wind turbine mast on a roof top. In order to achieve acceptable stability of the mast, a set of three or more guy wires need to be used to pull the mast from the roof anchorage points. For a relatively higher mast, two or more sets of guy wires along the height of the turbine mast are required to increase the rigidity of the mast. Such guy wire installations do not necessarily simplify the roof mounting tasks. The available roof anchorage points for the guy wires will be very different from roof to roof, and this will require a structural assessment for each guy wired installation. [0005] The present innovation provides an alternative and flexible installation method for roof mounted small wind turbine generator projects by allowing a small wind turbine to be mounted on the ridge or a surface of a pitched tiled or metal roof. SUMMARY OF INVENTION [0006] Roof structures on Australian domestic houses or industrial buildings varies in batten spacing, pitch angle, roofing material and so on. In order to have a standardised roof installation system to mount various types of small wind 3 turbines on different roofs throughout Australia, a flexible roof mounting system needs to be developed. The present invention has features with flexibility and stability which are described here by the following aspects. [0007] According to the first aspect of the invention, there is a mast supporting structure for mounting various types of small wind turbine generators on the ridge or a surface of a tiled and metal roof. A tubular wind turbine mast is fixed on a mast base assembly whose main body is a square hollow section. The mast base assembly is to be placed in parallel to the batten rows of the roof. When installed, the mast base assembly does not have direct contact with the roof as it is supported by six telescopic support members with three on each side of the mast base body. This feature distinguishes the invention from most currently applied small wind turbine mounting systems, wherein the mast base will have to be directly contacting and supported by the roof. Due to the ever changing nature of the wind loads, such direct roof contacting point between the mast and the roof will have to withstand the structural vibration and the wind loads. The advantage of the present invention is the system can distribute the structural vibration and wind loads evenly through the six telescopic support members onto the roofing structure. At the end of each telescopic support member, there is a reversed T shaped footing plate. For metal roofs, the footing plates at both sides of the mast base assembly are to be mounted to the suitable battens through the metal roof with two or more long screws. For a tiled roof, tile hooks will be used to connect two long rails, one on each side of the mast base assembly to the suitable rafters or battens, then the footing plates will be mounted on the top of the rails by screws or bolts.

4 [0008] According to the Second aspect of the invention, there are provided telescopic support members whose length can be adjusted to suit batten spacing of different standard roofing structures. Each telescopic support member is a telescopic support assembly which provides support and connection between the mast base assembly and roof. The telescopic support assembly includes an outer telescopic sleeve, an inner telescopic sleeve and a telescopic thread rod. The outer and inner telescopic sleeves are square hollow sections and fixed together by bolt connection. The telescopic thread rod is a solid round steel rod with outer threads that can be screwed into the inner threads at the lower end of the inner telescopic sleeve. The top of the outer telescopic sleeve has a welded lug so that it can be bolted on the counter part on the mast base assembly. The bottom of the telescopic thread rod has a similar welded lug to be bolted on the footing plate. [0009] According to the third aspect of the invention, there are provided design features allowing an opening angle between the two telescopic support members on both sides of the mast base assembly to be adjustable. The two telescopic support members can be adjusted to achieve a wide range of angles so that the mast structure can be mounted on the ridge or on a surface of most pitched roofs. Three connecting plates are welded on the mast base assembly; each of these connecting plates is designed to connect two telescopic support members. At the lower part of each connecting plate, below the bottom surface of the mast base body, there are three through holes with one at the upper centre and two at each lower corner. The welded-on lug of the outer telescopic sleeve of each telescopic support member has a through hole at the upper centre of the lug plate, and a long through hole in arc shape 5 at the lower centre of the lug plate. The opening angle of the telescopic support members between both sides of the mast base assembly is adjusted by using the arc long through holes when mounting two telescopic support members onto a connecting plate of the mast base assembly. [0010] According to the forth aspect of the invention, there are provided design features to limit the wind turbine mast's movement in the longitudinal and transverse directions of the mast base assembly. A short steel pipe section is welded on the top surface of the mast base body at the centre. Two inner reinforcing plates and two outer reinforcing plates are used to limit the turbine mast's movement in the mast base's longitudinal direction. A long hex head bolt connection is used to tighten the mast and the two sets of inner and outer reinforcing plates together. On both sides of the mast base assembly, between the middle telescopic support member and the wind turbine mast, there is a supporting rod assembly to provide support to the mast and stop the mast from moving along the transverse direction of the mast base assembly. The supporting rod assembly comprises a supporting sleeve and a supporting thread rod. The supporting rod is to be turned into and out of the support sleeve by thread connection. This thread connection allows the length of the supporting rod assembly to be adjusted according to the opening angle between the two telescopic support members, while still providing rigid support to the mast. [0011] According to the fifth aspect of the invention, there is provided a mast base system that can fit with different mast designs to mount different types of small wind turbine generators thereon. One mast top design is to have a counter 6 flange welded on the mast top with four or more stiffeners. Another mast top design is to have several through holes to mount a small wind turbine generator to the mast by sleeve connection. Either horizontal axis or vertical axis small wind turbine generators can be mounted on the roof top using the present invention. BREIF DESCRIPTION OF DRAWINGS [0012] Figure 1 illustrates the side view of a small wind turbine generator mounted on the ridge of a roof by the flexible roof mounting system. [0013] Figure 2 illustrates the perspective view of the flexible roof mounting system mounted on the ridge of a roof. [0014] Figure 3 illustrates the side view of the assembled flexible roof mounting system mounted on a surface of a pitched roof. [0015] Figure 4 illustrates connection between the flexible roof mounting system and the metal (tin) roof structure. The figure shows the installation on metal (tin) roof where the footing plate is to be mounted on the roof and suitable battens using long screws (not shown); [0016] Figure 5 illustrates connection between the flexible roof mounting system and the tiled roof structure. The figure shows the installation on a tiled roof where tile hooks are 7 used to connect two rails to the rafters of the roof. The footing plates are then mounted on the rails; [0017] Figure 6 illustrates the perspective view of the mast base assembly. [0018] Figure 7 illustrates the perspective view of the outer telescopic sleeve, the top component of a telescopic support member. [0019] Figure 8 illustrates the expanded cross sectional view of the welded-on lug plate at the top of the outer telescopic sleeve. [0020] Figure 9 illustrates the expanded view of the welded on side connecting plate of the mast base assembly. [0021] Figure 10 illustrates expanded side view of the assembled status of two telescopic support members on the side connecting plate of the mast base assembly. [0022] Figure 11 illustrates the front view of the mast base assembly. [0023] Figure 12 illustrates the front view of the mast base assembly at complete installation status. This figure shows how the two inner reinforcing plates, the two outer 8 reinforcing plates and the mast are bolted together to stop the mast from moving in the longitudinal direction of the mast base body. [0024] Figure 13 illustrates the side view of the mast base assembly at complete installation status. This figure shows how the two supporting rod assemblies are connected between the mast and the telescopic support member to stop the mast from moving in the transverse direction of the mast base body. [0025] Figure 14 illustrates the expanded perspective view of the centre of the mast base assembly. This figure shows how the reinforcing plates and the supporting rod assemblies are working together to provide rigid support to the mast. [0026] Figure 15 illustrates flange connection between the turbine mast and the small wind turbine generator. [0027] Figure 16 illustrates sleeve connection between the turbine mast and the small wind turbine generator. [0028] Figure 17 illustrates the side view of the flexible roof mounting system that can be fitted with different mast top designs for mounting various types of small wind turbine generators thereon.

9 DESCRIPTION OF EMBODIMENTS [0029] Mounting locations on any roof top are subjected to a certain degree of turbulence from the wind. When deciding the mounting location of a small wind turbine generator on the roof top, the designer and installer should consider locations where the turbine should have minimum turbulence from the surroundings, the roof structure is strong and the working space is safe for the installation. The turbine location must have safe distance from potential hazards like overhead power lines. [0030] Installation of a small wind turbine generator on a roof using this flexible roof mounting system is to integrate the turbine and the mounting system into the roof building structure. Necessary steps will have to be taken to ensure the integrated structure meets and exceeds applicable regulations and laws. As a general guideline, the design of this flexible roof mounting system should be reviewed and certified by a qualified structural engineer according to applicable wind loading standards and building codes. Installation should strictly follow the installation manual. Site specific roof structure assessment should be performed for commercial sites to ensure the roofing structure is suitable for the project purpose. [0031] The embodiments of the current invention will be described in the following paragraphs. [0032] The first embodiment is illustrated in Figure 1, 2 and 4. Figure 4 uses a partial side view to show how the flexible 10 roof mounting system is applied to mount a small wind turbine generator 1 (small wind turbine generator as shown on Figure 1) above the ridge of a pitched metal roof 60. The first embodiment represents a most common application of the flexible roof mounting system and it incorporates most features of the invention. Referring now to Figure 1 and 2 for the side view and perspective view of the flexible roof mounting system, the system comprises a small wind turbine generator mast 2, a mast base assembly 3, six telescopic support members 4 and two supporting rod assemblies 5. [0033] The mast base assembly 3 is placed above the ridge of the roof with its length in parallel with the ridge line. Three telescopic support members 4 are bolted on each side of the mast base assembly 3 by two side connecting plates 15 (shown on Figure 6) and one middle connecting plate 16 (shown on Figure 6). Figure 6 provides a perspective view of the mast base assembly. Now refer to Figure 7 and 8, hole 32 and long hole 33 in arc shape on the welded-on lug plate 17 of the outer telescopic sleeve 6 are bolted on hole 30 and 31 on the connecting plates 15 and 16 of the mast base assembly 3. Referring back to Figure 4, the footing plate 9 at the other end of each telescopic support member 4 is screwed on the metal roof 60, through the metal roofing material (tin) 61, into the selected row of batten 62. In order to suit the pitched angle of the roof, a suitable opening angle between the telescopic support members 4 on both sides of the mast base assembly 3 is achieved by adjusting the angle using the long hole 33. This adjustment is illustrated on Figure 10. The length of the telescopic support member can be adjusted to the exact distance between hole 30 and the selected battens on the roof. As illustrated by Figure 4, to adjust the length of the telescopic support assembly, a coarse adjustment is done by 11 adjusting the bolt connection between the outer telescopic sleeve 6 and the inner telescopic sleeve 7, then a fine adjustment is done by adjusting the thread connection between the inner telescopic sleeve 7 and the telescopic rod 8. [0034] At the centre of the top surface of the mast base assembly 3, there is a welded on wind turbine mast seat 14 as shown on Figure 6 and Figure 11. As shown on Figure 12, when the wind turbine mast 2 is placed on the mast seat 14, two inner reinforcing plates 12 and outer reinforcing plates 13 will stop the mast from moving in the longitudinal direction of the mast base assembly 3. The wind turbine mast 2 and the four reinforcing plates 12, 13 are bolted together by bolt connection 40. [0035] Now refer to Figure 1 and Figure 4, in order for the turbine mast 2 to be at upright position, the lengths of the two supporting rod assemblies 5 will have to be adjusted. This adjustment is achieved through adjusting the thread connection between the supporting sleeve 11 and the supporting rod 10. As also shown on Figure 12, when suitable lengths are achieved, the supporting rod assemblies 5 are bolted to the mast 2 by bolt connection 44 and the telescopic support assembly member 4 by bolt connect 45. When bolted, both supporting assemblies can stop the mast 2 from moving in transverse direction of the mast base assembly 3. Figure 13 is the expanded side view of such arrangement. Figure 14 is the expanded perspective view showing how the turbine mast 2 is fixed on the mast base assembly 3 when installed.

12 [0036] The second embodiment is illustrated in Figure 1, 2 and 5. Figure 5 uses a partial side view to show how the flexible roof mounting system is applied to mount a small wind turbine generator 1 (small wind turbine generator as shown on Figure 1) above the ridge of a pitched tiled roof 64. The second embodiment represents another very common application of the flexible roof mounting system. The tiled roof embodiment uses the same flexible roof mounting system except for additional two rails 18 and tile hooks 19 are used to achieve connection between the mounting system and the tiled roofing structure. [0037] Now refer to Figure 5, before installation, the installer requires to determine a suitable row of batten 67 to work on. According to the installation manual, mark the positions of the tile hooks 19 with proper spacing between each tile hook along the selected batten (67) on each side of the ridge. The tile 65 immediately above the tile hook 19 position will have to be pushed upward to give enough working space for the installer to screw the tile hook on the rafter 68 at a proper position above the selected batten 67. When the tile hook 19 is mounted to its position on the rafter 68, the tile 65 can be moved back to its original position to cover the lower part of the tile hook 19. After all tile hooks are installed, and above tiles are back to position, the rails 18 can be mounted onto the tile hooks. Then footing plates 9 of each telescopic support member 4 can be mounted on the rails 18. [0038] Use the same method as described in the first embodiment to adjust the length of each telescopic support member to the exact distance between hole 30 on the connecting 13 plate 15 of the mast base assembly 3 and mounting hole (not shown) on top of the rails 18. The rest of the installation and features of the roof mounting system are the same as those described in the first embodiment. [0039] The third embodiment is illustrated in Figure 3 using a partial side view to show how the flexible roof mounting system is applied to mount a small wind turbine generator 1 (small wind turbine generator as shown on Figure 1) on a surface of a pitched metal roof 69. [0040] In this embodiment, instead of mounting the flexible roof mounting system on the ridge of a pitched metal or tiled roof, the system can be mounted on any flat surfaces. Figure 3 depicts but one example of mounting a small wind turbine generator 1 on a pitched surface of a tin roof 69. In this example, the opening angle between two telescopic support members 4 has been adjusted to its maximum value to reach the right battens 70 and 73 under the tin roof 71. The adjustment method of this opening angle has been described in the first embodiment. The adjustment method of the length of the telescopic support members 4 is the same as that described in the first embodiment. The left and right supporting rod assemblies 5, comprising a supporting sleeve 11 and supporting rod 10, are adjusted differently to ensure the mast 2 at its upright position. The adjustment method is the same and has been described in the first embodiment. [0041] Although the present invention has been described with reference to the above described embodiments, it will be appreciated by those skilled in the art that the invention is 14 not restricted in the described applications. It will be also appreciated that a variety of modifications and changes (for instance, varied dimensions of the components) can be made without departing from the principles of the invention. Therefore, it is understood that the invention includes all such modifications and changes within its scope. [0042] In the claims which follow and in the preceding description of the invention, unless the context requires otherwise, the word "comprise" or its variations such as "comprises" or "comprising" is to be understood to imply the inclusion of a started integer or group of integers but not the exclusion of any other integer or group of integers. [0043] It is to be understood that, if any prior art publication is referred to throughout this specification, such reference does not constitute an admission that the publication forms a part of the common knowledge in the art, in Australia and other countries.

Claims

1. A flexible roof mounting system for a small wind turbine generator, the system comprises: A tubular mast for mounting a small wind turbine generator of various types thereon through flange or sleeve connection; A mast base assembly for mounting the tubular mast thereon; the main body of the said mast base assembly is a square hollow section with three welded-on connecting plates and four welded-on reinforcing plates; Six telescopic support members bolted to the said connecting plates, three on each of two sides of the mast base assembly, to support the mast base assembly above the ridge or a surface of a metal or tiled roof; In addition to above said components, if on a tiled roof, two rails for mounting the said telescopic support members thereon; In addition to above said components, if on a tiled roof, a number of tile hooks to mount the said rails on the rafters or battens of the tiled roof.

2. A flexible roof mounting system as claimed in claim 1 wherein the length of each telescopic support members can be adjusted to suit different batten spacing of various roofing structures. Each of the telescopic support members is an assembly comprising an outer telescopic sleeve, an inner telescopic sleeve, a telescopic thread rod and a footing plate. The outer and inner telescopic sleeves are square hollow sections. The inner telescopic sleeve is to be inserted 2 into the outer telescopic sleeve and bolted together. The telescopic thread rod is a solid steel rod with outer threads that can be screwed into the inner threads at the bottom of the inner telescopic sleeve. The total length of the telescopic support assembly is adjustable by two mechanisms: the first adjustment is by adjusting the insertion of the inner telescopic sleeve into the outer telescopic sleeve and locking both square hollow section sleeves by bolt connection; the second adjustment is to turn the telescopic support rod in and out of the inner telescopic sleeve by the thread connection between the rod and the inner sleeve. At the end of each telescopic support member, there is a reversed T shaped footing plate. For metal roofs, the footing plates at both sides of the mast base assembly are to be mounted through the metal roof to the battens with two or more long screws. For a tiled roof, tile hooks will be used to mount two long rails to the suitable rafters or battens. Then the footing plates will be mounted on the top of the rails by screws or bolts.

3. A flexible roof mounting system as claimed in claim 1 wherein the opening angle between the telescopic support members on both sides of the mast base assembly is adjustable. The two telescopic support members can be adjusted to achieve a wide range of angles so that the system can be mounted on the ridge or on a flat surface of most roofs. Three connecting plates are welded on the mast base assembly and each of these connecting plates is designed to connect two telescopic support members with one on each side of the mast base assembly. At the lower part of each connecting plate, there are three through holes, one at the upper centre and two at 3 each lower corner. The welded-on lug at the top of the outer telescopic sleeve of each telescopic support member has a through hole at the upper centre and a long through hole in arc shape at the bottom centre. The opening angle of the telescopic support members between both sides of the mast base assembly can be adjusted by using the arc long through holes when mounting two telescopic support members onto a connecting plate of the mast base assembly.

4. A flexible roof mounting system as claimed in claim 1 wherein design features can stop the wind turbine mast from moving in the longitudinal and transverse directions of the mast base assembly. A short steel pipe section is welded on the top surface of the mast base body at the centre. Two inner reinforcing plates and two outer reinforcing plates are used to limit the turbine mast's movement in the mast base's longitudinal direction. A long hex head bolt is used to tighten the mast and the two sets of inner and outer reinforcing plates together. On both sides of the mast base assembly, between the middle one of the three telescopic support members and the wind turbine mast, there is a supporting rod assembly to provide support to the mast and stop the mast from moving in the transverse direction of the mast base assembly. The supporting rod assembly comprises a supporting sleeve and a supporting thread rod. The supporting rod is to be turned into and out of the supporting sleeve by thread connection between the two components. This thread connection allows the length of this supporting rod assembly to be adjusted according to the opening angle between the two telescopic support members, while still providing rigid support to the mast. 4

5. A flexible roof mounting system as claimed in claims 1 to 4 wherein the mast base assembly can be used to support small wind turbine generators of different types by changing the connecting interface between the mast top and the turbine. One mast top design is to have a counter flange to be welded on the mast top with four or more stiffeners. Another mast top design is to have several through holes to mount a small wind turbine generator to the mast by sleeve connection. Both horizontal axis and vertical axis small wind turbine generators can be mounted on the roof top using the present invention.