US20130343897A1 - Helix Type Vertical Axis Turbine Blades and Method for Continuously Making Same - Google Patents
Helix Type Vertical Axis Turbine Blades and Method for Continuously Making Same Download PDFInfo
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- US20130343897A1 US20130343897A1 US13/783,683 US201313783683A US2013343897A1 US 20130343897 A1 US20130343897 A1 US 20130343897A1 US 201313783683 A US201313783683 A US 201313783683A US 2013343897 A1 US2013343897 A1 US 2013343897A1
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- 239000002184 metal Substances 0.000 claims abstract description 56
- 238000005452 bending Methods 0.000 claims 2
- 238000007493 shaping process Methods 0.000 claims 1
- 238000004513 sizing Methods 0.000 claims 1
- 230000009977 dual effect Effects 0.000 description 2
- 239000011888 foil Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000009751 slip forming Methods 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 1
- 235000021152 breakfast Nutrition 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 230000003467 diminishing effect Effects 0.000 description 1
- 235000012465 frozen bakery product Nutrition 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
Images
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D3/00—Wind motors with rotation axis substantially perpendicular to the air flow entering the rotor
- F03D3/06—Rotors
- F03D3/062—Rotors characterised by their construction elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D25/00—Working sheet metal of limited length by stretching, e.g. for straightening
- B21D25/02—Working sheet metal of limited length by stretching, e.g. for straightening by pulling over a die
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D53/00—Making other particular articles
- B21D53/78—Making other particular articles propeller blades; turbine blades
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/14—Form or construction
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D3/00—Wind motors with rotation axis substantially perpendicular to the air flow entering the rotor
- F03D3/06—Rotors
- F03D3/061—Rotors characterised by their aerodynamic shape, e.g. aerofoil profiles
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2220/00—Application
- F05B2220/70—Application in combination with
- F05B2220/706—Application in combination with an electrical generator
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2230/00—Manufacture
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2230/00—Manufacture
- F05B2230/50—Building or constructing in particular ways
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2240/00—Components
- F05B2240/20—Rotors
- F05B2240/21—Rotors for wind turbines
- F05B2240/211—Rotors for wind turbines with vertical axis
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2250/00—Geometry
- F05B2250/20—Geometry three-dimensional
- F05B2250/25—Geometry three-dimensional helical
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/74—Wind turbines with rotation axis perpendicular to the wind direction
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49316—Impeller making
- Y10T29/49336—Blade making
Definitions
- This application relates to vertical axis turbine blades and, more particularly, to sheet helical shape vertical axis turbine blades and methods of their continuous manufacture.
- This application claims priority to and is a continuation-in-part of provisional patent application Ser. No. 61/662,536 filed Jun. 21, 2012 to the extent allowed by law.
- savonius turbines When looking down on the rotor from above, having an S-shape in cross section, if it was of the two-blade variety.
- Savonius turbines are considered to be of the drag-type of device and are used whenever cost or reliability is more important than efficiency.
- Having a helix shaped vertical axis wind turbine blade provides a surface that will “catch” the wind from differing directions.
- the placement of dual helix shaped blades 180 degrees apart or triple helical shaped blades 120 degrees apart or quadruple helical blades 90 degrees apart provide for a reliable turbine configuration that aids in providing turbine rotation for just about any direction of wind passing thereby.
- Prior known vertical axis helically shaped blades have been built and constructed in a segmented faction because the outer curved edge area of a helically constructed turbine blade has a larger surface than the area thereof adjacent a vertical axis of each blade.
- the prior art discloses a plurality of segmented curved end blades that are stacked upon one another to provide an approximation of a helical shaped blade, as shown in U.S. Pat. No. 7,364,406.
- each turbine blade When a larger helically configured sheet is utilized in a vertical axis wind turbine, such as shown in advertising for Alternative Power Turbines Gale R15 series, the outer edge of each turbine blade is not vertically oriented as it is not parallel to the vertical axis of the turbine blade because of the extra surface area needed toward the outer edge of each blade.
- a helically shape turbine blade for use in a turbine that generates electrical and mechanical energy.
- the blade comprises a vertical inner edge having a length l.
- Like sized top and bottom edges of the blade each have a straight edge extending outwardly from the inner edge in a substantially straight line for a predetermined length, and thereafter curved into a semicircular shape.
- the amount of stretch needed to form the helix varies depending on the distance from the axis of rotation. For any point along the cross section of the helix, from the inside edge of the blade to the outer edge of the blade, the stretch can be calculated by the known vertical length of the blade and the length of the swept line created by the chosen point on the cross section when the turbine blade rotates around a center of rotation for the desired angle.
- the blade is made by feeding a sheet metal blank over metal dies to stretch the metal between the inner and outer edge thereof.
- the sheet metal blank is then formed and finally cut at a predetermined length.
- the metal form tools continuously press and form helically shaped metal blades.
- FIG. 1 is a top perspective view of a prototype segment of a vertical axis turbine blade constructed in accordance with the present invention
- FIG. 2 is a horizontal elevational view of the blade shown in FIG. 1 ;
- FIG. 3 is a schematic view of the top of a VAT blade as it would appear in finished form
- FIG. 4 is a diagrammatic sketch showing how to compute, by triangulation, the stretch needed to construct a helix form on sheet metal;
- FIG. 5 is a horizontal perspective view of the beginning of the dies and press for creating the helical blade of the invention
- FIG. 6 is a horizontal perspective view of the middle and end of the dies and press for creating the helical blade of the invention
- FIG. 7 is an end perspective view of the dies and press showing the formed turbine blade exiting the press
- FIG. 8 is a horizontal perspective view of the opposing side of the dies and press.
- the ability to continuously produce a helix shaped vertical axis turbine blade depends in large part on the correct stretching of an original metal sheet blank.
- the stretch is to accommodate a twist in the helix across its surface.
- the inside edge may be adapted to be mounted on either vertical axis or a center of rotation of the blade assembly.
- the axis can be a spine, backbone, stave, or simply a center of rotation and is preferably a straight vertical line.
- FIG. 1 a sheet metal prototype turbine blade segment 10 is shown in an upper 3 ⁇ 4 perspective view.
- FIG. 2 is a horizontal elevational view of the blade segment shown in FIG. 1 .
- the turbine blade segment 10 has an inner edge 12 , an upper edge 14 , an outer edge 16 , and a bottom edge 18 .
- the inner edge 12 has apertures or perforations 13 positioned in spatial relation to each other providing for mounting the inner portion of the turbine blade to a vertical axis or spine (not shown).
- the upper edge 14 of the helical turbine blade 10 extends outward from the top of the inner edge 12 in a substantially straight line for a predetermined length, and is thereafter curved into a semicircular shape at the end towards the outer edge 16 .
- the bottom edge 18 has the same kind of substantially straight line and is thereafter curved into a semicircular shape at the end towards the outer edge 16 as is the upper edge 14 .
- the outer edge 16 of the vertical blade segment 10 contacts the upper edge 14 and forms a helical shaped curvature between the top and bottom.
- FIG. 3 is a schematic top down view of the upper edge of the turbine blade.
- the substantially straight portion 32 of the upper edge extends from the end 36 connecting with the inner edge of the turbine blade.
- the other end of the upper edge that goes to the outer edge of the turbine blade is curved into a semicircular shape portion 34 outwardly of the substantially straight portion 32 .
- the semicircular shape portion 34 has a known radius.
- the semicircular portion 34 together with a substantially straight dimension 32 a from the inner edge of portion 34 to the center of rotation 38 , form the upper edge in a “J” shaped profile.
- the center of rotation 38 is slightly off the inner edge of the helical turbine blade ( FIG. 11 ). When the dual turbine blade is assembled ( FIG. 9 ), the center of rotation does not necessarily fall onto the body of the helical turbine blade as will be shown in more detail below.
- One way to view the length of the outer edge of the helical turbine blade is to think of the diagonal edge of a cardboard tube, such as seen in the packaging for a frozen bakery product like breakfast rolls, etc., or in the spiral edge of a cardboard tubular shipping container that eventually folds back on itself and is glued together. If the axis on the cardboard paper of the tubular spiral is turned vertical, a horizontal line between that axis along the circumference of the tube to that outer glue edge becomes the second side of a triangle and the diagonal edge becomes the third side. If we open up that tubular member somewhat to a semicircular position, that triangular relationship still exists.
- a three bladed turbine could have each blade manufactured to twist through 120° over a given length. Alternately, the blades could twist through a full 180° of rotation, or even more, over an increased length so as to increase the power output.
- the distance from the turbine center of rotation 38 to any specific point on the part profile is the radius used in calculating the swept line for that point.
- the part profile in this case is the “J” shaped turbine blade upper edge.
- the turbine blade sweeps an arc using the radius r for an angle that equals the included angle of the arc segment 34 determined above.
- the length of this arc is the swept line s, and it can be calculated by:
- the length l of the hypotenuse 40 is the square root of the vertical distance plus the horizontal distance squared.
- the stretch x is usually approximately 15% of the vertical distance v. Additionally, much of the inner part of the bent helix is correspondingly proportionally stretched, with the stretch diminishing toward the center of rotation.
- detents 53 and indents 50 flutes or inwardly closed louvers
- a metal forming press such as shown in FIG. 5 to provide the needed stretch (throughout) the metal sheet.
- the vertical axis turbine blade having a helical outline is formed in an automated press which is indexed to digitally feed the sheet metal blank 52 over the metal form 51 as shown in FIG. 5 .
- the outer side 54 of the form 51 adjacent the outer edge of the helix of the sheet has the “V” shaped indents 50 and detents 53 formed in it as shown in FIG. 5 .
- the inner edge of that form 51 has clamping members 57 positioned thereon to assure that the sheet 52 stays stationary when the press is in operation.
- the “U” shaped indents 50 and detents 53 are sized and shaped to follow the length of indexing of the sheet metal 52 as it passes over the form 51 . When the sheet metal 52 is pressed by these “U” shaped indents 50 and detents 53 , the indents 50 and detents 53 make the sheet metal 52 wavy and the surface of the sheet metal 52 is stretched.
- FIG. 6 shows the processing of the sheet metal blank 52 immediately after the sheet metal 52 is stretched as illustrated in FIG. 5 .
- FIG. 8 provides an illustration of the processes shown in FIGS. 5 and 6 , from the opposing side of the dies and press. The sheet metal is first pressed by the first metal form 51 , and by the second metal form 61 shortly thereafter.
- FIG. 6 shows the sheet metal blank 52 being indexed in several movements, bent over the second metal form 61 .
- the latter part of the second metal form 52 includes a fairly flat top portion 63 and a fairly flat bottom portion.
- the bottom portion is not shown in the figure because it is under the metal blank 52 .
- the wavy stretched portion of the sheet metal is formed prior to forming the flat sheet metal into the “J” shape, the wavy stretched portion could also be formed after forming that “J” shape.
- FIG. 7 shows an end perspective view of the dies and press.
- the sheet metal 52 is moved across the end of the form portion of the press 70 .
- a shear operation is formed to cut the turbine blade to a predetermined length.
- the guillotine shear 71 can be programmed to cut the sheet metal at any desired length to provide turbine blades of any desired length. The entire operation, while the sheet metal is digitally moved forward, can form a multiple of turbine blades in a fairly continuous manner.
- the metal forming portion of the operation and the dies used to form same may result in a spiraling of the entire blade to some extent, including the inner vertical edge.
- the sheet metal is of such thickness that any curvature therein can be corrected when that edge is attached to a spine, vertical support member or complementary second blade, as shown in more detail below.
- the resulting vertical axis turbine blade has a helical shape which has the ability to “catch the wind” coming from just about any of a number of directions to provide for rotation of the vertical axis thereof.
- turbine blade thus formed can be combined with additional turbine blades to also form a double blade function, triple blade function or a quadruple blade function on a vertical axis turbine.
- the invention is at a full remove from generating power, it aids in making helical style turbines, which are put on generators and then used to generate the power.
- the efficiency of the generator they are attached to can vary all over.
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- Life Sciences & Earth Sciences (AREA)
- Sustainable Development (AREA)
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- Chemical & Material Sciences (AREA)
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- Fluid Mechanics (AREA)
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- Wind Motors (AREA)
Abstract
A sheet metal blank is formed into a helical turbine blade by stretching an outer portion of the blank by creating indents and detents thereon. Then the stretched side is flattened and the stretched structure is formed into a helical shape.
Description
- This application relates to vertical axis turbine blades and, more particularly, to sheet helical shape vertical axis turbine blades and methods of their continuous manufacture. This application claims priority to and is a continuation-in-part of provisional patent application Ser. No. 61/662,536 filed Jun. 21, 2012 to the extent allowed by law.
- Vertical axis wind turbines can be divided into two general types, savonius turbines and darrieus turbines. Darrieus turbines tend to have a plurality of symmetrical air foils that have a zero rigging angle, that is, the angle that the air foils are set relative to the structure on which they are mounted. Savonius turbines, when looking down on the rotor from above, having an S-shape in cross section, if it was of the two-blade variety.
- Savonius turbines are considered to be of the drag-type of device and are used whenever cost or reliability is more important than efficiency.
- Having a helix shaped vertical axis wind turbine blade provides a surface that will “catch” the wind from differing directions. The placement of dual helix shaped blades 180 degrees apart or triple helical shaped blades 120 degrees apart or quadruple helical blades 90 degrees apart provide for a reliable turbine configuration that aids in providing turbine rotation for just about any direction of wind passing thereby.
- Prior known vertical axis helically shaped blades have been built and constructed in a segmented faction because the outer curved edge area of a helically constructed turbine blade has a larger surface than the area thereof adjacent a vertical axis of each blade. As a result, the prior art discloses a plurality of segmented curved end blades that are stacked upon one another to provide an approximation of a helical shaped blade, as shown in U.S. Pat. No. 7,364,406.
- When a larger helically configured sheet is utilized in a vertical axis wind turbine, such as shown in advertising for Alternative Power Turbines Gale R15 series, the outer edge of each turbine blade is not vertically oriented as it is not parallel to the vertical axis of the turbine blade because of the extra surface area needed toward the outer edge of each blade.
- Another helical shaped vertical axis wind turbine is shown at U.S. Pat. No. 7,494,315 which by its nature is cut into a large single segment, specifically constructed for the height and width of the turbine blade.
- A need has developed for helical shaped vertical axis turbine blades that are formed inexpensively from sheet material in a somewhat continuous manner so that helical blades of differing lengths or heights can be constructed as desired and approximately continuously formed to be cut at such desired lengths.
- It is, therefore, an object of the invention, generally stated, to provide a new and improved vertical axis helically shaped turbine blade and an improved method for continuous manufacturing the blades.
- A helically shape turbine blade for use in a turbine that generates electrical and mechanical energy. The blade comprises a vertical inner edge having a length l. Like sized top and bottom edges of the blade each have a straight edge extending outwardly from the inner edge in a substantially straight line for a predetermined length, and thereafter curved into a semicircular shape.
- The amount of stretch needed to form the helix varies depending on the distance from the axis of rotation. For any point along the cross section of the helix, from the inside edge of the blade to the outer edge of the blade, the stretch can be calculated by the known vertical length of the blade and the length of the swept line created by the chosen point on the cross section when the turbine blade rotates around a center of rotation for the desired angle.
- The blade is made by feeding a sheet metal blank over metal dies to stretch the metal between the inner and outer edge thereof. The sheet metal blank is then formed and finally cut at a predetermined length. The metal form tools continuously press and form helically shaped metal blades.
- The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The invention may best be understood from the following detailed description of currently preferred embodiments thereof taken in conjunction with the accompanying drawings wherein like numerals refer to like parts, and in which:
-
FIG. 1 is a top perspective view of a prototype segment of a vertical axis turbine blade constructed in accordance with the present invention; -
FIG. 2 is a horizontal elevational view of the blade shown inFIG. 1 ; -
FIG. 3 is a schematic view of the top of a VAT blade as it would appear in finished form; -
FIG. 4 is a diagrammatic sketch showing how to compute, by triangulation, the stretch needed to construct a helix form on sheet metal; -
FIG. 5 is a horizontal perspective view of the beginning of the dies and press for creating the helical blade of the invention; -
FIG. 6 is a horizontal perspective view of the middle and end of the dies and press for creating the helical blade of the invention; -
FIG. 7 is an end perspective view of the dies and press showing the formed turbine blade exiting the press; -
FIG. 8 is a horizontal perspective view of the opposing side of the dies and press. - The ability to continuously produce a helix shaped vertical axis turbine blade depends in large part on the correct stretching of an original metal sheet blank. The stretch is to accommodate a twist in the helix across its surface. The inside edge may be adapted to be mounted on either vertical axis or a center of rotation of the blade assembly. The axis can be a spine, backbone, stave, or simply a center of rotation and is preferably a straight vertical line. Some mathematical approximations are necessary in order to determine the amount of stretch that should be imparted to any given portion and of the metal sheet that is made into a half of a helical turbine blade assembly.
- Referring to
FIGS. 1 and 2 , inFIG. 1 , a sheet metal prototype turbine blade segment 10 is shown in an upper ¾ perspective view.FIG. 2 is a horizontal elevational view of the blade segment shown inFIG. 1 . The turbine blade segment 10 has aninner edge 12, anupper edge 14, anouter edge 16, and abottom edge 18. In this embodiment, theinner edge 12 has apertures orperforations 13 positioned in spatial relation to each other providing for mounting the inner portion of the turbine blade to a vertical axis or spine (not shown). In this example, theupper edge 14 of the helical turbine blade 10 extends outward from the top of theinner edge 12 in a substantially straight line for a predetermined length, and is thereafter curved into a semicircular shape at the end towards theouter edge 16. Thebottom edge 18 has the same kind of substantially straight line and is thereafter curved into a semicircular shape at the end towards theouter edge 16 as is theupper edge 14. Theouter edge 16 of the vertical blade segment 10 contacts theupper edge 14 and forms a helical shaped curvature between the top and bottom. -
FIG. 3 is a schematic top down view of the upper edge of the turbine blade. The substantially straight portion 32 of the upper edge extends from theend 36 connecting with the inner edge of the turbine blade. The other end of the upper edge that goes to the outer edge of the turbine blade is curved into asemicircular shape portion 34 outwardly of the substantially straight portion 32. - The
semicircular shape portion 34 has a known radius. In this embodiment, thesemicircular portion 34, together with a substantially straight dimension 32 a from the inner edge ofportion 34 to the center ofrotation 38, form the upper edge in a “J” shaped profile. In the illustrated embodiment inFIG. 3 , the center ofrotation 38 is slightly off the inner edge of the helical turbine blade (FIG. 11 ). When the dual turbine blade is assembled (FIG. 9 ), the center of rotation does not necessarily fall onto the body of the helical turbine blade as will be shown in more detail below. - One way to view the length of the outer edge of the helical turbine blade is to think of the diagonal edge of a cardboard tube, such as seen in the packaging for a frozen bakery product like breakfast rolls, etc., or in the spiral edge of a cardboard tubular shipping container that eventually folds back on itself and is glued together. If the axis on the cardboard paper of the tubular spiral is turned vertical, a horizontal line between that axis along the circumference of the tube to that outer glue edge becomes the second side of a triangle and the diagonal edge becomes the third side. If we open up that tubular member somewhat to a semicircular position, that triangular relationship still exists.
- In a helical shaped vertical axis turbine blade, there may be a portion of the blade immediately adjacent the vertical spine that is not curved, but is straight in nature. One must measure the swept line length of the outer edge when the turbine blade is rotating around the center of rotation of the blade.
- We first determine the desired angle of rotation of the turbine blade based on appropriate engineering constraints such as number of blades, total turbine length, and the desired power output. For example, a three bladed turbine could have each blade manufactured to twist through 120° over a given length. Alternately, the blades could twist through a full 180° of rotation, or even more, over an increased length so as to increase the power output.
- The distance from the turbine center of
rotation 38 to any specific point on the part profile is the radius used in calculating the swept line for that point. In the illustrated embodiment shown inFIG. 3 , the part profile in this case is the “J” shaped turbine blade upper edge. The turbine blade sweeps an arc using the radius r for an angle that equals the included angle of thearc segment 34 determined above. The length of this arc is the swept line s, and it can be calculated by: -
- Since we can measure the vertical distance v (44) from the beginning of the helix of the blade, we can calculate the length of the hypotenuse 40 as shown in
FIG. 4 . The swept line becomes theshort side 42 of the right-angled triangle inFIG. 4 . The vertical distance becomes the long side of the right-angled triangle inFIG. 4 . Therefore, the length l of the hypotenuse 40 is the square root of the vertical distance plus the horizontal distance squared. -
l=√{square root over (h 2 +v 2)} - Then by subtracting the length l of the hypotenuse 40 from the
vertical length 44, we can calculate the stretchy needed to form the outer edge of the helix by: -
x−l−v - For a point at the outer edge of the helix, the stretch x is usually approximately 15% of the vertical distance v. Additionally, much of the inner part of the bent helix is correspondingly proportionally stretched, with the stretch diminishing toward the center of rotation.
- Once one knows the amount of stretch needed per unit length for the outer edge of the helical formation, one skilled in the art can produce
detents 53 and indents 50 (flutes or inwardly closed louvers) in a metal forming press such as shown inFIG. 5 to provide the needed stretch (throughout) the metal sheet. - In a preferred embodiment, the vertical axis turbine blade having a helical outline is formed in an automated press which is indexed to digitally feed the sheet metal blank 52 over the
metal form 51 as shown inFIG. 5 . The outer side 54 of theform 51 adjacent the outer edge of the helix of the sheet has the “V” shaped indents 50 anddetents 53 formed in it as shown inFIG. 5 . The inner edge of thatform 51 has clamping members 57 positioned thereon to assure that thesheet 52 stays stationary when the press is in operation. The “U” shaped indents 50 anddetents 53 are sized and shaped to follow the length of indexing of thesheet metal 52 as it passes over theform 51. When thesheet metal 52 is pressed by these “U” shaped indents 50 anddetents 53, theindents 50 anddetents 53 make thesheet metal 52 wavy and the surface of thesheet metal 52 is stretched. - In the preferred embodiment, once the necessary stretching adjacent the outer edge of the
sheet metal 52 has been formed, then the entire width of theturbine blade sheet 52 is passed over a second portion ofmetal form 61 shown atFIGS. 6 and 8 .FIG. 6 shows the processing of the sheet metal blank 52 immediately after thesheet metal 52 is stretched as illustrated inFIG. 5 .FIG. 8 provides an illustration of the processes shown inFIGS. 5 and 6 , from the opposing side of the dies and press. The sheet metal is first pressed by thefirst metal form 51, and by thesecond metal form 61 shortly thereafter. -
FIG. 6 shows the sheet metal blank 52 being indexed in several movements, bent over thesecond metal form 61. The latter part of thesecond metal form 52 includes a fairly flattop portion 63 and a fairly flat bottom portion. The bottom portion is not shown in the figure because it is under themetal blank 52. - It should be noted that while in the preferred embodiment the wavy stretched portion of the sheet metal is formed prior to forming the flat sheet metal into the “J” shape, the wavy stretched portion could also be formed after forming that “J” shape.
-
FIG. 7 shows an end perspective view of the dies and press. Thesheet metal 52 is moved across the end of the form portion of the press 70. As the indexing identifies that a predetermined length ofsheet metal 52 has passed thereover, a shear operation is formed to cut the turbine blade to a predetermined length. It should be noted that, as the turbine blade continues to be formed, the guillotine shear 71 can be programmed to cut the sheet metal at any desired length to provide turbine blades of any desired length. The entire operation, while the sheet metal is digitally moved forward, can form a multiple of turbine blades in a fairly continuous manner. - It should be noted that in forming the turbine blades, the metal forming portion of the operation and the dies used to form same may result in a spiraling of the entire blade to some extent, including the inner vertical edge. However, the sheet metal is of such thickness that any curvature therein can be corrected when that edge is attached to a spine, vertical support member or complementary second blade, as shown in more detail below. The resulting vertical axis turbine blade has a helical shape which has the ability to “catch the wind” coming from just about any of a number of directions to provide for rotation of the vertical axis thereof.
- Additionally, it should be noted that the turbine blade thus formed can be combined with additional turbine blades to also form a double blade function, triple blade function or a quadruple blade function on a vertical axis turbine.
- The invention is at a full remove from generating power, it aids in making helical style turbines, which are put on generators and then used to generate the power. The efficiency of the generator they are attached to can vary all over.
- While one particular embodiment of a continuously formed vertical axis turbine blade of the present invention has been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the true spirit and scope of the present invention. It is the intent of the appended claims to cover all such changes and modifications as fall within the true spirit and scope of the invention.
Claims (9)
1. A sheet turbine blade for use in a vertical axis turbine, the sheet turbine blade comprising:
an inner edge, an upper edge, an outer edge and a bottom edge;
said upper edge and bottom edge contacting said inner edge, said upper edge extending outward from the top of the inner edge in a substantially straight line for a predetermined length from said inner edge, and thereafter said upper edge is curved into a semicircular shape;
said outer edge contacting said upper edge, said outer edge extending downwardly and forming a helical shaped curvature of said outer edge.
2. The sheet turbine blade of claim 1 , wherein:
said sheet turbine blade is made of metal.
3. A method for making a helically shaped turbine blade from a sheet metal blank, the method comprising the steps of:
calculating the amount of stretch needed per unit length thereof for forming a helical outer edge on said sheet metal blank;
feeding the sheet metal blank over a first metal form to produce detents and indents on said blank in a first metal form for providing the needed stretch to said sheet metal blank;
bending said sheet metal blank over a second metal form to flatten the stretched indents and detents; and
cutting the sheet metal blank to a predetermined length.
4. The method of claim 3 , further including the step of:
providing an inner edge of said metal form with clamping members assuring that said sheet metal blank stays stationary when said press is in operation.
5. The method of claim 3 , further including the step of:
sizing and shaping said indents and detents follow the digital length of indexing of said sheet metal blank as it passes over said first metal form.
6. The method of claim 3 , further including the step of:
forming said blank into a helical shape before feeding said sheet metal blank over said first metal form.
7. The method of claim 3 , further including the step of:
forming said blank into a helical shape after bending said sheet metal blank over the second metal form;
the method of claim 3 further including the step of flattening said stretched indents and detents.
8. The method of claim 3 wherein:
the steps for calculating the amount of stretch needed per unit length for forming an helical outer edge include:
a. calculating the length of a swept line s created by said outer edge when each of said turbine blade rotates around a center of rotation;
b. measuring the vertical distance l, of the helically shaped turbine blade from said bottom edge;
c. finding the length l of the hypotenuse applying the equation:
l=√{square root over (h 2 +v 2)}
l=√{square root over (h 2 +v 2)}
d. finding the amount of stretch x needed to form the outer edge of the helix by subtracting v from l
x−l−v.
x−l−v.
9. The method of claim 8 , wherein:
the steps for calculating the length of a swept line s created by the outer edge when each said turbine blade rotates around a center of rotation include:
a. measuring the included angle of rotation of the turbine blade by dividing the number of turbine blades used in the system into 360°;
b. determining the radius r by measuring the perpendicular distance from the turbine blade center of rotation to any specific point on the part profile;
c. determining the swept line s applying the equation:
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/783,683 US20130343897A1 (en) | 2012-06-21 | 2013-03-04 | Helix Type Vertical Axis Turbine Blades and Method for Continuously Making Same |
PCT/US2013/046710 WO2013192375A2 (en) | 2012-06-21 | 2013-06-20 | Helix type vertical axis turbine blades and method for continuously making same |
BR112014030197A BR112014030197A2 (en) | 2012-06-21 | 2013-06-20 | method for making helically shaped turbine blade from raw sheet metal and sheet turbine blade |
MX2014015690A MX2014015690A (en) | 2012-06-21 | 2013-06-20 | Helix type vertical axis turbine blades and method for continuously making same. |
IN2529MUN2014 IN2014MN02529A (en) | 2012-06-21 | 2014-12-12 | |
US15/219,538 US10458390B2 (en) | 2012-06-21 | 2016-07-26 | Method for continuously making a helical type curved shaped turbine blade |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201261662536P | 2012-06-21 | 2012-06-21 | |
US13/783,683 US20130343897A1 (en) | 2012-06-21 | 2013-03-04 | Helix Type Vertical Axis Turbine Blades and Method for Continuously Making Same |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/219,538 Division US10458390B2 (en) | 2012-06-21 | 2016-07-26 | Method for continuously making a helical type curved shaped turbine blade |
Publications (1)
Publication Number | Publication Date |
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US20130343897A1 true US20130343897A1 (en) | 2013-12-26 |
Family
ID=49769694
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
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US13/783,683 Abandoned US20130343897A1 (en) | 2012-06-21 | 2013-03-04 | Helix Type Vertical Axis Turbine Blades and Method for Continuously Making Same |
US15/219,538 Expired - Fee Related US10458390B2 (en) | 2012-06-21 | 2016-07-26 | Method for continuously making a helical type curved shaped turbine blade |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
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US15/219,538 Expired - Fee Related US10458390B2 (en) | 2012-06-21 | 2016-07-26 | Method for continuously making a helical type curved shaped turbine blade |
Country Status (5)
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US (2) | US20130343897A1 (en) |
BR (1) | BR112014030197A2 (en) |
IN (1) | IN2014MN02529A (en) |
MX (1) | MX2014015690A (en) |
WO (1) | WO2013192375A2 (en) |
Cited By (4)
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US20140215822A1 (en) * | 2011-09-16 | 2014-08-07 | Siemens Aktiengesellschaft | Method for producing a compressor blade |
US20150165397A1 (en) * | 2012-06-20 | 2015-06-18 | Philadelphia Mixing Solutions, Ltd. | High efficiency, non-ragging, formed axial impeller |
WO2016176352A1 (en) * | 2015-04-28 | 2016-11-03 | Chris Bills | Vortex propeller |
USD818414S1 (en) | 2016-11-30 | 2018-05-22 | Chris Bills | Vortex propeller |
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CN110695180B (en) * | 2019-10-08 | 2021-11-16 | 江西洪都航空工业集团有限责任公司 | Large aircraft skin blank structure and skin stretch forming method |
WO2023086110A1 (en) * | 2021-11-10 | 2023-05-19 | Airiva Renewables, Inc. | Turbine wall apparatus/system and method for generating electrical power |
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- 2013-06-20 BR BR112014030197A patent/BR112014030197A2/en not_active IP Right Cessation
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Also Published As
Publication number | Publication date |
---|---|
MX2014015690A (en) | 2015-08-06 |
US20170002793A1 (en) | 2017-01-05 |
US10458390B2 (en) | 2019-10-29 |
WO2013192375A2 (en) | 2013-12-27 |
BR112014030197A2 (en) | 2017-06-27 |
IN2014MN02529A (en) | 2015-07-24 |
WO2013192375A3 (en) | 2014-02-13 |
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