Patent Application
20130009612
The invention relates to energy extraction devices for extracting energy from renewable energy sources, for example, wind turbine generators for extracting energy from the wind. Energy extraction devices according to the invention have a hydraulic transmission including a hydraulic pump driven by a rotating shaft and a hydraulic motor driving a load, such as an electrical generator.
The technical background to the invention will now be discussed with reference to energy extraction devices which are wind turbine generators (WTGs), for extracting energy from the wind, however the same principles will apply to other types of energy extraction devices, for extracting energy from other renewable energy sources, and to energy extraction devices with motors driving other types of load from which at least some energy can be recovered.
In the case of a WTG or other energy extraction device which generates electrical power for an electricity grid using an electrical generator, a significant amount of power may be lost due to the operation of the electrical generator, rather than transmitted to the electricity grid. Electrical generators lose energy due to friction and typically also consume a significant amount of power independently of their rate of rotation or field current due to so-called ‘winding losses’. These losses can be substantial, and can significantly reduce the efficiency of electrical generation, particularly at low fractions of maximum power output. However, for wind and other renewable energy sources, the rate of energy capture will typically vary and so it is important for electrical generation to be efficient at a range of power levels.
U.S. Pat. No. 4,274,010 (Lawson-Tancred) discloses a WTG in which a wind turbine is coupled to an electrical generator through a hydraulic circuit including a working fluid receptacle in the form of a piston loaded with a weight. The electrical generator can be switched off for a period of time, during which time working fluid is stored in the piston, and then driven at a constant power for a period of time. Once the stored working fluid has been depleted, the electrical generator is again switched off. This reduces energy losses by having periods of time when power loss through the electrical generator is minimised. Advantageously, the wind turbine can continue to rotate and store power while the electrical generator is switched off and thereby in a dormant mode.
It is also known to provide a WTG which has a hydraulic transmission including two electrical generators connected in parallel. At greater than 50% of maximum power output, at least one electrical generator is switched on at all times and both electrical generators are switched on for some of the time. At less than 50% of maximum power output, one electrical generator is switched on at some times and both electrical generators are switched off the remainder of the time. More than two electrical generators can be connected in parallel, and devices where the two electrical generators are not equally sized are also possible.
However, it requires a substantial amount of energy for an electrical generator (e.g. a synchronous generator) to be returned to the speed required to provide power at the correct frequency and phase for an electrical grid. Therefore, it has been found that the improvements in energy efficiency arising from the above approaches are limited.
Thus, the invention seeks to solve the technical problem of reducing the energy losses arising from the operation of electrical generators in energy extraction devices having a hydraulic transmission including a hydraulic pump driven by a rotating shaft and a hydraulic motor driving a load.
According to a first aspect of the invention there is provided an energy extraction device for extracting energy from a renewable energy source, the device comprising a controller and a hydraulic circuit, the hydraulic circuit comprising:
Thus, energy is recovered from the load and used to pressurise working fluid received from the low pressure manifold and to output it to the high pressure manifold, either directly or indirectly (for example, into a pressurised working fluid store in continuous or selective fluid communication with the high pressure manifold). The energy is therefore stored and can later be used to return energy to the load, by carrying out further motoring cycles, to increase overall energy efficiency.
The invention is useful where the load can supply energy for a period of time, for example, due to inertia. It may be that the load is an electrical generator having a rotor and the energy from the respective load is rotational kinetic energy from the rotation of the rotor. Thus, the rotational kinetic energy of the rotor is to at least some extent recovered and used to pressurise working fluid, thereby storing the energy for later use in accelerating the rotor until it is again at the required frequency and phase to be synchronous with the electrical grid.
As well as storing rotational kinetic energy which would otherwise be lost, the increased pressure can facilitate rapid start up of the hydraulic motor at a later time. This may, for example, allow the minimum operating pressure in the high pressure manifold to be lower (typically slightly lower) than would otherwise be the case while still ensuring that, after storing the recovered kinetic energy of the rotor into the pressurised working fluid, there is sufficient pressure for rapid start up of the hydraulic motor. It also increases the overall energy capture of the energy extraction device because much less energy is dissipated as heat than when the generator slows down naturally due to friction and windage.
Typically, the high pressure manifold is in (continuous or selective) fluid communication with at least one working fluid receptacle. The at least one working fluid receptacle typically comprises at least one pressurisable container having a working fluid retaining volume which varies with the volume of working fluid retained in the or each working fluid receptacle. The at least one pressurisable container may, for example, be a gas-charged oleo-pneumatic accumulator filled at one end with pressurised nitrogen or other gases, a length of rubber and rigid hose or a fluid volume.
Preferably, there is a net flow of working fluid into the at least one working fluid receptacle when the at least one hydraulic motor carries out pumping cycles. Thus the at least one working fluid receptacle increases the capacity of the hydraulic transmission to store energy. Typically, there is a net flow of working fluid out of the at least one working fluid receptacle when the hydraulic motor is switched to the active state.
Preferably, in an operating mode of the energy extraction device, the pump is operable to continue to receive energy and to displace working fluid from the low pressure manifold to the high pressure manifold (and one or more working fluid receptacles, where present), while the hydraulic motor is in the dormant state.
Typically, the controller is configured to operate some or all of the hydraulic motors alternately in the dormant state or the active state, wherein in the dormant state, the at least one hydraulic motor has low or no net displacement of working fluid and in the active state, the at least one hydraulic motor has substantially the same net rate of displacement of working fluid on successive occasions. (The net rate of displacement of working fluid in the active state may vary significantly over longer periods of time).
Preferably, the volumes of the working chambers do not cycle in the dormant state (i.e. the shaft of the hydraulic motor is stationary) and the controller controls the electronically operated valves such that there is no displacement of fluid between the high and low pressure manifolds. It may be that the volumes of the working chambers continue to cycle but the controller selects the volume of working fluid displaced by the working chambers in the dormant state so that there is no, or no significant net displacement of working fluid, or at least that the net rate of displacement of working fluid is less than one-tenth, or preferably less than one-twentieth of the net rate of displacement of working fluid in the active state. For example, the controller may operate the electronically controlled valves in the dormant state to cause the working chambers execute idle cycles in which they remain sealed from the high pressure manifold and there is therefore no net displacement of working fluid from the high pressure manifold to the low pressure manifold. Typically, if the volumes of the working chambers continue to cycle, they do so at a rate which is less than one-tenth, or preferably less than one-twentieth of the rate at which they cycle in the active state. During idle cycles it may be that working fluid received from the low pressure manifold is displaced back to the low pressure manifold or that the working chamber remains sealed throughout a cycle of working chamber volume, in a cavitation idle mode, for example as disclosed in WO/2007/088380, which is incorporated herein by this reference.
The controller may comprise a processor and a computer readable storage device (such as memory) in electronic communication with the processor and storing program code, thereby configuring the controller to cause the energy extraction device to function as an energy extraction device according to the first aspect of the invention or according to the method of the second aspect of the invention (below).
Where the load is an electricity generator, the electricity generator preferably comprises an output in electrical communication with an electricity grid through an isolator. The energy extraction device (e.g. the isolator, or the isolator under control of the controller of the energy extraction device) may be configured to isolate the output of the electricity generator from the electricity grid when the hydraulic motor is in the dormant state, and optionally also while the hydraulic motor is carrying out pumping cycles. The energy extraction device may be configured to switch off power, or to vary the power (typically to reduce the power supplied) to one or more field circuits of the electricity generator through which current is passed in the active state, when the hydraulic motor is in the dormant state.
The energy extraction device may, for example, be a wind turbine generator, or a turbine generator for generating energy from the flow of moving water, such as a tidal turbine.
According to a second aspect of the present invention there is provided a method of controlling an energy extraction device for extracting energy from an energy flow from a renewable energy source, the device comprising a controller and a hydraulic circuit, the hydraulic circuit comprising:
Thus, the method may comprising switching the respective hydraulic motor from an active state in which it carries out motoring cycles to a pumping state in which it carries out one or more pumping cycles to a dormant state in which there is minimal or no net displacement of working fluid from the high pressure manifold to the low pressure manifold through the respective hydraulic motor.
Typically, one or more of the at least one hydraulic motors is operated alternately in the dormant state or the active state, wherein in the active state, the at least one hydraulic motor has substantially the same rate of net rate of displacement of working fluid on successive occasions, and in the dormant state, the at least one hydraulic motor has a net displacement of working fluid which less than one-tenth of the net displacement in the active state (and preferably less than one-twentieth, or no net displacement).
Typically, the load is an electrical generator having a rotor and the energy from the respective load is rotational kinetic energy from the rotation of the rotor. Typically, energy from the respective load is used transiently to pump working fluid from the low pressure manifold to the high pressure manifold. Thus the method may comprise switching from the active state to the dormant state via a transient pumping mode which is transient and in which the shaft of the hydraulic motor rotates. It may be that in the dormant state, the shaft of the hydraulic motor is substantially stationary.
It may be that, in an operating mode of the energy extraction device in which the hydraulic motor is in the dormant state, the pump continues to receive energy and to displace working fluid from the low pressure manifold to the high pressure manifold (and one or more working fluid receptacles, where present).
It may be that when the hydraulic motor is switched from the dormant state to the active state, the proportion of cycles of working chamber volume for which the electrically controlled valves are operated to cause a working chamber to displace a net amount of working fluid increases through at least one intermediate value.
Optional features discussed above in relation to either the first or second aspect of the invention are optional features of both the first and second aspects of the invention.
The invention extends in a third aspect to a computer readable storage medium storing program code which, when executed by the controller of an energy extraction device according to the first aspect of the invention, causes the energy extraction device to operate according to the second aspect of the invention.
An example embodiment of the present invention will now be illustrated with reference to the following Figures in which:
The hub is connected directly to a pump (129), through a rotor shaft (125), acting as the rotatable shaft, which rotates in the direction of rotor rotation (127). The pump has a fluid connection to a hydraulic motor (131), which is described further below with reference to
The hydraulic motor is connected to a generator (157), acting as the load, through a generator shaft (159). The generator is connected to an electricity network through a contactor (161), which receives a contactor control signal (162) from a generator and contactor controller (163) and is operable to selectively connect the generator to or isolate the generator from the electricity network. The generator and contactor controller receives measurements of voltage, current and frequency from electricity supply signals (167) and generator output signals (169), measured by electricity supply sensors (168) and generator output sensors (170) respectively, communicates them to the controller (112) and controls the output of the generator by adjusting field voltage generator control signals (165) in accordance with generator and contactor control signals (175) from the controller.
The pump and motor report the instantaneous angular position and speed of rotation of their respective shafts, and the temperature and pressure of the hydraulic oil, to the controller, and the controller sets the state of their respective valves, via pump actuation signals and pump shaft signals (171) and motor actuation signals and motor shaft signals (173). The controller receives coordinating signals (177) and sends monitoring signals (179), from and to respectively a farm controller (not shown in this figure). The monitoring signals typically comprise the pressure Ps of the high pressure manifold and the pressure Pacc of the accumulators, as well as the rotor speed wr. Of course the monitoring signals may further comprise any values useful for monitoring the status and function of the WTG. The controller uses power amplifiers (180) to amplify the pitch actuation signals, the isolating valve signals, the pump actuation signals and the motor actuation signals.
The working chambers are each associated with Low Pressure Valves (LPVs) in the form of electronically actuated face-sealing poppet valves (214), which face inwards toward their associated working chamber and are operable to selectively seal off a channel extending from the working chamber to a low pressure conduit (216), which functions generally as a net source or sink of fluid in use and may connect one or several working chambers, or indeed all as is shown here, to a low pressure port (217) which is fluidically connected to the low pressure manifold (135) of the WTG. The LPVs are normally open solenoid closed valves which open passively when the pressure within the working chamber is less than or equal to the pressure within the low pressure manifold, i.e. during an intake stroke, to bring the working chamber into fluid communication with the low pressure manifold, but are selectively closable under the active control of the controller via LPV control lines (218, being some of the motor actuation and motor shaft signals 173) to bring the working chamber out of fluid communication with the low pressure manifold. Alternative electronically controllable valves may be employed, such as normally closed solenoid opened valves.
The working chambers are each further associated with High Pressure Valves (HPVs) (220) in the form of pressure actuated delivery valves. The HPVs open outwards from the working chambers and are operable to seal off a channel extending from the working chamber to a high pressure conduit (222), which functions as a net source or sink of fluid in use and may connect one or several working chambers, or indeed all as is shown here, to a high pressure port (224, acting as the inlet of the hydraulic motor) which is in fluid communication with the high pressure manifold (133). The HPVs function as normally-closed pressure-opening check valves which open passively when the pressure within the working chamber exceeds the pressure within the high pressure manifold. The HPVs also function as normally-closed solenoid opened check valves which the controller may selectively hold open via HPV control lines (226, being some of the motor actuation and motor shaft signals 173) once that HPV is opened by pressure within the associated working chamber. Typically the HPV is not openable by the controller against pressure in the high pressure manifold. The HPV may additionally be openable under the control of the controller when there is pressure in the high pressure manifold but not in the working chamber, or may be partially openable, for example if the valve is of the type and is operated according to the method disclosed in WO 2008/029073 or WO 2010/029358.
Operation (300) of the WTG will now be described with reference to
In an active state (301), the hydraulic motor carries out motoring cycles by the procedure described in, for example, EP 0 361 927, EP 0 494 236, and EP 1 537 333, the contents of which are hereby incorporated herein by way of this reference. In this procedure, the controller selects the net rate of displacement of fluid from the high pressure manifold by the hydraulic motor by actively closing one or more of the LPVs shortly before the point of minimum volume in the associated working chamber's cycle, closing the path to the low pressure manifold which causes the fluid in the working chamber to be compressed by the remainder of the contraction stroke. The associated HPV opens when the pressure across it equalises and a small amount of fluid is directed out through the associated HPV. The controller then actively holds open the associated HPV, typically until near the maximum volume in the associated working chamber's cycle, admitting fluid from the high pressure manifold and applying a torque to the rotatable shaft. Arrows on the ports (217,224) indicate fluid flow in the motoring mode; in the pumping mode which is discussed below, the flow is reversed. A pressure relief valve (228) may protect the hydraulic motor from damage.
By this procedure, the hydraulic motor drives the generator rotor by way of a rotating shaft, generating electricity which is output to the electricity grid.
The rate of rotation of the hydraulic motor shaft, and its phase, is typically dictated by the requirement that generated electricity be in phase with the electricity grid (i.e. that the generator and the hydraulic motor must rotate at a fixed frequency related to that of the electricity grid, and at a suitable phase relative to it). The hydraulic motor is typically driven at a substantially constant rate of displacement of working fluid selected to provide optimally efficient power transfer from the rotor to the electricity grid. As the amount of displacement of working fluid during each cycle of working chamber volume can be selected by the controller, the rate of displacement of working fluid can be varied to some extent while continuing to drive the electrical generator at the correct frequency and phase.
Referring now to
In order to shut down the hydraulic motor, the controller decreases the hydraulic motor's rate of displacement of working fluid until the electrical output power of the generator is zero. This is preferably done gradually over several seconds to avoid disturbing the hydraulic system with sudden changes in the rate of displacement of working fluid. Once the electrical output power has been reduced to zero the controller instructs the generator contactor controller (163) to open the contactors (161) and isolate (303) the electrical output of the generator from the electrical grid. Since at this time the torque provided by the hydraulic motor is only enough to make up the losses of the generator, the hydraulic motor and generator do not accelerate beyond their speed during normal operation.
The controller then changes (304) the timing of valve control signals to cause the hydraulic motor to carry out pumping cycles. To create pumping cycles, the controller send a control signal to close one or more of the LPVs which is near the point of maximum volume in the associated working chamber's cycle, closing the path to the low pressure manifold and thereby directing fluid out through the associated HPV on the subsequent contraction stroke. In comparison to normal operation, in order to command the pumping cycles, the controller does not send a control signal to hold open one or more of the HPVs on the expansion stroke of any of the working chambers. The controller can select the proportion of cycles of working chamber volume for which pumping cycles take place and can also vary the precise phasing of the closure of the LPVs with respect to the varying working chamber volume to select the net displacement of working fluid on each cycle.
As the hydraulic motor and generator are decelerating towards a threshold speed which is below the normal (grid-connected) operating speed of the generator, the controller instructs the generator and contactor controller to reduce the field excitation so that the generator terminal voltage is reduced proportionally to the speed, reaching zero at the threshold speed.
The controller monitors the speed of the hydraulic motor or the electrical generator (305), and when they are almost stationary the controller switches off the electrically operated valves (306) so that the LPVs of the hydraulic motor are open and the HPVs of the hydraulic motor are closed.
The effect of this procedure is that the generator rotor is rapidly decelerated but, instead of being dissipated the angular kinetic energy of the rotor is instead stored by pumping working fluid from the low pressure manifold to the high pressure manifold.
At a later time, the controller decides (310) to restart the hydraulic motor. This may take place, for example, because the amount of working fluid stored in the high pressure accumulators or the pressure in the high pressure manifold has exceeded a threshold, or for other operational reasons. The controller then sends control signals to electronically controlled valves to cause the hydraulic motor to carry out motoring cycles (311) as before. Initially, the controller selects the net displacement by the hydraulic motor to cause the shaft of the hydraulic motor, and therefore the generator rotor, to accelerate rapidly to get the generator rotor to near to the angular velocity required to generate electricity at the correct frequency for the electricity grid (313).
The controller monitors the speed of the hydraulic motor or the electrical generator (315), and when the speed reaches a threshold, the current to the generator field coils is switched on (312) and the controller selects the net displacement by the hydraulic motor such that the phase and frequency of the generator rotor converges on the correct phase and frequency required for electricity generation. Typically, during this time, the hydraulic motor will displace working fluid at a rate significantly lower than during the previous acceleration phase. It requires a significant amount of energy to be input for the hydraulic motor and generator rotor to reach the correct frequency of rotation and this energy is obtained from the energy stored in the form of pressurised fluid in the high pressure manifold and the high pressure accumulators.
Once the generator rotor is rotating at the correct frequency and phase to generate electricity in synchrony with the electrical grid (313), the generator and contactor controller is instructed to reconnect (314) the electricity generator to the electricity grid. The controller then continues to operate the hydraulic motor in its normal active mode (301).
By carrying out some pumping cycles when the hydraulic motor is switched to the dormant state, the WTG stores energy which can be later used to restart the hydraulic motor and to get the electricity generator rotor up to the correct frequency for electricity generation. Thus, in contrast to known WTGs in which a generator is allowed to continue rotating, gradually dissipating its kinetic energy as heat, less rotational kinetic energy is lost. While the hydraulic motor is dormant, the hydraulic pump continues to be driven by the turbine, and pressurised fluid is accumulated in the high pressure accumulators.
The invention therefore enables significant energy savings. In contrast to allowing generators to coast to a stop over a period of time, spinning losses can be avoided in the dormant state. Another benefit is that, as energy from the generator rotor is used to pressurise working fluid, the minimum operating pressure in the high pressure manifold during normal operation and/or the amount of hydraulic fluid stored in the high pressure accumulators that is required for the generator to be rapidly started up may be a little less than would otherwise be the case (because the step of capturing the electrical generator's kinetic energy will boost the pressure in the high pressure manifold such that it is sufficient to restart the electrical generator from the hydraulic motor), or the additional pressure or supply of pressurised fluid could enable the generator to be brought up to speed more quickly.
In some embodiments, the hydraulic circuit will comprise more than one hydraulic motor connected in parallel, with each motor driving an electrical generator. In that case, the hydraulic motors can be individually operated, so that different numbers of hydraulic motors are operated at different times. For example, in a WTG with two electricity generators of equal capacity, receiving energy at 54% of the maximum rated output power, it may be preferable for one electricity generator to be on at all times and for both electricity generators to be on for some of the time. Thus, one generator, or both generators in turn, might be switched off for a period of time by the method described above and later restarted.
One skilled in the art will appreciate that alternative types of hydraulic motor may be employed which can selectively execute pumping cycles. Also, there is scope for varying the connecting or disconnecting of the electrical generator to and from the electricity grid, varying the generator field current, and varying the rate of displacement of working fluid through the hydraulic motor during the acceleration and deceleration of the electrical generator, depending on the particular machines employed and the goals of the designer.
Further modifications and variations falling within the scope of the invention will present themselves to those knowledgeable of the art.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2011/003887 | 7/6/2011 | WO | 00 | 4/30/2012 |
