Patent Application
20090019846
1. Field of the Invention
The present invention relates to applying Stirling engine principles to the design and use of power conversion equipment. In particular, the present invention relates to applying Stirling engine principles for electrical and mechanical power generation, especially in the direct current (DC) mode or in the alternating current (AC) modes.
2. Discussion of the Related Art
The Stirling engine is a heat engine that operates by converting the heat energy which flows between two portions of the heat engine having different temperatures into mechanical power. A typical Stirling engine uses the heat energy to drive a coordinated and reciprocating motion of a set of pistons. Numerous designs of Stirling engines can be found in the prior art, including: U.S. Pat. Nos. 6,578,359, 6,050,092, 6,195,992, 6,735,946 and 6,164,263. The designs of these Stirling engine are typically complex and include numerous moving parts. Consequently, these designs are costly to manufacture and their efficiencies are low.
The present invention provides a heat engine enclosed in a housing having two zones maintained at different temperatures. The first zone (“hot zone”) receives heat energy from an external power source. The second zone (“cold zone”) is connected to the hot zone, such that a fluid (e.g., air, water, or any other gas or liquid) filling the two zones can circulate between the two zones. The expansion of the fluid in the hot zone and the compression of the fluid in the cold zone provide a symmetrical thermodynamic cycle to drive a turbine to provide a power output. The fluid may be pressurized to enhance efficiency.
In one embodiment, the turbine propels an axle in a rotational motion to transmit the mechanical power output of the heat engine. In one embodiment, the turbine propels an axle in a rotational motion to transmit the power output of the heat engine to an electrical generator outside of the heat engine's housing. In one embodiment, the turbine includes a first set of blades attached to a plate located in the hot zone and a second set of blades attached to a plate located in the cold zone. The blades may each have a flat profile having two unequal surfaces, such that the turbine rotates preferentially in one direction. Blade set 103a and blade set 103b of the turbine rotate as a result of fluid flow pressure between the two zones of different temperatures within housing 107. According to another embodiment, turbine blades rotate and create vortices in the working fluid. The velocity of the working fluid put the turbine into doing useful work. The torque in the rotary motion of the turbine, therefore, may be used to drive machinery (e.g., a generator) through a power axle or a shaft. In one embodiment, the electrical generator includes one or more magnets in rotational motion according to the rotational motion of the axle, and one or more conductive coils coupled to the magnetic fields of the one or more magnets. The amount of coupling between the magnets and the coils may be controlled by a step motor moving the coils into different positions relative to the magnets. In one embodiment, the electrical generator delivers AC power. Alternatively, DC power may be provided by either rectifying the AC power, or by selectively coupling those coils that have an instantaneous positive voltage relative to a ground terminal. To synchronize the coil selection, a position sensor may be provided to sense the positions of the magnets. In one embodiment, the position sensor includes a light sensitive sensor, a light emitting diode and a light reflector.
According to one embodiment of the present invention, a temperature sensor may be used to control the power output of the heat engine. A signal output of the temperature sensor indicates a temperature difference between the hot and cold zones. Based on this output signal of the temperature sensor, a control circuit adjusts the coupling between the magnets and the coils in the electrical generator. In an AC power generation application, a control circuit senses to the frequency of the electrical generator's output power to control the output power of the electrical generator.
In one embodiment, adding power output is achieved using thermal couples and thermionic devices. The thermal couple takes advantage of the temperature difference between the hot and cold zones. The thermionic devices extract heat from the housing of the heat engine. These devices may be stored in an insulated area between two plates separating the hot and cold zones.
The present invention provides a heat engine in which the gas or fluid transferring heat between the hot and cold zones is used to drive the turbine, resulting in low power loss in the energy conversion process. In addition, the housing provides fluid flow between the hot zone and the cold zone through a center shaft and a peripheral space so as to allow 100% component use with no dead time. The cylindrical symmetry of the heat engine provides stability with minimum vibration and an absence of drag during operation. The heat engine of the present invention has a simple design with few moving parts, without the requirements of a displacer, a piston or a regenerator. Thus, the heat engine of the present invention is light weight, low component cost and easy to maintain.
A heat engine of the present invention may be used to power an automobile or another vehicle. It can also be incorporated, for example, in any application in which a source of heat energy is provided (e.g., fuel cells or energy recovery from combustion of waste).
In addition, the control system of the present invention provides a consistent output power to enhance fuel efficiency.
The present invention is better understood upon consideration of the detailed description below and the accompanying drawings.
The present invention provides a heat engine, operating under Stirling engine principles, for converting heat energy into mechanical and electrical energy. The electrical energy derived using a heat engine of the present invention may be in the form of alternating current (AC) power, for immediate distribution, or in the form of direct current (DC) to allow storage or other applications.
The heat engine of the present invention may operate with any source of heat energy, including solar, geothermal, fossil, landfill recovered or other fuels.
Hot portion 107a (“hot zone”) and cold portion 107b (“cold zone”) are insulated from each other by insulating zone 106. Except for insulating zone 106, housing 107 may be metallic (e.g., steel) to allow rapid and even heat distribution. A turbine in a heat engine, according to the present invention, may be located in any suitable location inside the hot zone 107a and the cold zone 107b of the housing 100, to provide the output power of the engine. The turbine may be in any suitable size or material, depending on the application of the heat engine 100. In one embodiment, heat engine 100 includes turbine 103; in the implementation shown in
Center axle 101 is unsheathed in air shaft 102 that runs from top to bottom along the entire lengths of hot portion 107a and cold portion 107b of housing 107, connecting the hot and cold zones. The hot and cold zones are also connected by annular air space 104 along the circumference of the outer wall of housing 107. Center axle 101 is held by bearings 105, which allow center axle 101—and thus blade sets 103a and 103b also—to rotate about its center axis. Because the contact points between bearings 105 and center axle 103 are the only locations in heat engine 100 which experience mechanical wear and tear, heat engine 100 has a long service life and a low service requirement and thus easily maintained. A portion of center axle 101 extends outside of housing 107. Cylindrical magnet 108 attaches to and rotates with this portion of center axle 101 which extends outside of housing 107. One or more coils 109 surround magnet 108. Coils 109 may be driven by step-motor 110 in an up and down motion to vary the amount of magnet flux coupling the magnetic field of magnet 108.
In this embodiment, when coils 109 includes more than one coil (as may be desirable for DC power generation), a multiplexing switch 601 may be provided, as shown in
During operation, as heat builds up in hot portion 107a of housing 107, the expanding fluid in the hot zone rises and pushes against blade set 103a on support plate 114. Thus, turbine 103 begins to rotate about the axis of center axle 101 due to the torque of the expanding fluid. The expanding fluid moves radially outward towards the periphery and into the cold zone 107b via annular air space 104. As the expanding fluid enters into cold zone 107b, the fluid in cold zone 107b contracts by a cooling mechanism (e.g., the walls of housing 107 in cold zone 107b may include pipes circulating a cooling fluid). The contracting fluid draws the expanding fluid into cold zone 107b. As blade set 103b on support plate 115 in cold zone 107b is connected by center axle 101 to rotating blade set 103a on support plate 114, blade set 103b rotates at the same angular speed as blade set 103a, thereby contributing to the torque rotating turbine 103. The cooled fluid in cold zone 107b is drawn by convection radially towards center axle 101 and is forced into hot zone 107a via air shaft 102. Thus, a circulation of fluid is established which flows radially outwards in hot zone 107a, enters cold zone 107b via annular air space 104, flows radially inwards in cold zone 107b and returns to hot zone 107a through air shaft 102. In this process, the relatively hot fluid from hot zone 107a that expands and flows into cold zone 107b is cooled in cold zone 107b, while the relatively cold fluid from cold zone 107b is heated in hot zone 107a. During an engine cycle, the working fluid urges on all the blades of blade set 103a or all the blades of blade set 103b at the same time. Each blade of blade set 103a or blade set 103b contributes work at the same time. Therefore, fluid control structures such as nozzles and pipes, which are generally used in fluid driven system to direct the working fluid to a particular portion of the turbine so as to provide an impulse, are not necessary in a heat engine of the present invention.
As magnet 108 rotates with center axle 101, the result varying magnetic field induces one or more electrical currents in coils 109. This electric current can be used to generate AC or DC electrical power, as discussed in further detail below. A temperature difference between hot zone 107a and cold zone 107b may be established, such that the output power and the heat dissipated from housing 107 equals the input power. Cold zone 107b may be cooled and maintained at a pre-determined temperature by fluid (e.g., air). Such fluid may flow in channels provided in walls of housing 107b, or by other means known to those skilled in the art. Efficiency for the heat transfer may be enhanced by pressurizing the hot and cold zones. Alternatively, rather than using air, other gases may also be used.
According to another embodiment, the working fluid flows through blade sets 103a and 103b and put blade set 103a and 103b into a preferred rotational direction to maximize torque generation. During operation, as heat builds up in hot zone 107a, the expanding working fluid in hot zone 107a urges against blades set 103a to create a torque to cause turbine 103 to rotate. The rotation of blades set 103a interacts with the working fluid movement and may impact the direction of the working fluid, or other fluid characteristics that change within the working fluid path. Such characteristics, for example, may include the working fluid velocity, direction, and volume. Blade set 103a or blade set 103b may rotate and bring the working fluid into rotational motion resulting in vortex or vortices forming in the working fluid. Vortices are a result of a rotational movement of the working fluid rotating about a center. Rotational working fluid has angular momentum and may be used to rotate the next blade set in the working fluid path. A continuous rotational working fluid can be maintained by a series of rotational working fluid portions supported by turbine blade sets. Thus, each portion of the working fluid adds an angular momentum to the working fluid. In addition, the rotational movement of the working fluid may be carried through one or more portions of the working fluid path to the entire working fluid path. A continuous rotational working fluid in an engine can be achieved by collaboration of turbine blade sets and the curvature of the working fluid path. Thus, the angular momentum of working fluid can be accumulated and used to drive turbine blade sets. Therefore, the expansion, contraction and rotational movements of working fluid can be combined and act on turbine blades sets to create maximum torque. One suitable turbine for this application may be provided by blades that are designed to maintain or increase the rotational motion of working fluid. Alternatively, turbine blade sets may be provided in a different configuration (e.g., a different material, differently shaped blades, performing different functions) to achieve different design objectives).
In another embodiment, if a rotational working fluid is maintained during a complete engine cycle, the working fluid flow from cold zone 107b to hot zone 107a may create a rotating updraft. Similarly, a rotational working fluid flow from hot zone 107a to cold zone 107b creates a rotating downdraft. These rotating drafts can be utilized to increase the velocity of the working fluid and power turbine 103. The momentum of the working fluid is continuously increased during each engine cycle, where the hot working fluid meets the cold working fluid. Working fluid under continuously heating, expanding, cooling and contracting in the respective zones during each engine cycle. Therefore, a complete engine cycle and a complete working fluid path are provided within housing 107.
As discussed above, the working fluid has a continuous momentum, resulting from the heating and cooling of the working fluid, and the rotational motion of the blade set 103a and blade set 103b. Turbine 103 rotates due to the working fluid flow and, in turn, drives the working fluid into a rotational motion. In each cycle, the working fluid is accelerated by the combined forces of the vertical rotation downdraft and the rotational uplift. Therefore, under this environment, the longer the engine runs, the faster the working fluid circulates. The working fluid velocity is increased by the kinetic energy, which is then converted by the heat engine into mechanical work. The working fluid is carried more effectively through the working fluid path in the form of a spinning draft. The high fluid velocities result from conservation of angular momentum. The engine design is based on using the continuously heating and cooling pressure to move the working fluid, and to use the working fluid velocity to move the turbine. This design use enhanced working fluid velocity to power a turbine. The operating temperature difference between hot zone 107a and cold zone 107b either by the cooling method discussed above, by controlling the output power, or both. The output power can be controlled by increasing or decreasing the magnetic field coupling between magnet 108 and coils 109 by motor 110 driving coils 109 up or down. A temperature sensor (not shown) sensitive to the temperature difference between hot zone 107a and cold zone 107b may be provided to sense the operating temperature difference.
For generating AC electrical power, position sensor 112 may be used to detect the rotational frequency of axle 101. Positional sensor 112 asserts a control signal (e.g., control signal t) to control circuit 501 whenever reflector 111 comes into the detection field of positional sensor 112. The time difference between successive assertions of the control signal allows control circuit 501 to determine the frequency of the rotating magnetic field of magnet 108, and thus the frequency of the output AC power.
As mentioned above, for AC power generation, coils 109 need only be a single coil, output terminal y is a single output. Without further processing, the output power is delivered in the form of an AC current flowing between terminal y and the ground terminal, whose frequency is proportional to central axle 101's angular speed of rotation. Because the amount of output power is a load on center axle 101, increasing the amount of magnetic coupling between magnet 108 and coils 109 increases the load on center axle 101, thereby affecting the angular speed of rotation. Accordingly, the output terminal y may be coupled into a high impedance input terminal of control circuit 501, which may be provided a frequency sensing circuit (e.g., a trigger circuit). The detected frequency of the output AC current is used to adjusted through step motor 110, which drives coils 109 up or down according to output control signal w. This control scheme may thus be used to provide an output power from heat engine 110 which is compatible with 50 or 60 Hz household AC power.
In DC power generation, coils 109 may include multiple coils. At any given time, some of terminals x have positive voltages relative to the ground terminal, and others of terminals x have negative voltages relative to the ground terminal. During DC power generation, the position sensor associated with each of coils 109 provides to control circuit 501 control signal t which indicates when the associated reflector comes into the detection field of the position sensor. Once the particular coil of coils 109 is identified as having the desired positive voltage phase, control circuit 501 provides control signals z to switch 601 (
The signal in output terminal y may be shaped to a constant voltage using, for example, a low-pass filter or a voltage regulator.
Alternatively, the AC output power generated according to discussion above may be rectified to provide a DC power output, using any suitable rectifier circuits known to those skilled in the art.
Additional energy conversion may be accomplished using thermal couples that provide output signals according to the temperature difference between hot zone 107a and cold zone 107b. Alternatively, the walls of housing 107 at hot zone 107a may be used to generate power using thermionic principles. The thermal couples or thermionic components can be housed insulating zone 106 of
The above detailed description is provided to illustrate the specific embodiments of the present invention and is not intended to be limiting. Numerous modifications and variations with in the scope of the present invention are possible. The present invention is set forth in the following claims.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/US05/36391 | 10/7/2005 | WO | 00 | 4/12/2007 |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10963274 | Oct 2004 | US |
| Child | 11577163 | US |
