Patent Grant
8912678
1. Field of the Invention
This invention is concerned with a wave activated power generation system using a rack and pinion mechanism, in which a plurality of rectangular power generation buoys manufactured from fiber-reinforced plastic material are activated by wave action.
2. Description of the Prior Art
It is a root demand to enjoy a safe, comfortable civilization life. Modern civilization is based on electrical energy. The demand for electrical energy never disappears as long as the human race exists.
With ocean energy, wave activated power generation is the steadiest form of power generation energy. It is characterized by the large amount available. The energy per unit area is 20-30 times of photovoltaic generation energy and is at least five times more than the force of winds. The ability of the wave activated power generation is given by natural environment in the installation location and the weather conditions. It is not uniform in all the oceans. The usage of wave activated power generation is put to practical use as a power supply of beacon buoys now. However, there is still a problem with stability and potential damage during stormy weather.
The advantages in which the wave activated power generation is adopted are as follows.
The system of wave activated power generation has some methods. When classified roughly, it is as follows.
The method of (a) is being researched by a lot of research laboratories. That is the one to operate the turbine by ventilating the compressed air generated by a top and bottom of the wave vibration. This method is called the turbine method and a vibration water column type. The structure is simple and is excellent in durability. It is a main current now. There is also a simple method, such as moving the coil up and down in the magnetic field floating body vibration. Moreover, there is the one of the pendulum type that uses the horizontal vibration of the wave of (b), too.
3. Problems the Invention is Solving
This invention is directed to the application of a wave activated power generation system by rack and pinion mechanism in which pluralities of square pillars manufactured from FRP material are activated by sea wave.
With ocean energy, wave activated power generation is the steadiest form of power generation energy. It is characterized by the large amount available. The energy per unit area is 20-30 times of photovoltaic generation energy and is at least five times more than the force of winds. However, wave activated power generation is not so widespread. The usage is limited to small-scale power supply equipment, and it has a problem of being damaged by stormy weather.
As for the method called the turbine and vibration water column method, the structure used therein is simple and has excellent durability. But it is necessary to turn the turbine blades by compression air. A large amount of energy is needed to turn the turbine blades with air. The energy of the sea wave becomes large if it totals it. However, individual energy is small. It is thought that a mechanical method is preferable to take out a lot of small energy.
The corrosion problem with seawater is not solved. Steel and aluminum have enough structural strength for wave activated power generation, but they are easily corroded by seawater. The power generation buoy that is bored by corrosion loses buoyancy. Wood also rots by seawater. FRP material is excellent in structural strength and durability. However, its manufacturing cost is expensive because the manufacturing process has not been established.
To answer the problems and the current state demanded by the use of a wave activated power generation system, the processing technology and concept for them are described herein.
In terms of the wave activated power generation system, the most important problem that should be solved is the manufacturing of a power generation buoy that can endure exposure to seawater. The demand on the power generation buoy is not only the endurance against corrosion. It is necessary that the power generation buoy floats on the sea and stands up vertically in the sea. Moreover, it is preferable that the power generation buoy is filled with the material that prohibits the infiltration of seawater.
Also, a second demand is that the mechanism of converting the vertical movement into the gyration works with good efficiency. It is preferable that the mechanism has the ability to stop power generation system during stormy weather.
To satisfy the first demand, glass fiber FRP material is chosen. Glass fiber FRP is a compound material of the glass fiber and epoxy resin, and neither the glass fiber nor epoxy resin can be corroded by seawater. Moreover, it is easy to get the raw materials as price of such material is low. The process of manufacturing FRP structural material for the wave activated power generation is the same process as the application Ser. No. 13/407,196 “A HONEYCOMB STRUCTURE HAVING HONEYCOMB CORE ARRANGED PARALLEL TO A PANEL SURFACE AND A MANUFACTURING PROCESS THEREFOR”. The FRP structures for power generation buoy are manufactured from four-corner type though the FRP structure shown in application Ser. No. 13/407,196 is a honeycomb structure of six-corner type. This method can mass-produce FRP structural material at low cost.
The honeycomb structure of six-corner type is less limited in the size than four-corner type structure, and is more excellent in structural strength. However, the power generation buoy only moves up and down in the shroud assembly by ocean wave. The power generation buoy does not need special strength. It is enough in the FRP structure of four-corner type.
In application Ser. No. 13/407,196, vapor pressure power is used to pressurize the internal pressure device made of heat proof plastic. In this invention, styrene foam is used instead of the vapor pressure power of water and alcohol. The bead of the styrene foam foams because of steam when heating it filling the bead of the styrene foam in the internal pressure device. The internal pressure device is pressurized by the foaming pressure of the styrene foam. The styrene foam remains in the FRP structure. The styrene foam filled in the internal pressure device prevents seawater from invading into the power generation buoy.
The power generation buoy is filled with the styrene foam, so it floats on the sea. And when the weight of iron is attached at the bottom part of buoy, the power generation buoy stands vertically in seawater. However, because the weight of iron is corroded with seawater, it is inferior to durability. When iron rubbish is filled at the bottom part of the power generation buoy and the iron rubbish is hardened with the urethane resin, the power generation buoy stands vertically in the sea. The iron rubbish does not come in contact directly with seawater because it is hardened with the urethane resin.
To satisfy the second demand, the mechanical method of converting the vertical movement into the gyration is chosen. Current method by compression air is inefficient. The reason is that the energy of the wave is converted into thermal energy by the process into which air is compressed. The thermal energy generated by compressed air is the loss in vain. In this invention, the energy of the wave is taken out as vertical movement generated by a buoyancy of the seawater and the gravity of the earth.
In general, crank and piston mechanism is used to convert the vertical movement into the gyration. It is adopted for the piston engine etc. However, the crank and piston mechanism is not applicable to the power generation buoy. The reason is that the amplitude of the wave is not constant. The crank mechanism does not rotate when the amplitude of the vertical movement is not constant.
In this invention, the mechanism of rack and pinion is adopted. Rack and pinion mechanism can convert the vertical movement of the variable amplitude wave into the gyration. Of course, there is some limitation. The amplitude of the wave at stormy weather has the danger to exceed the length of the rack gear. At stormy weather it is necessary to stop the vertical movement generated by the wave.
The power generation buoy repeats the vertical movement because of buoyancy and gravity. The pinion gear converts the vertical movement of the rack gear, which is attached to power generation buoy into the gyration. The wave activated power generation turns a dynamo with the rotating torque of the pinion gear, and obtains the electric power. The rotating torque load of the dynamo is equal to the frictional force for the power generation buoy. The power generation buoy does not fall down by gravitation when the frictional force is larger than the gravity load. The power generation buoy stops the vertical movement in the air. When the pinion gears are connected to the dynamo with the gearless transmission, the torque of the dynamo can be arbitrarily varied. It becomes possible to stop the power generation buoy at stormy weather.
The speed of the pinion gear is changed by the wave conditions. When rotating movement of the pinion gear generates electricity, the electricity is an exchange current. The rotation speed of dynamo is not constant. The frequency of current is varied by the rotating speed of dynamo. It is preferable that the current of the wave activated power generation is converted into the direct current.
Referring to the drawing as follows, it explains the form of concrete execution of the manufacturing process of power generation buoy and explains wave activated power generation system by rack and pinion mechanism.
The square pillar internal pressure device (1) can be made from the tube of heatproof plastic material, so the length of the internal pressure device (1) is arbitrary. The beads of the styrene foam (2) are foamed by heat and the pressure of steam.
The reason why every corner of the square pillar internal pressure device is chamfered is following reasons:
At room temperature, the soft FRP prepreg (5) is a wet soft cloth, so it is not difficult to wrap the square pillar internal pressure device (3) with the soft FRP prepreg (5). The adhesive of prepreg deteriorates at the room temperature; it is preferable to preserve the product within the freezer at minus 5° C. or less.
The reasons why a square solid pressure device is necessary are as follows.
At room temperature, the soft FRP prepreg (10) is the wet soft cloth, so it is not difficult to wrap square solid-type pressure device (11) with the soft FRP prepreg (10). Because the adhesive of prepreg deteriorates at the room temperature, it is preferable to preserve the product within the freezer at minus 5° C. or less.
Theoretically, the square pillar can be infinitely arranged. However the structural position is not unique. It is difficult to connect more than four pillars to one unit. Honeycomb structure is superior for a large-scale structure. But, the square pillar can be manufactured in low-cost when it is compared with the honeycomb structures. The square pillar is suitable for the power generation buoy of wave activated power generation.
The pressurizing process and the heat stiffening process by the internal pressurizing device and the external frame reaction force are the same as the manufacturing process of the application Ser. No. 13/407,196 “A HONEYCOMB STRUCTURE HAVING HONEYCOMB CORE ARRANGED PARALLEL TO A PANEL SURFACE AND A MANUFACTURING PROCESS THEREFOR”.
Internal pressure device by the styrene foam is useful for expanding method instead of the vapor pressure. Water and alcohol need not be drained from the internal pressure device after the heat stiffening process; the process is shown in application Ser. No. 13/407,196. Epoxy resin stiffens completely during the cooling time though epoxy resin, which is the bonding resin of the FRP prepreg, starts stiffening at 130° C. Therefore, the internal pressure device should keep pressurizing the FRP prepreg during the cooling time. The styrene foam is manufactured from cooling gradually with pressurizing it. The manufacturing process is the same.
The power generation buoy is filled with the styrene foam. Seawater cannot invade into the power generation buoy, so it floats on the sea. And when the weight of iron is installed at the bottom part of buoy, the power generation buoy stands vertically in seawater. The weight mass is the one that the iron rubbish was hardened with the urethane resin. The iron rubbish does not come in contact directly with seawater because it is hardened with the urethane. And, glass fiber FRP is a compound material of the glass fiber and epoxy resin, and neither the glass fiber=nor epoxy resin is corroded by seawater. Therefore, the power generation buoy is not corroded with seawater. The durability of power generation buoy is excellent.
The specs of the power generation buoy of
Rack and pinion systems are installed in both surfaces of the left and a right of the buoy. Therefore, the hand of cut of the right side pinion is opposite to the left side pinion. The rotation speed of the pinion is varied by the cycle of the wave. When electricity is generated by rotating movement of the pinion, the generated electricity is an exchange current and its frequency is not constant. It is preferable that the current generated by the wave activated power generation is converted into the direct current electricity.
In this invention, the rack and pinion mechanism can convert the vertical movement of the variable wave into the gyration. Of course there is some limitation. The amplitude of the wave at stormy weather has the danger to exceed the length of the rack gear. At stormy weather it is necessary to stop the vertical movement of power generation buoy.
The power generation buoy repeats the vertical movement by the buoyancy and gravity. The pinion gear converts the vertical movement into the gyration. The wave activated power generation unit turns dynamo with the rotating torque of the pinion gear, and obtains the electric power. The rotating torque load of the dynamo is equal to the frictional force for the power generation buoy. The power generation buoy does not fall down by gravitation when the frictional force is larger than the gravity load. The power generation buoy stops the vertical movement in the air. When the pinion gears are connected to the dynamo with the gearless transmission, the torque of the dynamo can be arbitrarily varied. Therefore, it becomes possible to stop the power generation buoy at stormy weather.
The motion of the power generation buoy is simulated by using the sample power generation buoy and ocean wave data. Ocean wave is generated by the wind and gravity. The wave data is observed as a function of the velocity of the wind. Table 2 shows the observational data:
The length of the power generation buoy is 6,000 mm. The buoyancy of the buoy is calculated to be 13,500 kgf from the volume. Weight material of the buoy is calculated to be 3,222 kgf. The weight force of the iron rubbish is 1,463 kgf. The total weight force is 4,685 kgf (46865=3222+1463), so the depth of sinking by buoy weight (Hb) is about 2,082 mm. The power generation buoy sinks 2,082 mm and stands up vertically in the sea.
Electricity is not generated in the system of
The depth of sinking by buoy weight (Hb) is 2082 mm. The depth of sinking by torque load (Htq) is 444 mm. The depth of sinking by buoy weight and torque load (Hadd) is 2526 mm. The period of stop in descent (t1a) is calculated to be 1.47 sec. The period of descent (t1b) is calculated to be 2.18 sec. The period of stop in rise (t2a) is calculated to be 0.98 sec. The period of rise (t2b) is calculated to be 2.67 sec. The moving height by gravity (Hmg) is calculated to be 2056 mm. The moving height by buoyancy (Hmb) is calculated to be 2056 mm. The data of the torque load and the buoy assembly is shown in Table 3:
Analysis of movement at 2500 mm height, torque load 1000 kgf
1. Analysis of movement by buoyancy
2. Movement analysis-1 by gravity
3. Movement analysis-2 by gravity
4. Actual movement
This calculation is considerably rough. The viscosities etc. of seawater are not considered. Because the buoy receives the torque load in the neighborhood of the bottom dead center, the buoy will stabilize in the neighborhood of the bottom dead center. It is impossible to get the stability point by the hand calculation.
Calculation of work and work rate at 2500 mm height, torque load 1000 kgf:
1. Work by buoyancy
The depth of sinking by buoy weight (Hb) is 2082 mm. The depth of sinking by torque load (Htq) is 1111 mm. The depth of sinking by buoy weight and torque load (Hadd) is 3193 mm. The period of stop to balance point (t1a) is calculated to be 1.69 sec. The period of stop in descent (t1b) is calculated to be 1.20 sec. The period of descent (t1c) is calculated to be 1.11 sec. The period of stop in rise (t2a) is calculated to be 1.42 sec. The period of rise (t2b) is calculated to be 1.87 sec. The reference time (t3) from descending point to bottom dead center is 0.76 sec. The moving height by gravity (Hmg) is calculated to be 1389 mm. The moving height by buoyancy (Hmb) is calculated to be 1389 mm. The data of the torque load and the buoy assembly is shown in Table 4:
Analysis of movement at 2500 mm height, torque load 2500 kgf
1. Movement analysis by buoyancy
Calculation of work and work rate at 2500 mm height, torque load 2500 kgf
1. Work by buoyancy
The optimization of the torque load is a difficult problem. In the calculation, the torque load that becomes ½ of the height of waves obtains the maximum efficiency. However, the power generation buoy comes not to descend easily by gravity when the torque load becomes large.
The buoyancy that corresponds to the torque load 2800 kgf is 1244 mm. The buoyancy that corresponds to weight (4685 kgf) of the buoy is 2082 mm. The total load that adds torque force (2800 kgf) to weight (4685 kgf) of the buoy is 7485 kgf. The buoyancy that corresponds to the total load (7485 kg) is 3326 mm. The data of the torque load and the buoy assembly is shown in Table 5:
The depth of sinking by buoy weight (Hb) is 2082 mm. The depth of sinking by torque load (Htq) is 1244 mm. The depth of sinking by buoy weight and torque load (Hadd) is 3193 mm. The period of stop to balance point (t1a) is calculated to be 1.69 sec. The period of stop in descent (t1b) is calculated to be 1.68 sec. The period of descent (t1c) is calculated to be 0.15 sec. The period of stop in rise (t2a) is calculated to be 1.97 sec. The period of rise (t2b) is calculated to be 1.83 sec. Gravity begins to act from the point (C). However, it is only 0.15 second to the bottom dead center. It is thought that the power generation buoy does not move when the torque load is 2800 kgf. In this case, it is impossible to get the answer by the hand calculation.
The power generation buoy is assumed to be stopping at the bottom dead center (A). The frictional force does not act on the object that is stopping. Similarly, the torque load does not act on the power generation buoy that is stopping. The power generation buoy does not rise until the buoyancy exceeds the torque load though the power generation buoy obtains the buoyancy as the wave rises.
Buoyancy acts from the point (A) to the point (D). The torque load and the buoyancy do the balance in point (B). When the power generation buoy exceeds the point (B), it rises with turning the dynamo. The torque load is freed a few seconds before the top dead center (D). Point (C) is the point to free the torque load. The weight of power generation buoy and the buoyancy do the balance when the torque load is freed at the point (D). The potential energy of the power generation buoy at the point (D) recovers greatly though power generation is not done from the point (C) to the point (D).
Gravity acts from the point (D) to the point (F). When gravity is larger than the torque loads, the power generation buoy goes down to the bottom dead center (F). The torque load and the buoyancy do the balance in point (E). When the power generation buoy exceeds the point (E), it descends with turning the dynamo. And, the weight of the power generation buoy and the buoyancy do the balance, and the power generation buoy stabilizes in neighborhood of the bottom dead center (F). The dynamo generates electricity from the point (D) to the point (F) by gravitation.
Analysis of movement at 2500 mm height, torque load (2800 kgf) with freeing the load at the top dead center
1. Movement analysis by buoyancy-1
Calculation of work and work rate at 2500 mm height, torque load (2800 kgf) with freeing the load at the top dead center
1. Work by buoyancy
When the method of controlling in
The power generation buoy does not descend by gravity when the torque load becomes larger than the weight of the power generation buoy. At stormy weather, the power generation buoy can be stopped by this method.
Because the calculation becomes complex, the following calculations are calculated by the method of uniform torque load. Table 6 shows the forecast of the power generation ability calculated by the method of the uniform torque load as shown below:
The incidence of the wave in North Ocean is assumed as shown in Table 7:
Power generation (kW) in this sample unit is calculated as shown in Table 8:
The amount of power generation (kW*h/year) during year in this sample wave activated power generation unit is calculated as shown in Table 9:
The module is produced like the bar in which the rigidity is high. It is desirable that the power generation module is manufactured at the factory. Therefore, the longitudinal length is limited by the size of the manufacturing factory. The power generation module in this image chart is composed by 10 power generation units.
It is not realistic to manufacture 100 m in length power generation module in one unit. Two power generation modules of 36 m in length are connected, and the long size power generation module is 72 m in length. The long size power generation module will not be inclined greatly by 100 m wavelengths.
In rack and pinion method, the power generation energy is obtained from the relative movement of shroud assembly and power generation buoy. The power generation buoy always synchronizes with the wave. When the shroud assembly is floating on the sea, it is inevitable to move up and down by the wave. The power generation efficiency worsens when the shroud assembly and the power generation buoy synchronize at the same time. It is necessary to restrain the shroud assembly when we adopt the rack and pinion method in practical use.
It is easy to connect the shroud assembly to the foundation block buried in bottom of the sea with cable. However, this method has some faults. There are a flood tide and an ebb tide in the sea. The cable loosens at the ebb tide when the length of the cable is matched to the surface of the sea of the flood tide. Oppositely, the cable is cut by the tension at the flood tide when the length of the cable is matched to the surface of the sea of the ebb tide. Moreover, the height of the wave is not constant.
The power generation energy is obtained from the relative movement between the shroud assembly and the power generation buoy. It is useless work to manage the absolute position of the shroud assembly. The purpose can be achieved by shifting the phase of movement. Seawater has the viscosity. The phase of the buoy and the shroud assembly shifts by installing the dumping weight to the power generation module.
However, the power generation module should be connected to the bottom of the sea with cable. Otherwise, the power generation module drifts by the wave. A pair of tension buoy is installed at both ends of the power generation module. The tension buoy is connected to the foundation block in the bottom of the sea, and is floating on the sea. In the tension buoy, there is a mechanism that constantly controls the cable tension. The tension mechanisms are composed of the motor drum that winds up the cable and the tension spring that gives cable the tension. The magnitude of the tension is calculated from the buoyancy of the barge. The cable becomes long by the control program at high water. Oppositely, the cable shortens at low water. At stormy weather, the cable tension in leeward is freed. Though the power generation efficiency of the power generation module deteriorates, the power generation module is prevented being damaged.
The wave activated power generation barge in sample chart is composed of 20 power generation modules and is composed of 400 power generation units. The barge is side by side connected by a lot of tying cables. The wave activated power generation barge is produced like a carpet with high flexibility. Each power generation module is almost independent. The wave activated power generation barge is constructed on open sea. There is little limitation in the length of barge.
Ability of power generation in this sample wave activated power generation unit is calculated as shown in Table 10:
The wave activated power generation is one of the steadiest power generation methods by natural energy. It is characterized by its large amount of energy. The energy for each area is 20-30 times of photovoltaic generation energy and is five times or more the force of the wind. It is said that the wave activated power generation can generate 30,000 kW in the area of 1K square meters. The sample power generation farm, in which 12 barges are arranged in the area of 500 m×1000 m, is calculated to generate 39,024 kW. And, the ability of power generation per year is calculated to be 362,870,400 kW*h/year. The power generation cost after the equipment cost is redeemed is only maintenance cost. The wave activated power generation will become a cheap, safe, permanent energy source.
It will be appreciated that modifications may be made in the present invention. The usage field of FRP structure materials in this invention is not limited to power generation buoy. The power generation buoy of this invention stands vertically in seawater. Moreover, glass fiber FRP that is the material is not corroded with seawater. The square pillar structure of FRP is the best for the construction materials in the sea.
The spirit of this invention is achievement of an efficient wave activated power generation system. For that purpose, this invention developed the power generation buoy made of FRP, the rack and pinion mechanism and controlling system by gearless transmission. Accordingly, it should be understood that we intend to cover by the appended claims all modifications falling within the true spirit and scope of our invention.
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