CROSSFLOW AXES ROTARY MECHANICAL DEVICES WITH DYNAMIC INCREASED

SWEPT AREA
Note: CARM devices - Crossflow Axes Rotary Mechanical devices, DISA - Dynamic Increased Swept Area

ABSTRACT
The new invention deals with Crossflow Axes Rotary Mechanical devices with Dynamic Increased
Swept Area. These new devices include at least two rotors attached to a support structure, having their
axes of rotation parallel to each other, and perpendicular to the fluid (cross flow axes). These rotors
rotate relative to each other in synchrony by a rotors synchronizing mechanism, and have at least one
blade attached to each rotor via the radial arm, where the swept area formed by the blades of each rotor
intersect, and the blades of the opposite rotors do not collide during the rotation (prevented by the rotors
synchronizing mechanism). The rotors with arms and blades share their spaces, the fluid, the support
structure, the rotors synchronizing mechanisms, the electric machines, the braking systems, the yawing
systems, as well as the characteristics, parameters, effects and additional mechanisms that the crossflow
axes rotary mechanical devices with Dynamic Increased Swept Area have compare to the crossflow axes
rotary mechanical devices without Dynamic Increased Swept Area.
FIELD OF THE INVENTION
The invention relates to a new class of Crossflow Axes Rotary Mechanical (CARM) devices with
Dynamic Increased Swept Area (DISA), such energy extracting devices (different types of wind
turbines, hydro turbines), and energy exerting devices (different types of propellers, fans, blowers,
ventilators, pumps, compressors, mixers etc), and a range of applications suitable for different fluid
types.
BACKGROUND OF THE INVENTION
There are two classes of rotary mechanical devices:

The flow axis rotary mechanical devices class

The crossflow axis rotary mechanical devices class

FLOW AXIS ROTARY MECHANICAL

DEVICES
ENERGY
ENERGY
EXTRACTING
EXERTING
DEVICES
DEVICES
RENEWABLE
ENERGY
ENERGY
EFFICIENCY
TURBINES
HAWT Lift
type
HAWT Drag
type
(FOR ANY FLUID
TYPE)

MixersBlenders
Fans-BlowersVentilators
PumpsCompressors
Propellers
etc
Diag.1

CROSSFLOW AXIS ROTARY

MECHANICAL DEVICES
ENERGY
ENERGY EXERTING
EXTRACTING
DEVICES
DEVICES
ENERGY EFFICIENCY
RENEWABLE
ENERGY
TURBINES
VAWT Lift
type
VAWT Drag
type
(FOR ANY FLUID
TYPE)

Mixers-Blenders
Fans-BlowersVentilators
PumpsCompressors
Propellers
etc

The devices of each class are used in the same type of applications as shown in the diagram Diag.1
(either energy extracting devices or energy exerting devices), but they differ from each other based on
the orientation of their axis of rotation relative to the flow direction (the crossflow axis rotary
mechanical devices have a parallel axis of rotation relative to the flow direction, while the crossflow
axis rotary mechanical devices have a perpendicular axis of rotation relative to the flow direction).
The devices of crossflow axis rotary mechanical class share a common fundamental characteristic which
is a direct result of the orientation of their axis of rotation relative to the flow direction, and this is the
device swept area which is 3 dimensional and symmetrical to the flow direction (Fig.1a is a schematic
view of the swept area for the lift type turbine, Fig.1a is a schematic view of the swept area for the drag
type turbine). Meanwhile the devices of this class differ from each other based on other non
fundamental characteristic such as electric machines (electric generators to extract energy from the fluid
or electric motors to exert energy from the fluid), blades (lift type, drag type), types of applications they
are used etc.
We are going to analyze one representative of the crossflow axis rotary mechanical devices class such as
crossflow axis turbines (more specifically the lift type turbine which is a more complex case considering
the fluid dynamic effects), and would assume the other crossflow axis rotary mechanical devices follow
the same logic and explanation.
The crossflow axis turbines have a long history of designs, and their main advantage compare to the
flow axis turbines is being omni directional (the crossflow axis turbines do not need to be pointed into
the flow direction compare to the flow axis turbines, and this a result of a 3 dimensional and
symmetrical swept area to the flow direction).
Main disadvantages of crossflow axis turbines compare to the flow axis turbines is being less efficient
than the flow axis turbines (Tab. 1), the pulsation of the blades for each revolution passing through
different pressure parts (especially for the lift type crossflow axis turbines that have stress forces on the
blades vary from compressional to tensional for each revolution), bending moment created by one
directional rotation of the rotor, the negative effects that the turbulent wakes created by the blades of
lift type turbine have on the blades that passes them (lift type turbines), the transmission of the
fluctuating loads to the support structure (as well as to the other systems such as the foundation system,
shaft system, generator system, bearings etc), self starting problem (lift type turbines), lack of fluid
dynamic braking (aerodynamic braking or hydrodynamic braking), unsmooth torque curve and
vibrations.

Tab.1
The advantages and disadvantages of crossflow axis turbines compare to the flow axis turbines have
the same origin, which is the swept area - because of the limited swept area used by the crossflow axis
devices to extract or exert energy (Fig.1a is a schematic display of a crossflow axis lift turbine 10, rotor
11, the swept area 24 and the limited swept area Lift Area used by the turbine to create positive
torque, while Fig.1b is a schematic display of a crossflow axis drag turbine 10, rotor 11, the swept area
24 and the limited swept area or Energy Extraction Area used by the turbine to create positive torque).

The invention seeks to provide a new class of crossflow axes rotary mechanical devices, where the new
devices become more efficient than the current class of crossflow axis rotary mechanical devices and
overcome some of the disadvantages listed above, at the expense of other attributes such as the omni
directional, etc.
SOLUTION
From the background of the invention, it is clear that the cause of the disadvantages of the crossflow
axis rotary mechanical devices of the conventional class (as well as the cause of the advantages) is the
swept area. The inventive idea is dealing with this fundamental attribute by increasing the swept area
dynamically (for the same or almost the same space & material wise), in the way that the new devices
would include at least two rotors rotating relative to each other in synchrony by one rotors
synchronizing mechanism (counter rotating or in some cases co rotating rotors), wherein the swept area
formed by the blades of each rotor intersect and the blades of the opposite rotors do not collide during
the rotation (prevented by the rotors synchronizing mechanism).
The new devices based on two relative rotating rotors with arms and blades would share their spaces, the
fluid, the support structure, the rotors synchronizing mechanism, the electric machine, the braking
system, the yawing systems etc, and this could be realized by:
fixed blades, offset rotors counter/co rotating (lift type devices Fig.3b)
variable blades, co rotors counter rotating (drag type devices - Fig.7 or Fig.8)
fixed blades, co rotors counter rotating (drag type devices - Fig.9)
fixed blades, offset rotors counter rotating (drag type devices Fig.10)
variable blades, offset rotors counter rotating (drag type devices Fig.11)
The swept area of the new devices is again 3 dimensional, but there are two changes of it:
1. The swept area is increased dynamically
2. The swept area is not symmetrical anymore from the fluid direction point of view, thus the omni
directional characteristic is not an advantages anymore, because for the highest efficiency the
new devices become one directional (even though the new devices are sort of semi omni
directional, meaning that they would function again in any direction of the fluid relative to the
device, but the performance would be different)
The Crossflow Axes Rotary Mechanical devices with Dynamic Increased Swept Area create a new
class compare to the conventional Crossflow Axes Rotary Mechanical devices without Dynamic
Increased Swept Area (Diag. 2).
CROSSFLOW AXIS ROTARY MECHANICAL DEVICES WITH DYNAMIC
INCREASED SWEPT AREA
ENERGY EXTRACTING DEVICES
ENERGY EXERTING DEVICES ENERGY
RENEWABLE ENERGY
EFFICIENCY
Mixers-Blenders
Fans-Blowers-Ventilators
Pumps-Compressors
Propellers
etc

TURBINES
VAWT Lift type
VAWT Drag type
(FOR ANY FLUID TYPE)
Diag.2

The new Crossflow Axes Rotary Mechanical devices with Dynamic Increased Swept Area class
include/inherit all the characteristics, effects, parameters and mechanisms of the conventional Crossflow
Axes Rotary Mechanical devices without Dynamic Increased Swept Area class, plus new ones such as:

New characteristics - the main new characteristic the CARM devices with DISA have compare to
the conventional CARM devices (without DISA), is the increased swept area (especially the
energy extracting/exerting part of the swept area) in a dynamic way, comparing to the
conventional CARM devices that may increase their swept area statically by static ducting, helical
blades etc. The increase of the energy extracting/exerting part of the swept area means more
fluid being processed by the CARM devices with DISA (space and material wise), or less fluid
escaping unprocessed from these devices (from this point of view the Dynamic Increased Swept
Area concept is equivalent to the Dynamic Increased Processed Fluid concept). The CARM
devices with DISA may change the size of their swept area (or the amount of fluid being
processed) depending on different factors, such as the device relative position to the flow
direction, counter or co rotating rotors, blade pitch angle etc.
(Fig.2a is a schematic display of a crossflow axes lift turbine with DISA 10 showing
counter rotating Rotor11 and 12 with a rotors offset Ro, the general swept area of each
rotor 24 and 25 creating a general increase of the swept area of the turbine (space wise)
compare to the swept area of a conventional crossflow lift turbine (Fig.1a), the energy
extracting Lift Area 11 and Lift Area 12 created by respective Rotor 11 and 12, while
Fig.2b is a schematic display of a crossflow axes drag turbine with DISA 10 showing
counter rotating Rotors 11 and 12 with a rotors offset Ro, the swept areas 24 and 25, the
Energy Extracting Area 11 and 12 created by respective Rotor 11 and 12 on both sides of
the device compare to the Energy Extracting Area of conventional crossflow drag turbine
Fig.1b)
Another characteristic of the CARM devices with DISA is the modularity. The base of the CARM
devices with DISA is a module of at least two rotors sharing their spaces, the fluid, the support
structure, rotors synchronizing mechanisms, the electric machines (electric generator or electric),
the braking systems, the yawing systems, as well as the characteristics, parameters, and effects.
The CARM devices with DISA can have a plurality (array) of modules, where they can share
among them the support structure, the electric machines as well as the torque, the fluctuating loads
etc.
(Fig.4a shows a crossflow axes lift turbine with DISA 10 having an array of modules 7
rotor 11 and 12 per module counter rotating with a rotors offset Ro, blades 1 with the
same height attached to the rotors via arms, one rotors synchronizing mechanism 4 per
module, one shared electric generator 5 and support structure 6. This embodiment has
different blades spacing BSR per each rotor on each side of it, and this can smooth the
torque curve, and share the loads on different modules.
Fig.4b shows a crossflow axes lift turbine with DISA 10 having an array of modules 7
rotor 11 and 12 per module counter rotating with a rotors offset Ro with different blades
height per different modules attached to the rotors via arms, having different electric
machine 5 along the array of modules, and in this case each electric machine may have a
dual role as a generator/motor and rotors synchronizer and support structure 6).

New effects there are new dynamic effects, resulting from the interaction of the fluid with the
new CARM devices with DISA:
Dynamic Fluid Ducting it is created by the blades of opposite rotors rotating relative to
each other, decreasing the escaping or unprocessed fluid from the device, thus increasing
the processed fluid by entrapping it (space and material wise), and it effects both lift and
drag type devices (Fig.5b is a schematic display of a crossflow axes lift type turbine with
DISA where the Dynamic Ducting zone 28 is created by blades 21 and 22, entrapping the
fluids in a dynamic way)
Dynamic Flow Deflection - it is created by the blades of opposite rotors rotating relative to
each other, changing in turn the direction of the fluid by entrapping it, increasing the
processed fluid by the device (space and material wise), and it effects both lift and drag
type devices (Fig.5b is a schematic display of a crossflow axes lift type turbine with DISA
where the Dynamic Flow Deflection U1 is created by the blade 22, changing the direction
and the speed of the fluid in a dynamic way)

 Dynamic Fluid Shield - it is created by the blades of opposite rotors rotating relative to each
other, where for the lift type devices each blade of one rotor forms a fluid shield to the
blades of the opposite rotor decreasing the negative drag forces, while for the drag type
devices the blades rotating against the fluid direction reduce their shape thus decreasing the
negative drag forces and it effects both lift and drag type devices (Fig.5a is a schematic
display of a crossflow axes lift type turbine with DISA where the blades 22 of rotor 12 create
a Dynamic Fluid Shield 26 for the blades 21 of rotor 11 and the blades 21 of rotor 11 create
a Dynamic Fluid Shield 27 for the blades 22 of rotor 12)
Dynamic Fluid Braking - it is created by positioning the new CARM devices with DISA
relative to the flow direction, thus changing the size of the energy extracting/exerting part
of the swept area, or the amount of the fluid processed by the device, and it effects both lift
and drag type devices
Dynamic Wake Cancel - it is created by the lift type blades of the opposite rotors counter
rotating relative to each other, producing counter rotating wakes that may cancel each other
in the process, thus decreasing the wake effect to the blades on the down flow part, and it
effects only the lift type devices (Fig.6 is a schematic display of a crossflow axes lift type
turbine with DISA where the Vortex 11 created by the blades 21 of rotor 11 and the counter
rotating Vortex 12 created by the blades 22 of rotor 12 later on can cancel each other in the
process)
Dynamic Change of Blade Angle of Attack (by Dynamic Flow Deflection) - it is created by
the foil (lift) blades of opposite rotors rotating relative to each other, maintaining an optimal
blade angle of attack for the lift forces during the rotation, as well as delaying the deep
stalling and the wake creation process, and it effects only the lift type devices (Fig.5b is a
schematic display of a crossflow axes lift type turbine with DISA where the Dynamic
Change of Blade Angle of Attack is created where the blade 21 maintains a steady increase of
the angle of attack of blade 21 for an optimal lift, delaying the deep stalling process as well
as the wake creation process)
These effects depend on different factors such as the type of the devices (lift, drag), relative
position of the devices to the flow direction, rotors offset Ro, counter rotating or co rotating rotors,
blade numbers, blade pitch angle, blade spacing between Rotors BSBR etc (different combination of
the factors mentioned above may favor some effects and disfavor the others).

New parameters the CARM devices with DISA have new parameters compare to the
conventional CARM devices (without DISA), such as:
BR - the space between each blades tip and the opposite rotor-arm plane for both lift and
drag turbines (Fig.3b shows a crossflow axes lift turbine with DISA, where BR is the
space between blade 21 tip and the opposite rotor 12 plane)
B - the minimum space between two crossing blades from opposite rotors for both lift and
drag turbines (Fig.3b shows a crossflow axes lift turbine with DISA, where B is the space
between two crossing blades 21 and 22 from rotors 11 and 12)
Ro - Rotors Offset, which is the distance between two offset parallel rotors axes for both
lift and drag turbines (Fig.3b shows a crossflow axes lift turbine with DISA, and Ro as the
distance between two offset parallel rotors axes)
Y - Yaw angle which determines the position of the devices energy extracting/exerting
part of the swept area relative to the flow direction
BSBR Blade Spacing Between Rotors 00 <= BSBR < 1800, which is the angle between the
two close blades from opposite rotors on a plane parallel to the rotors, where one of the
blades is at the = 00 rotating phase angle
BRA - Blade Rotation Angle 00 < BRA < 900, which is the maximum angle of the rotating
drag type blade relative to its rotor on the rotor-arm plane (Fig.7 shows a crossflow axes
drag turbine with DISA type 3, and BRA is the maximum angle of the rotating drag type
blade 1 relative to its rotor 44)
Additional mechanisms the CARM devices with DISA have additional mechanisms compare to
the conventional CARM devices (without DISA), such as:

 rotors synchronizing mechanism a mechanism that synchronizes the rotors rotation relative
to each other with the same TSR or different TSR, avoiding the blades of the opposite rotors
collision during the rotation, serving as shaft mechanism as well and can be used on lift and
drag devices (Fig.3b shows a crossflow axes lift turbine with DISA, where the rotors
synchronizing mechanism is shown by number 4)
blade-rotor synchronizing mechanism a mechanism that synchronizes the rotation of
variable blade relative to its rotor along with the rotors synchronizing mechanism in such
way that the blades of the opposing rotors do not collide during the rotation and can be used
on drag devices (Fig.7 shows a crossflow axes drag turbine with DISA type 3, and a bladerotor synchronizing mechanism 40)
blades synchronizing mechanism a mechanism that synchronizes the variable blades
rotation (for the same rotor) during the rotors rotation, and is linked to the blade-rotor
synchronizing mechanism in such way that the blades of the opposing rotors do not collide
during the rotation and can be used on drag devices (Fig.7 shows a crossflow axes drag
turbine with DISA type 3, and a blades synchronizing mechanism 42)
yaw mechanism a mechanism that orients the new devices energy extracting/exerting
part of the swept area relative to the flow direction for a maximum energy
extracting/exerting value, and can be used on lift and drag devices
The CARM devices with DISA of the new class (supper class Dig.2) tent to become conventional
CARM devices without DISA (conventional class Dig.2) when the CARM devices with DISA are
dismounted or half mounted (in this case the CARM devices with DISA loses completely the new
characteristics, new parameters, new effects and the additional mechanisms, becoming conventional
CARM devices without DISA) or when the CARM devices with DISA change their position relative to
the flow direction (in this case the CARM devices with DISA decrease the energy extracting/exerting
part of swept area, decreasing their gains from the new characteristics, new parameters, new effects and
the additional mechanisms, tenting to become conventional CARM devices without DISA).
Fig.3a and Fig.3b show the transformation of a conventional crossflow axis lift type turbine without
DISA (Fig.3a) to a new crossflow axes lift type turbine with DISA (Fig.3b).
The transformation is realized by moving the upper rotor 11 to a new upper support structure 6 by a
distance Ro (which is the distance between the two offset parallel rotors axes 11 and 12) becoming rotor
12, adding an additional blade (there are 2 blades 21 of rotor 11 and 2 blades 22 of rotor 12 along with
the struts), adding a rotors synchronizing mechanism 4 to synchronize the rotors relative rotation.
The new crossflow axes lift type turbine with DISA (Fig.3b) is like having two turbines (the lower rotor
11 with 2 blades 21 rotating anticlockwise and the upper rotor 12 with 2 blades 22 rotating clockwise),
sharing a common space, the fluid (gases or liquids), the support structure 6, the electric generator 5, the
rotors synchronizing mechanism 4 as well as other mechanism that can be added such as the braking
system, the yawing system etc. So for almost the same space (the differences Ro) and almost the same
material (the difference is the additional blade and synchronizing mechanism) the new crossflow axes
lift type turbine with DISA has a higher efficiency and can fix the other disadvantages
The new CARM devices with DISA are characterized by a tradeoff between the advantages and
disadvantages of the conventional CARM devices with DISA. The main advantage of the conventional
CARM devices without DISA which is omni directional (meaning the device would perform equally on
any flow direction) would becomes less advantageous for the new CARM devices with DISA, because
the new CARM devices with DISA are not fully omni directional anymore but semi omni directional,
meaning that the new CARM devices with DISA will still work on any direction, but their performance
it will be different.
On the other hand the main disadvantages of the conventional CARM devices without DISA (the lack of
device efficiency, the pulsation of the blades, the bending moment created on the rotor shaft, the
negative effects of the turbulent wakes, the transmission of the fluctuating loads, self starting
problem, lack of fluid dynamic braking, unsmooth torque curve, vibrations) would become less

disadvantageous for the new CARM devices with DISA compare to the conventional devices without
DISA, such as:
1. The efficiency - the new CARM devices with DISA would have a higher efficiency than
conventional CARM devices without DISA (space and material wise), because the new devices
have an increased swept area (double compare to the old ones), especially an increase of the energy
extracting/exerting parts of it - considering the power output P = 0.5*Cp**A*U3, it is obvious the
swept area A has on the device efficiency, space & material wise.
The factors tending to decrease the efficiency of new CARM devices with DISA are:
a. The Ro - offset Rotors, increasing the new device overall space area (effecting lift & drag
type devices with offset rotors)
b. The flow interference to each rotors energy extracting/exerting parts of swept area (effecting
lift type devices)
c. The rotors synchronizing mechanism (effecting lift & drag type devices)
d. The struts system (effecting lift type devices when it is applied)
e. The decrease of lift forces on the down flow part of the new devices (effecting lift type
devices)
f. Blade-rotor synchronizing mechanism & blades synchronizing mechanism (effecting drag
type devices when it is applied)
The factors tending to increase the efficiency of new CARM devices with DISA are:
a. Dynamic Fluid Ducting (effecting lift & drag type devices)
b. Dynamic Flow Deflection (effecting lift & drag type devices)
c. Dynamic Fluid Shield (effecting lift & drag type devices)
d. Dynamic Wake Cancel (effecting lift type devices)
e. Dynamic Change of Blade Angle of Attack by Dynamic Flow Deflection (effecting lift type
devices)
2. The pulsation of the blades - the new CARM devices with DISA have less pulsation of the blades
for each revolution passing through different pressure parts resulting from:
a. Dynamic Fluid Shield (effecting lift & drag type devices)
b. Dynamic Wake Cancel (effecting lift type devices)
3. The bending moment created on the rotor shaft (especially for large structures) - the new CARM
devices with DISA have less bending moment created on the rotor shaft resulting from the counter
rotating rotors which a zero resultant moment of force, when the rotors have equal rotor arms, are
counter rotating and have the same TSR. The modularity of the new devices could decrease
bending moment even when the rotors have unequal rotor arms, are co rotating and have different
TSR, but the modules could be arranged such as create a zero resultant moment of force (effecting
lift & drag type devices).
4. The negative effects of the turbulent wakes - the new CARM devices with DISA have less
turbulent wakes created by the blades of lift type turbine resulting from Dynamic Wake Cancel
(effecting lift type devices).
5. The transmission of the fluctuating loads - the new CARM devices with DISA have less
fluctuating loads transmitted to the support structure (as well as to the other systems such as the
foundation system, shaft system, generator system, bearings etc), resulting from:
a. the modularity of the new CARM devices with DISA, decreasing the transmission of
fluctuating loads (effecting lift & drag type devices)
b. the rotors synchronizing system (effecting lift & drag type devices)
6. Self starting problem - the new CARM devices with DISA (the lift type devices) have less self
starting problem resulting from:
a. Dynamic Increase of Swept Area of the device, especially the dynamic increase of
extracting/exerting parts of it

b. Dynamic Fluid Shield

7. Lack of fluid dynamic braking (aerodynamic braking, hydrodynamic braking, etc) the new
CARM devices with DISA have some sort of fluid dynamic braking resulting from the positioning
of the new devices relative to the flow direction, which changes the size of the energy
extracting/exerting part of the swept area, or the amount of the fluid processed by the devices (it
effects both lift and drag devices).
8. Unsmooth torque curve - the new CARM devices with DISA have a smoother torque curve
resulting from the relative rotation of at least two rotors, along with the rotors synchronizing
mechanism as well as other effects mentioned above.
9. Vibrations - the new CARM devices with DISA have less vibrations resulting from the new
characteristics and effects mentioned above
FIGURES

Fig.1a

Fig.2a

Fig.1b

Fig.2b

Fig.3a

Fig.3b

Fig.4a

Fig.4b

Fig.5a

Fig.5b

Fig.6

Fig.8

Fig.10

Fig.7

Fig.9

Fig.11