The present invention relates to an apparatus and method for generating power during motion of a bearing.
A bearing can be defined as any of various machine elements that constrain the relative motion between two or more parts to only the desired type of motion. This is typically to allow and promote free rotation about a longitudinal axis and/or restrain any linear movement of a component in a normal direction respective to the bearing. Bearings may be classified broadly according to the motions they allow and according to their principle of operation, as well as by the directions of applied loads they can handle.
Bearings undergo significant use, which causes wear to the various bearing components. Over time, the wear on the bearing can result in mechanical failure. Mechanical failure can impact the rotational motion and/or the axial linear restraint. Failure to control either of these movements can cause catastrophic failure to the machinery relying upon the bearing.
Bearing reliability and predictive servicing can impact the operation and uptime of equipment. Bearings are used in many applications, including vehicles, wind turbines, automated machinery, and the like. Over time, the bearings wear. Bearing failure during operation can cause significant damage to the equipment and possibly the surrounding area. The bearing failure could even potentially cause injury or death to people should the right circumstances come occur.
Bearing monitoring systems require power for operation. Power is utilized for operating the condition monitoring sensors, providing power for any computing devices, and providing power for transferring any collected information to a centralized system. The power is provided through wiring to the devices.
Bearing reliability and predictive servicing can be improved by monitoring the bearing. A monitoring system would require power. What is desired is a power generating system associated with the bearing assembly.
The present invention is directed towards an apparatus and respective method for generating electrical energy during the operation of equipment comprising a bearing.
In a first aspect of the present invention, a power generating bearing assembly, the power generating bearing assembly comprising:
a bearing comprising:
an electrical power generator including a generator core comprising an electrical coil wound about a magnetic core to generate electrical power, the electrical generator being attached to the respective rotational ring;
a magnetically polarized material carried by the sealing system; and
a generator positioning system that carries the electrical power generator and positions the electrical power generator proximate the magnetically polarized material,
wherein the relative motion between the bearing outer ring and the bearing inner ring passes the magnetically polarized material across the generator core causing the generator core to create an electrical current.
In a second aspect, the system further includes a processing device comprising a set of digital instructions for monitoring and analyzing digital data provided by a condition monitoring system integrated into the bearing assembly.
In another aspect, the generator positioning system further comprises a radial tolerance compensating system. The radial tolerance compensating system can include a radial biasing member assembled between a fixed mounting member and the electrical power generator, a generator core radial gliding material located between the mating surface of the electrical power generator and a ring end surface of the respective rotational ring.
In another aspect, the generator positioning system further comprises an axial tolerance compensating system. The axial tolerance compensating system provides a magnetically polarized material spanning across a distance of an axially oriented surface. The electrical power generator can include a friction-reducing interface enabling the electrical power generator to positionally adjust across the axially oriented surface in an axial direction. The friction-reducing interface can include a circumferential gliding material, one or more bearings, and the like.
In another aspect, the generator core can be assembled with a longitudinal axis being in a radial orientation and the magnetically polarized material is assembled in an annular ring extending axially from the sealing system.
In another aspect, the magnetically polarized material can be provided in a complete annular ring; in a single section covering a partial circularly shaped section; or in a series of sections which are spatially at equal radial distances from a bearing ring center.
In another aspect, the generator core can be assembled with a longitudinal axis being in an axial orientation and the magnetically polarized material is assembled in an orientation substantially parallel with the sealing system.
In another aspect, the electrical power generator can be carried by a radial registration control member, wherein the radial registration control member enables radial positioning of the electrical power generator. The electrical power generator can be radially positioned by engaging one or more generator radial guide features with one or more generator guide tracks, wherein the generator guide track is formed within the sealing system. The generator radial guide features engage with the generator guide track to align the electrical power generator with the magnetically polarized material. A biasing member can be integrated into the power generating subassembly, ensuring the generator core remains positioned proximate to the magnetically polarized material during operation.
One advantage of the present invention is the ability to generate a continued electrical current during motion of one of the rings of the bearing. The power can be utilized to operate bearing condition monitored equipment. The inclusion of an electrical power-generating device eliminates any need for a locally stored power (such as by a battery) or conveyed power from an external power source. By generating power at the location, the system can operate completely independent and un-tethered from any other device by providing sufficient power for wireless signal communications. While yet another advantage is that operation of the monitoring system can be limited to the time where the bearing is undergoing rotation. Power is only applied to the system when the generator is subjected to the relative motion between the bearing outer ring and the bearing inner ring.
Bearings can be utilized on equipment deployed in remote locations. The location could complicate any provisions for externally provided power for monitoring the condition of the bearing. The bearing(s) can be integrated into the equipment at a location that is difficult to access, particularly for wiring. Further, wires can accidentally interfere or become abraded by any rotational movements or other movements of components of the equipment.
Another advantage enables the registration between the electrical power generator and the magnetically polarized material to adapt to changes and wear of the bearing. The mechanical interface includes features to accommodate for radial and axial changes between the electrical power generator and the magnetically polarized material.
The use of a magnetic density operated generator core eliminates any wear and reliability issues associated with moving components. Any contacting surfaces can include bearings, friction reduced surfaces, and the like to minimize any impact resulting from relative motion between two moving components contacting one another.
These and other features, aspects, and advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims and appended drawings, which follow.
For a fuller understanding of the nature of the present invention, reference should be made to the accompanying drawings in which:
Like reference numerals refer to like parts throughout the several views of the drawings.
The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper”, “lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, and derivatives thereof shall relate to the invention as oriented in
A generic exemplary system schematic is presented in
The processing device 150 includes common digital data processing components, include a motherboard, at least one microprocessor, memory, a data recording device, digital instructions (such as software, firmware, and the like), input/output controllers, data communication devices, and the like. A user input device 154 and a user output device 152 are connected in signal communication to the processing device 150 through the input/output controllers. The digital data signal is received by the processing unit 150 and interpreted accordingly. The digital data signal would be provided when the power generating bearing assembly 100 is subjected to movement. The relative movement between the bearing inner ring 112 and the bearing outer ring 116 causes the power generating subassembly 200 to generate electrical power. Therefore, the electrical power is only available when the bearing inner ring 112 and bearing outer ring 116 are in relative motion to one another. It is understood that electrical power can be stored in a capacitor or battery integrated within the power generating subassembly 200. This would enable short cycles of additional power for continued operation after the bearing inner ring 112 and bearing outer ring 116 become stationary respective to one another. This would be beneficial for recording conditions of the bearing 110 after halting any operation, during cool down, and the like. The system can be recording conditions such as temperature, and the like.
A first exemplary embodiment of the power generating subassembly 200 is presented as a power generating subassembly 300 illustrated in
In the exemplary embodiment, the bearing 110 comprises a magnetically polarized material mount ring 320. The magnetically polarized material mount ring 320 can be provided as a complete annular ring extending axially from the sealing system 130. Alternatively, the magnetically polarized material mount ring 320 can be provided in a single section, referred to as a magnetically polarized material mount section 322 or multiple sections 322 equidistantly spaced about the bearing ring 112, 116, wherein each magnetically polarized material mount section 322 is located equidistant along a radial direction from a bearing center. The magnetically polarized material mount ring 320 (or magnetically polarized material mount section 322) includes a magnetically polarized material 324. The magnetically polarized material 324 can be any material or configuration of materials providing a variable reluctance. The magnetically polarized material 324 is assembled extending axially or perpendicular from the sealing system. The magnetically polarized material 324 can be secured to the sealing system 130 by a magnetically polarized material mount section 322. The magnetically polarized material mount section 322 is assembled to the sealing system 130 using any acceptable assembly interface. The exemplary assembly interface utilizes a mechanical assembly fastener 132. Alternative assembly interface options can include adhesive, providing the magnetically polarized material mount section 322 and sealing system 130 as a unitary construction, a mechanical interface such as a series of teeth and grooves, and the like, or any combination thereof. A circumferential gliding material 326 is preferably laminated over a contacting surface of the magnetically polarized material mount section 322/magnetically polarized material 324. The circumferential gliding material 326 provides a friction-reduced surface to reduce wear and aid in the reliability and longevity of the system. The magnetically polarized material mount ring 320/magnetically polarized material mount section 322 remains stationary upon the respective sealing attachment ring.
An electrical power generator 310 is assembled to an electronics box 330. The electronics box 330 is affixed to the respective rotational ring. The electrical power generator 310 is preferably biased against a circumferential gliding material 326 by at least one radial biasing member 340. Radial motion of the electrical power generator 310 can be aided by an inclusion of a generator core radial gliding material 140. The generator core radial gliding material 140 would be assembled between the electrical power generator 310 and the ring end surface 113, 117. The biasing force retains the electrical power generator 310 in contact with a mating surface of the circumferential gliding material 326. It is understood that the biasing force can be engineered to be overcome by air passing between the magnetically polarized material mount section 322 and the electrical power generator 310, wherein the air creates an air cushion therebetween. Alternatively, an optional plurality of circumferential motion bearings 314 can be integrated into either the electrical power generator 310 (as shown) or the magnetically polarized material mount section 322. The circumferential motion bearing 314 can be of any acceptable configuration known by those skilled in the art. It is understood that the circumferential gliding material 326 can be applied to a contacting surface of the electrical power generator 310 in an alternate embodiment or as an enhancement.
An electrical circuit can be integrated into the electronics box 330. The electrical circuit can include any monitoring circuitry and software; analysis circuitry and software; wired or wireless communication circuitry, hardware, and software, and the like.
In operation, as the bearing inner ring 112 and bearing outer ring 116 rotate respective to one another, the generator core 312 passes across the magnetically polarized material 324. The magnetically polarized material 324 includes variations in magnetic properties, wherein as the magnetically polarized material 324 moves relative to the generator core 312, the variations in magnetic properties changes the magnetic flux of a magnetic core 318 integrated into the generator core 312. The change in magnetic flux creates an electrical current in an electrical coil 316 wrapped about the magnetic core 318. The electrical current is conveyed to other equipment by wires or other electrical conduits.
It is understood that the magnetically polarized material mount section 322 can include a lead in taper to aid in engagement between the electrical power generator 310 and the magnetically polarized material mount section 322 as they pass by one another.
The radial biasing member 340 can be any compression spring, including a coil spring, a cantilevered spring, and the like.
The circumferential gliding material 326 can be any friction reducing material, including Polytetrafluoroethylene (PTFE), and the like. PTFE is a synthetic fluoropolymer of tetrafluoroethylene that finds numerous applications. The most well known brand name of PTFE is Teflon™ manufactured by the DuPont Company™. Other materials, including Polyoxymethylene (POM), also known as acetal, polyacetal, and polyformaldehyde, is an engineering thermoplastic used in precision parts that require high stiffness, low friction and excellent dimensional stability The most well known exemplary brand name of POM is Delrin™, also manufactured by the DuPont Company™.
A second exemplary embodiment of the power generating subassembly 200 is presented as a power generating subassembly 400 illustrated in
An electrical power generator 410 is carried by a generator radial registration control member 450, where the generator radial registration control member 450 is supported by an electronics box 430. The electronics box 430 is secured to the respective rotational ring by any attachment interface. The electronics box 430 can include a generator box anchor 432 enabling attachment of the electronics box 430 to the respective rotational ring by a plurality of mechanical fasteners (not shown but well understood). The generator radial registration control member 450 is slideably assembled to the electronics box 430 through a registration control member sleeve 452. The registration control member sleeve 452 enables the generator radial registration control member 450 to move along a radial tolerance compensating motion 459. The electrical power generator 410 is assembled to the generator radial registration control member 450 by one or more axially positioning members. The exemplary embodiment employs a plurality of axial tolerance control members 460, enabling an axial tolerance compensating motion 419. The axial tolerance control member 460 are secured to the electrical power generator 410 and extend through apertures aperture 454, enabling axial movement of the axial tolerance control member 460. An axial tolerance control member cap 462 can be provided at an opposite end of the axial tolerance control member 460, wherein the axial tolerance control member cap 462 retains the axial tolerance control member 460 assembled to the generator radial registration control member 450. The electrical power generator 410 is retained against the sealing system 130 by a biasing force provided by an axial tolerance compensating biasing member 464. The axial tolerance compensating biasing member 464 extends between opposing faces of the electrical power generator 410 and the generator radial registration control member 450.
The inner generator guide track 134 and outer generator guide track 136 can be used as a guide for registration of an electrical power generator 410. A plurality of generator radial guide features 414 extends axially from a contacting surface of the electrical power generator 410. The generator radial guide feature 414 ride along each of the generator guide tracks 134, 136, ensuring the generator core 412 remains in alignment with the magnetically polarized material 424. The generator radial guide feature 414 can additionally ensure that predetermined gap remains between the generator core 412 and the magnetically polarized material 424. The radial guide features 414 and/or the generator guide tracks 134/136 are preferably made of any friction reduction material, including Polytetrafluoroethylene (PTFE), and the like. PTFE is a synthetic fluoropolymer of tetrafluoroethylene that finds numerous applications. The most well known brand name of PTFE is Teflon™ manufactured by the DuPont Company™. Other materials, including Polyoxymethylene (POM), also known as acetal, polyacetal, and polyformaldehyde, is an engineering thermoplastic used in precision parts that require high stiffness, low friction and excellent dimensional stability The most well known exemplary brand name of POM is Delrin™, also manufactured by the DuPont Company™.
The illustrated exemplary configuration assembles the electronics box 330, 430 to the bearing inner ring 112 and the sealing system 130 is affixed to the bearing outer ring 116. It is also understood that the electronics box 330, 430 can be assembled to the bearing outer ring 116 and the sealing system 130 is affixed to the bearing inner ring 112.
Since many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalence.
Number | Date | Country | Kind |
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EP2012/057434 | Apr 2012 | EP | regional |
This is a National Stage application claiming the benefit of International Application Number PCT/EP2013/057381 filed on 09 Apr. 2013 (Sep. 4, 2013), which claims the benefit of International Application Number PCT/EP2012/057434 filed on 24 Apr. 2012 (24.04.2012), both of which are incorporated herein by reference in their entireties.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2013/057381 | 4/9/2013 | WO | 00 |