Some mechanical devices capable of motion are controlled mostly or entirely by fluid power such as hydraulics or pneumatics. It may desirable to redesign or upgrade these types of systems to include electric power and/or electric components. It would be desirable to have a power generator to power the electronics that could easily be integrated or retrofitted into such a hydraulic or pneumatic mechanical system to power any electronics added to the system. It would further be desirable if such a power generator was capable of use in any other device requiring power, whether or not such device is a hydraulic or pneumatic type of device.
According to a first aspect of the disclosure, a pneumatic power generator includes a pneumatic motor, a coupler member, an alternator, and an electronics housing. The pneumatic motor has an inlet port at a first end thereof configured to receive pressurized gas, and an output shaft at a second end opposite the first end, the pneumatic motor configured to convert pressurized gas into mechanical energy. The coupler member has a first bore at a first end and a second bore at a second end opposite the first end, the output shaft of the motor being positioned within the first bore and rotationally coupled to the coupler member. The alternator has an input shaft at a first end, the input shaft positioned within the second bore of the coupler member and rotationally coupled to the coupler member, the alternator configured to convert mechanical energy into AC power. The electronics housing is coupled to the alternator and has an electronic board and at least one power storage device positioned therein, the electronic board including a rectifier configured to convert AC power output from the alternator into DC power and a bidirectional DC-to-DC converter configured to store the DC power in the power storage device. The pneumatic power generator is configured for generating power less than about 100 W and at least one power storage device is configured to provide power on demand to a device connected to the power generator.
The power storage device may be a supercapacitor or a battery. A connector in the electronics housing may include a power and a ground. The power generator may include a valve system configured to regulate flow of pressurized gas into the pneumatic motor. The valve system may be mounted to the pneumatic motor. The valve system may include an inlet fitting and an outlet fitting with a valve positioned between the inlet and outlet fittings. The valve may have a closed condition in which pressurized gas is prevented from flowing from the inlet fitting to the outlet fitting, and an open condition in which pressurized gas is capable of flowing from the inlet fitting to the outlet fitting. A first tube may couple the outlet fitting of the valve system to the inlet port of the pneumatic motor. A second tube may have a first end coupled to the inlet fitting of the valve system, and a second end opposite the first end configured to be coupled to the device connected to the power generator.
According to another aspect of the disclosure, a method of providing on-demand electric power to a device with a pneumatic power generator includes directing pressurized gas from the device to an inlet port of a pneumatic motor to rotate an output shaft of the pneumatic motor. Rotation of the output shaft is transmitted to an input shaft of an alternator via a coupler member, the coupler member including a first bore coupled to the output shaft of the pneumatic motor and a second bore coupled to the input shaft of the alternator. AC power generated by the alternator is directed to an electronic board within an electronics housing coupled to the alternator and the AC power is converted into DC power via a rectifier on the electronic board. The DC power is stored in at least one power storage device in the electronics housing. The pneumatic power generator is configured for generating power less than about 100 W.
The power storage device may be a supercapacitor or a battery. The pneumatic power generator may include a valve system mounted to the power generator. The valve system may be operated to regulate flow of the pressurized gas into the inlet port of the pneumatic motor. A valve of the valve system may be closed to stop flow of the pressurized gas into the inlet port of the pneumatic motor when the power storage device reaches an upper limit power storage value. The valve of the valve system may be opened to start flow of the pressurized gas into the inlet port of the pneumatic motor when the power storage device reaches a lower limit power storage value. A first tube may couple the connected device to an inlet fitting of the valve system and a second tube may couple an outlet fitting of the valve system to the inlet port of the pneumatic motor. A valve of the valve system may have an open condition in which pressurized gas is free to flow from the connected device to the inlet port of the pneumatic motor via the valve system. The valve of the valve system may have a closed condition which restricts pressurized gas from flowing from the connected device to the inlet port of the pneumatic motor.
According to yet another aspect of the disclosure, a pneumatic power generator includes a pneumatic motor having an inlet port at a first end thereof configured to receive pressurized gas, and an output shaft at a second end opposite the first end, the pneumatic motor configured to convert pressurized gas into mechanical energy. A coupler member has a first portion and a second portion, the output shaft of the motor being rotationally coupled to the first portion of the coupler member. An alternator has an input shaft at a first end, the input shaft rotationally coupled to the second portion of the coupler member, the alternator configured to convert mechanical energy into AC power when torque of the output shaft of the motor is transmitted to the input shaft of the alternator via the coupler member. Electronic components are coupled to the alternator and include an electronic board and at least one power storage device, the electronic board including a rectifier configured to convert AC power output from the alternator into DC power and a bidirectional DC-to-DC converter configured to store the DC power in the power storage device. The pneumatic power generator is configured for generating power less than about 100 W and the at least one power storage device is configured to provide power on demand to a device connected to the power generator.
The power storage device may be a supercapacitor or a battery. The electronic components may include a connector including a power and a ground. A valve system may be configured to regulate flow of pressurized gas into the pneumatic motor. The valve system may be mounted to a housing the pneumatic motor. The valve system may include an inlet fitting and an outlet fitting with a valve positioned between the inlet and outlet fittings. The valve may have a closed condition in which pressurized gas is prevented from flowing from the inlet fitting to the outlet fitting, and an open condition in which pressurized gas is capable of flowing from the inlet fitting to the outlet fitting. A first tube may couple the outlet fitting of the valve system to the inlet port of the pneumatic motor. A second tube may have a first end coupled to the inlet fitting of the valve system and a second end opposite the first end configured to be coupled to the device connected to the power generator. At least some of the electronic components may be in contact with the pneumatic motor. The first portion of the coupler member may a first gear and the second portion of the coupler member may be a second gear. The first gear and the second gear may have a 1:1 gear ratio.
According to still another aspect of the disclosure, a method of providing on-demand electric power to a device with a pneumatic power generator includes directing pressurized gas from the device to an inlet port of a pneumatic motor to rotate an output shaft of the pneumatic motor. Rotation of the output shaft may be transmitted to an input shaft of an alternator via a coupler member, the coupler member including a first portion coupled to the output shaft of the pneumatic motor and a second portion coupled to the input shaft of the alternator. AC power generated by the alternator may be directed to an electronic board operatively coupled to the alternator and the AC power may be converted into DC power via a rectifier on the electronic board. The DC power may be stored in at least one power storage device. The pneumatic power generator may be configured for generating power less than about 100 W.
The power storage device may be a supercapacitor or a battery. The pneumatic power generator may include a valve system mounted to the power generator. The method may also include operating the valve system to regulate flow of the pressurized gas into the inlet port of the pneumatic motor. The method may further include closing a valve of the valve system to stop flow of the pressurized gas into the inlet port of the pneumatic motor when the power storage device reaches an upper limit power storage value. The method may still further include opening a valve of the valve system to start flow of the pressurized gas into the inlet port of the pneumatic motor when the power storage device reaches a lower limit power storage value. A first tube may couple the connected device to an inlet fitting of the valve system and a second tube may couple an outlet fitting of the valve system to the inlet port of the pneumatic motor. A valve of the valve system may have an open condition in which pressurized gas is free to flow from the connected device to the inlet port of the pneumatic motor via the valve system. The valve of the valve system may have a closed condition which restricts pressurized gas from flowing from the connected device to the inlet port of the pneumatic motor.
The pneumatic motor 100 is best illustrated in
Pneumatic motor 100 may also have a flange member 130 and a threaded shaft 150. The flange member 130 may include internal threading to thread to the threaded shaft 150 of the motor 100. Flange 130 includes one or more apertures that align with one or more apertures in motor mount 160 so that a screw or other fastener may securely fix flange 130 to motor mount 160, preventing rotational movement between the housing of motor 100 and motor mount 160. It should be understood that other types of structures may be suitable to couple the pneumatic motor 100 to the motor mount 160.
The output shaft 140 of the motor 100 is coupled to the alternator 300 via a coupling member 200. Output shaft 140 may include at least one flat surface or other geometry to permit torque to be transmitted from the output shaft 140 to coupling member 200. An adapter or other member may be positioned over output shaft 140 to provide a desired geometric coupling between the output shaft 140 and coupling member 200. Otherwise, coupling member 200 may be compressed tightly over output shaft 140 to permit torque to be transmitted to allow for any desired geometry between coupling member 200 and output shaft 140. Coupling member 200 is illustrated best in
A mounting bracket 500 may optionally be provided with pneumatic power generator 10 to provide additional stability in connecting the power generator 10 to a device into which it is integrated. Mounting bracket 500 may include a plurality of apertures that align with corresponding apertures in motor mount 160 and alternator 300 so that the three components may be securely fixed to each other with fasteners or the like. As illustrated, mounting bracket 500 includes an additional flange 510 that may be used to securely fix mounting bracket 500 to the connected device. In the particular example illustrated, flange 510 of mounting bracket 500 includes two elongated slots to allow for mounting of mounting bracket 500 to the connected device at any position along the elongated slots using fasteners or the like. It should be understood that other configurations, such as apertures, may be used alternatively to the elongated slots in flange 510.
Alternator 300 is illustrated isolated from the other components of the pneumatic power generator 10 in
The electronics housing 400 is illustrated in
As should be understood from the above, the AC power generated by alternator 300 is rectified and stored in energy storage devices, which may provide the stored energy to electronics in the device on a demand basis. The power generated by pneumatic power generator 10 is preferably low power, on the order of less than about 100 Watts, the generated energy being stored in storage devices that may include, for example, batteries and capacitors in electronics housing 400. When the storage devices have charged to a high threshold capacity, the pneumatic motor 100 may be shut down by operation of valve system 700, described in greater detail below. As electronic components of the device incorporating pneumatic power generator 10 draw power on an on-demand basis from the storage devices, the charge stored in the storage devices will reduce until a low threshold is reached. In one example, power may be provided via wires 430 extending from inside electronics housing 400 through grommets 420 (or other suitable sealing components) the wires 430 including a two-pin in line connector to interface with the device demanding the power. Once enough power is drawn so that the storage devices reach the low threshold is reached, the valve system 700 may be further operated so that pneumatic motor 100 can continue operating to charge the storage devices again until they reach the high threshold capacity again.
Valve system 700 is best illustrated in
A second or bottom end of pneumatic motor 100′ may include a flange member similar to flange member 300 that may be coupled to an interior support 520′ of housing 500′, for example via screws, bolts, or other fasteners. A motor shaft may extend from the second or bottom end of pneumatic motor 100′ and into a first gear 210′ of coupling member 200′. First gear 210′ may be a spur gear positioned between interior support 520′ and bottom face 530′ of housing 500′. Coupling member 200′ may include a second gear 220′, which may also be a spur gear, adjacent to and engaged with first gear 210′. In the illustrated embodiment, gears 210′ and 220′ have a one-to-one gear ratio, but it should be understood that other gear ratios may be used if desired. Second gear 220′ may be coupled to an input shaft of alternator 300′. Alternator 300′ may be similar or identical to alternator 300. With the configuration described above, activation of pneumatic motor 100′ for example by compressed gas, results in the rotation of the input shaft of alternator 300′ via interaction with the coupling members 200′. It should be noted that one difference between power generator 10 and power generator 10′ is that, in power generator 10, the pneumatic motor 100 is axially aligned with the alternator 300, which is made possible by coupling member 200, whereas in power generator 10′, the pneumatic motor 100′ and alternator 300′ are positioned side-by-side, which is made possible in the illustrated embodiment by coupling member 200′.
Valve system 700′ may be identical or similar to valve system 700. Valve system 700′ may include a fitting F1′ adapted to couple to a tube (not illustrated), which may in turn be connected to a connected device which provides for a main air source to the valve system 700′. Valve system 700′ may function identically or similarly to valve system 700, allowing compressed gas to flow through the tube connected to fitting F1′ into valve system 700′ and then through tube T2′ to pneumatic motor 100′ when the charge storage devices are at a low threshold. Similar to generator 10, generator 10′ charges the storage devices through compressed air flowing to pneumatic motor 100′ and in turn rotating the input shaft of alternator 300′, with charge flowing from the alternator to the storage devices. Once the storage devices reach a high threshold, valve system 700′ may prevent compressed air flowing into the valve system from the tube connected to fitting F1′ from passing to tube T2′, so that the pneumatic motor 100′ does not operate when charging the storage devices is unnecessary. Exhaust from the valve system 700′ may pass through tube T4′. Both exhaust tubes T3′ and T4′ may be connected to side wall 540′ so that the exhaust passes into the space in which coupling member 200′ is positioned. The exhaust may serve to lubricate the gears 210′ and 220′ of coupling member 200. Remaining exhaust may exit the housing 500′ from a tube (not shown) coupled to fitting F5′.
Electronic components 400′ are best illustrated in
Housing 500′ may include, in addition to top face 510′, interior support 520′, bottom face 530′, and side face 540′, at least one additional side face 550′. Interior support 520′ may be positioned between top face 510′ and bottom face 530′, with the interior support being supported by connections to side faces 540′, 550′. The top face 510′ may be coupled to bottom face 530′ via the at least two sides faces 540′, 550′, and a plurality of bolts or other fasteners. Although only two side faces 540′ and 550′ are shown, it should be understood that two additional side faces (not shown) may be included to fully encapsulate the pneumatic motor 100′, the coupling member 200′, the alternator 300′, and the electronic components 400′. The positioning of the various components of generator 10′, which may be made possible at least in part by the coupling member 200′ and the housing 500′, may provide certain benefits over generator 10. For example, as noted above, positioning of the electronic components 400′ next to the pneumatic motor 100′ may provide a cooling function for the electronic components. Still further, the partial or complete enclosure of the pneumatic motor 100′, coupling member 200′, alternator 300′, and electronic components 400′ may provide for a small and convenient form factor, easy manufacturing, and a safety function by enclosing components that, in certain situations, could be dangerous if they were exposed. However, in most other aspects, operation of power generator 10′ is identical to the operation of power generator 10 described above.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 62/300,177 filed Feb. 26, 2016, the disclosure of which is hereby incorporated by reference herein.
Number | Date | Country | |
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62300177 | Feb 2016 | US |