This application claims the benefit of a Canadian Patent Application filed on Jun. 26, 2009, which is hereby incorporated herein by reference.
The specification relates to an energy recovery system. More particularly, the specification relates to an energy recovery system for converting vehicle motion into electrical power, which may be usable to charge an electrical vehicle.
The following is not an admission that anything discussed below is prior art or part of the common general knowledge of persons skilled in the art.
U.S. Pat. No. 3,861,487 (to Gill) discloses a vehicle power system comprising a power generating unit carried by a vehicle for reaction to movements between parts of a vehicle to produce energy that is transmitted through a power reserve unit to electric generating means for translation into electrical energy, which augments the battery power pack that supplies current for an electric system on such a vehicle.
The following summary is provided to introduce the reader to the more detailed discussion to follow. The summary is not intended to limit or define the claims.
According to one broad aspect, an energy recovery system for converting vehicle motion into electrical power is provided. The energy recovery system comprises an arm mounted between a chassis of the vehicle and an axle of the vehicle. The arm is pivotably mounted at first and second opposed ends thereof and is configured to pivot with respect to the chassis and the axle when the chassis is vertically displaced with respect to the axle. A one-way ratchet assembly couples the arm to an output shaft. The ratchet assembly is movable between an engaged position and a disengaged position. In the engaged position, the ratchet assembly induces rotation of the output shaft in a first direction about a longitudinal axis thereof when the arm pivots in the first direction, and prevents rotation of the output shaft in a second direction opposite the first direction. In the disengaged position, the ratchet assembly does not prevent rotation of the output shaft in the second direction. A torsion spring is coupled to the output shaft such that when the output shaft is rotated in the first direction, the torsion spring is tightened and rotational energy of the output shaft is stored as potential energy in the torsion spring. An electromechanical assembly is coupled to the ratchet assembly. The electromechanical assembly is configured to move the ratchet assembly from the engaged position to the disengaged position when the torsion spring reaches a pre-determined tightness, so that when the ratchet assembly is in the disengaged position, the torsion spring loosens and induces rotation of the output shaft in the second direction. A generator is coupled to the output shaft and is configured to convert rotational energy of the output shaft into electrical energy.
The one-way ratchet assembly may comprise a pawl assembly moveable between a pawl assembly engaged position and a pawl assembly disengaged position. When the pawl assembly is in the pawl assembly engaged position, the pawl assembly induces the rotation of the output shaft in the first direction when the arm pivots in the first direction. The one-way ratchet assembly may further comprise a clutch assembly moveable between a clutch assembly engaged position and a clutch assembly disengaged position. When the clutch assembly is in the clutch assembly engaged position, the clutch assembly prevents the rotation of the output shaft in the second direction. The ratchet assembly is in the engaged position when the clutch assembly is in the clutch assembly engaged position and the pawl assembly is in the pawl assembly engaged position.
In some embodiments, the pawl assembly comprises a cylinder extending collinear to the output shaft and having a toothed bore extending longitudinally therethrough. The cylinder may be coupled to the second end of the arm such that when the arm pivots in the first direction, the cylinder rotates about a longitudinal axis thereof in the first direction.
The pawl assembly may further comprise a toothed pawl received in the toothed bore and engaging the toothed bore when the pawl assembly is in the pawl assembly engaged position. When the toothed pawl engages the toothed bore, rotation of the cylinder in the first direction induces orbital rotation of the toothed pawl in the first direction about the longitudinal axis of the cylinder. The toothed pawl may be coupled to the output shaft such that the orbital rotation of the toothed pawl in the first direction induces the rotation of the output shaft in the first direction.
The pawl assembly may further comprise a pivot pin about with the toothed pawl is pivotal. The orbital rotation of the toothed pawl may induce orbital rotation of the pivot pin about the longitudinal axis of the cylinder. The pivot pin may be mounted to the output shaft, such that that the orbital rotation of the toothed pawl in the first direction induces the rotation of the output shaft in the first direction via the pivot pin.
In some embodiments, when the pawl assembly is in the pawl assembly engaged position, the toothed pawl is pivoted about the pivot pin to a first pivotal position in which the toothed pawl engages the toothed bore. When the pawl assembly is in the pawl assembly disengaged position, the toothed pawl is pivoted about the pivot pin to a second pivotal position. The toothed pawl may be moved between the first pivotal position and the second pivotal position by movement of a plunger between a first angular position and a second angular position with respect to the toothed pawl. The plunger may be mounted to a control shaft extending collinear to the output shaft, and the plunger may be moved between the first angular position and the second angular position by rotation of the control shaft. The control shaft may be rotated by an electromechanical assembly.
In some embodiments, the clutch assembly comprises a first toothed surface mounted to the output shaft such that rotation of the output shaft in the first direction induces rotation of the first toothed surface in the first direction. The clutch assembly may further comprise a second toothed surface moveable towards and away from the first toothed surface by the electromechanical assembly. The second toothed surface may be rotationally fixed with respect to the output shaft. When the ratcheting assembly is in the engaged position, the second toothed surface may be moved towards the first toothed surface to engage the first toothed surface to prevent rotation of the first toothed surface in the second direction. When the ratcheting assembly is in the disengaged position, the second toothed surface may be moved away from the first toothed surface.
In some embodiments, the output shaft is coupled to the torsion spring by at least one gear.
In some embodiments, the torsion spring is at least partially received in a housing comprising at least one catch on an inner surface thereof. The torsion spring may be tightened by winding of a first end thereof about a spring axis, and a second end thereof may be releasably secured to the catch. In some embodiments, the spring reaches the predetermined tightness when a force required to maintain the second end of the spring secured to the catch is less than a force required to continue winding the first end of the spring. When the spring reaches the predetermined tightness, the second end of the spring may be released from the catch and the spring may rotate about the spring axis.
In some embodiments, at least one of the release of the second end of the spring from the catch and the rotation of the spring about the spring axis triggers the electromechanical unit to move the ratchet assembly from the engaged position to the disengaged position.
In some embodiments, the housing comprises a plurality of catches on the inner surface thereof and positioned around an inner perimeter thereof. When the second end of the spring is released from the catch and the spring rotates about the spring axis, the second end of the spring snaps into another of the catches. In such embodiments, the snapping of the spring into the other of the catches may trigger the electromechanical unit to move the ratchet assembly from the engaged position to the disengaged position.
In some embodiments, the catch is a recess formed in the inner surface of the housing, and the second end of the spring is releasably received in the recess.
In some embodiments, the system further comprises a battery coupled to the generator and configured to store the electrical energy.
In some embodiments, the arm is mounted directly to the chassis. In other embodiments, the arm is mounted to a suspension system of the automobile.
According to another broad aspect, an automobile is provided which comprises the energy recovery system described herein.
According to another broad aspect, an energy recovery system for converting vehicle motion into electrical power is provided. The energy recovery system comprises an arm mounted between a first portion of the vehicle and a second portion of the vehicle. The arm is pivotably mounted at first and second opposed ends thereof and is configured to pivot with respect to the first portion and the second portion when the first portion is vertically displaced with respect to the second portion. A one-way ratchet assembly couples the arm to an output shaft. The ratchet assembly is movable between an engaged position and a disengaged position. In the engaged position, the ratchet assembly induces rotation of the output shaft in a first direction about a longitudinal axis thereof when the arm pivots in the first direction, and prevents rotation of the output shaft in a second direction opposite the first direction. In the disengaged position, the ratchet assembly does not prevent rotation of the output shaft in the second direction. A torsion spring is coupled to the output shaft such that when the output shaft is rotated in the first direction, the torsion spring is tightened and rotational energy of the output shaft is stored as potential energy in the torsion spring. An electromechanical assembly is coupled to the ratchet assembly. The electromechanical assembly is configured to move the ratchet assembly from the engaged position to the disengaged position when the torsion spring reaches a pre-determined tightness, so that when the ratchet assembly is in the disengaged position, the torsion spring loosens and induces rotation of the output shaft in the second direction. A generator is coupled to the output shaft and is configured to convert rotational energy of the output shaft into electrical energy.
According to another broad aspect, an energy recovery system for converting vehicle motion into electrical power is provided. The energy recovery system comprises an arm mounted between a chassis of the vehicle and an axle of the vehicle. The arm is pivotably mounted at first and second opposed ends thereof and is configured to pivot with respect to the chassis and the axle when the chassis is vertically displaced with respect to the axle. A one-way ratchet assembly couples the arm to an output shaft. The ratchet assembly is movable between an engaged position and a disengaged position. In the engaged position, the ratchet assembly induces rotation of the output shaft in a first direction about a longitudinal axis thereof when the arm pivots in the first direction, and prevents rotation of the output shaft in a second direction opposite the first direction. In the disengaged position, the ratchet assembly does not prevent rotation of the output shaft in the second direction. A torsion spring is coupled to the output shaft such that when the output shaft is rotated in the first direction, the torsion spring is tightened and rotational energy of the output shaft is stored as potential energy in the torsion spring. An electromechanical assembly is coupled to the ratchet assembly. The electromechanical assembly is configured to move the ratchet assembly from the engaged position to the disengaged position when the torsion spring reaches a pre-determined tightness, so that when the ratchet assembly is in the disengaged position, the torsion spring loosens and induces rotation of a second output shaft. A generator is coupled to the second output shaft and is configured to convert rotational energy of the second output shaft into electrical energy.
Various apparatuses or methods will be described below to provide an example of each claimed invention. No example described below limits any claimed invention and any claimed invention may cover processes or apparatuses that are not described below. The claimed inventions are not limited to apparatuses or processes having all of the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or process described below is not an embodiment of any claimed invention. The inventor(s), applicant(s), and/or owner(s) maintain that rights to such features are not dedicated to the public as a result of being unclaimed in this application, and may be the subject matter of claims presented in other applications, such as, for example, continuation, continuation-in-part, divisional, or similar applications.
Referring to
Referring still to
In the embodiment shown, the first 106 and second 107 energy recovery systems are substantially identical. As such, a description will be provided of only the first energy recovery system.
Referring to
In an alternate embodiment (not shown), the first end 109 of the arm 108 may be pivotally mounted to the chassis 101 indirectly. For example, the first end 109 of the arm 108 may be pivotally mounted to a portion of the suspension system 105. In a further alternate embodiment (not shown), the arm 108 may be a part of the suspension system.
When the axle 102 moves towards the chassis 101, the distance between the first end 109 of the arm 108 and the second end 110 of the arm 108 can shorten. The body 11 of the arm 108 can be telescopic, to facilitate pivoting of the arm 108 relative to the chassis 101 and the axle 102 in cases where the distance between the ends of the arm lengthens and shortens during operation.
When the axle 102 moves towards the chassis 101, the arm pivots at both ends thereof, such that the body portion rotates in a first direction, indicated by arrow A1 in
Referring now to
Referring to
Referring still to
Specifically, in the example shown, the pawl assembly 116 is movable between a pawl assembly engaged position and a pawl assembly disengaged position, and the clutch assembly 117 is movable between a clutch assembly engaged position and a clutch assembly disengaged position. When the pawl assembly 116 is in the pawl assembly engaged position, it induces the rotation of the output shaft 114 in the first direction when the arm 108 pivots in the first direction. When the clutch assembly 117 is in the clutch assembly engaged position, it prevents the rotation of the output shaft 114 about axis 115 in the second direction. Accordingly, when both the pawl assembly 116 and the clutch assembly 117 are in the engaged position, the ratchet assembly 113 is in the engaged position.
Referring still to
The cylinder 118 has a bore 120 extending longitudinally therethrough, along axis 115. The second end portion 127 of the output shaft 114 is received in the bore 120 of the cylinder 118, and in a bore 178 of the bracket 176. As mentioned hereinabove, this configuration pivotally mounts the second end 110 of the arm to the axle 102.
The bore 120 is defined by an inner surface 119 of the cylinder 118. The inner surface 119 comprises a plurality of teeth 121, which extend inwardly towards the axis 115, and extend parallel to the axis 115. Accordingly, the bore 120 may be referred to as toothed bore 120. Referring to
Referring still to
The pawl 122 is pivotal about the pivot pin 128 between a first pivotal position, shown in
In order to move the pawl 122 between the first pivotal position and the second pivotal position, a plunger 131 and control shaft 132 are provided. The control shaft 132 extends collinear to the output shaft 114, and has a first end portion 134, and an opposed second end portion 135. The output shaft 114 has a bore 133 defined therein, which extends along axis 115 and is in communication with recess 130. The first end portion 134 of the control shaft 132 is received in the bore 133. The plunger 131 is mounted to the first end portion 134 of the control shaft 132, and extends outwardly therefrom and into the recess 128, such that a distal end 136 of the plunger 131 contacts the pawl 122. A spring 137 is provided, which biases the plunger 131 to bear against the pawl 122. In order to move the toothed pawl 122 from the first pivotal position to the second pivotal position, the control shaft 132 is rotated about axis 115 in a direction indicated by arrow A4 in
The rotation of the control shaft is controlled by an electromechanical assembly 155, and will be described in further detail hereinbelow.
Referring still to
Accordingly, as the arm 108 repeatedly rotates back and forth in the first direction and the second direction, the cylinder 118 will repeatedly rotate back and forth in the first direction and the second direction about axis 115. When the pawl assembly 116 is in the pawl assembly engaged position, the rotation of the cylinder 118 in the first direction will induce orbital rotation of the toothed pawl 122 about axis 115 in the first direction (as shown by arrow A3). As the toothed pawl 122 is mounted to the output shaft 114 by the pivot pin 128, the orbital rotation of the toothed pawl 122 will induce orbital rotation of the pivot pin 128 about axis 115, which will in turn induce rotation of the output shaft 114 about axis 115 (i.e. the orbital rotation of the toothed pawl 122 in the first direction induces the rotation of the output shaft 114 in the first direction via the pivot pin 128). Due to the configuration of the pawl assembly 116, the rotation of the cylinder 118 in the second direction will not induce orbital rotation of the toothed pawl 122 in the second direction. Therefore, as the arm 108 repeatedly rotates back and forth, the output shaft 114 will rotate in only the first direction.
Referring now to
In the embodiment shown, the output shaft 114 is coupled to the torsion spring 137 by a series of gears 150. Specifically, in the embodiment shown, a first gear 138 is mounted around the output shaft 114. A plurality of additional gears 139 is provided between the first gear 138 and the torsion spring 137. Specifically, in the embodiment shown, the additional gears include a second gear 180 driven by the first gear 138, a third gear 181 driven by the second gear, and a fourth gear 182 driven by the third gear 181. Further, a fifth gear 183 (shown in dotted line) is mounted on the same gear shaft as the second gear 180, a sixth gear 184 is driven by the fifth gear 183, and a seventh gear 185 (shown in dotted line) is mounted on the same gear shaft as the sixth gear 184. The seventh gear 185 drives an eighth gear 186. The fourth gear 182 and the eighth gear 183 are mounted on the same gear shaft 141, which, as will be described hereinbelow, is coupled to the torsion spring 137. This configuration of gears serves to provide control to the system 100, and to maximize the energy output of the system 100. In alternate embodiments, however, an alternate configuration of gears, or only one gear may be provided.
In some embodiments (not shown), some of the gears 150 may be translatably mounted. For example, the gear shaft of the third gear 181 may be mounted such that the third gear 181 may move (with its shaft and orthogonally relative to its axis) slightly away from the fourth gear 182 in a vertical direction, so that the teeth of the third 181 and fourth 182 gear no longer engage. The second gear 180 may also be movably mounted, to accommodate the movement of the third gear 181. When the spring 137 unwinds, as will be described hereinbelow, it causes the fourth 182 gear to rotate, which causes the third gear to rotate, which causes the second gear 180 to rotate, which causes the first gear 138 to rotate. The rotation of the first gear 138 causes the output shaft 114 to rotate in the second direction. When the spring has finished unwinding, the fourth gear 182 will generally cease to rotate. The third gear can move slightly away from the fourth gear 182, and can (due to, for example its momentum), continue to rotate even after the spring has stopped unwinding. This will cause the second gear 180 and first gear 130, and therefore the output shaft 114, to continue rotating even after the spring 137 has stopped unwinding. This may further serve to maximize the energy output of the system.
The torsion spring 137 has a first or inner end 144, and a second or outer end 145, and extends along a spring axis 143. The second end 145 of the torsion spring is releasably fixed in position. For example, as shown, the torsion spring 137 is received in a housing 142. The housing 142 comprises a catch 146a on an inner surface 147 thereof, and the outer end 145 of the spring 137 is releasably secured to the catch 146a. In the example shown, the catch 146a is a recess formed in the inner surface 147 of the housing 142, and the second end 145 of the spring 137 comprises a protrusion 149 that is received in the recess and frictionally held therein. The inner end 144 of the spring 137 is coupled to the gear shaft 141, which extends along the spring axis 143. Accordingly, when the output shaft 114 rotates in the first direction, and the gears 150 rotate, the first end 144 of the spring 137 is wound about the spring axis 143, in a direction indicated by arrow A12, and the spring 137 is tightened.
Referring back to
Referring still to
The first bracket 151 comprises a first toothed surface 153, and the second bracket 152 comprises a second toothed surface 154. The first toothed surface 153 and the second toothed surface 154 are positioned in facing relation to each other. When the clutch assembly 117 is in the clutch assembly engaged position, the second bracket 152 is moved towards the first bracket 151, in a direction indicated by arrow A7, so that the second toothed surface 154 moves towards the first toothed surface 153 and contacts and engages the first toothed surface 153. The teeth on the first toothed surface 153 and the second toothed surface 154 are configured such that when the first 153 and second 154 toothed surfaces are engaged, the first bracket 151 may rotate in the first direction with respect to the second bracket 152; however, the first bracket 151 may not rotate in the second direction with respect to the second bracket 152. Particularly, the teeth on the first toothed surface 153 and the second toothed surface 155 are angled in opposite directions, so that rotational motion of the first bracket 151 with respect to the second bracket 152 may only occur in the first direction.
Accordingly, when the clutch assembly 117 is in the clutch assembly engaged position, rotation of the first bracket 151 in the second direction is prevented. As the first bracket 151 is fixedly mounted to the output shaft 114, rotation of the output shaft 114 in the second direction is prevented, and as such, unwinding of the spring 137 is prevented.
When the clutch assembly is in the clutch assembly disengaged position, as shown in
Accordingly, when the ratchet assembly 113 is in the engaged position, and as the arm 108 repeatedly pivots back and forth, the ratchet assembly 113 will rotate the output shaft 114 in the first direction, which will induce tightening of the torsion spring 137. Referring now to
Specifically, in the example shown, an electromechanical assembly 155 is provided, which is coupled to the ratchet assembly 113. The electromechanical assembly 155 is configured to move the ratchet assembly 133 from the engaged position to the disengaged position when the torsion spring 137 reaches the pre-determined tightness.
Referring again to
The sensors 156a-156d may be configured to sense the tightness of the spring 137 by sensing any of when the second end 145 of the spring 137 is released from the catch 145a, when the spring 137 rotates about the spring axis 143, and/or when the second end 145 of the spring 137 snaps into an adjacent catch. In the embodiment shown, the sensors 156a-156d are configured to sense when the second end 145 of the spring 137 snaps into an adjacent catch. Particularly, the sensors 156a to 156d are each provided on one of the catches 146a-146d. The sensors 156a-d may be pressure sensors for example, which sense when the second end 145 of the spring 137 snaps into the catch associated therewith. The sensors 156a-156d are in communication with the electromechanical assembly 155, and send a signal to the electromechanical assembly 155 when any of the sensors 156a-156d are triggered. This triggers the electromechanical assembly 155 to move the ratchet assembly 113 to the disengaged position.
Referring to
Referring to
Referring still to
After the shaft 161 has been turned in the direction indicated by arrow A13, the control unit 157 moves the first sliding arm 160 in the direction indicated by arrow A10, to withdraw the toothed end face 165 of the shaft 161 from the control shaft 132.
Referring to
When the pawl assembly 116 is in the pawl assembly disengaged position, and the clutch assembly 117 is in the clutch assembly disengaged position, the ratchet assembly 113 is in the disengaged position. When the ratchet assembly 113 is in the disengaged position, rotation of the output shaft 114 in the second direction is no longer prevented, and unwinding of the torsion spring 137 is no longer prevented. As such, the torsion spring 137 loosens or unwinds. The loosening of the torsion spring 137 induces the rotation of the output shaft 114 in the second direction. Specifically, referring to
Referring again to
A battery 171 is coupled to the generator 168, and is configured to store the electrical energy generated by the generator 168. The battery may be used to power various systems in the vehicle 100. For example, if the vehicle 100 is an electric automobile, the battery may power the motor of the automobile. Alternately, the battery may power any of the starter motor, the lights, or the ignition system of the vehicle 100. Alternately, some or all of the energy stored in the battery may be fed to an external electrical grid.
While the spring is unwinding, the arm 108 will continue to rotate back and forth as the chassis 101 moves towards and away from the axle 102. However, as the pawl assembly 116 is in the pawl assembly disengaged position, the movement of the arm 108 will not affect the output shaft 114.
Referring again to
In order to move the ratchet assembly 113 from the disengaged position back to the engaged position, the control unit 157 first moves clutch assembly 117 back to the clutch assembly engaged position. Specifically, the control unit moves the second sliding arm 167 in the direction indicated by arrow A7, which moves the second bracket in the direction indicated by arrow A7, so that the second toothed 154 surface contacts and engages the first toothed surface 153 to prevent rotation of the first toothed surface 153 in the second direction.
The control unit 157 then moves the pawl assembly 116 back to the pawl assembly engaged position. Specifically, the control unit 157 again moves the first sliding arm 160 in the direction indicated by arrow A9, so that the toothed face 165 of the shaft 161 engages the toothed face 166 of the arm. The control unit then rotates the shaft in a direction indicated by arrow A15 in
When the ratchet assembly 113 has been moved back to the ratchet assembly engaged position, the movement of the chassis 101 with respect to the axle 102 will again begin to cause tightening of the torsion spring 137. The sequence of tightening the torsion spring 137, and moving the ratchet assembly 113 to the disengaged position so that the torsion spring 137 unwinds and rotates the output shaft 114 in the second direction to generate energy is then repeated.
Although in the embodiment shown, the vehicle 100 is an automobile, in alternate examples, the vehicle may be another vehicle in which vertical displacement between two parts of the vehicle occurs during use. For example, the vehicle may be an aircraft, a boat, a motorcycle, a bicycle, a scooter, a truck, a two-wheeled self-balancing electric vehicle (such as those sold under the trademark Segway™), a train, a carriage, a cart, a snowmobile, an amphibious vehicle, or an all terrain vehicle. In such embodiments, the arm may be mounted between a first portion and a second portion of the vehicle which are vertically displaced with respect to each other.
In the embodiments described hereinabove, the unwinding of the torsion spring induces rotation of the output shaft in the second direction, and the rotational energy of the output shaft in the second direction is converted to electrical energy by the generator. In an alternate embodiment (not shown) a second output shaft may be provided in addition to the main output shaft, and the second output shaft may be connected to the torsion spring and the generator. The rotation of the main output shaft in the first direction may wind the torsion spring, and the unwinding of the torsion spring may induce rotation of the second output shaft. The generator may be coupled to the second output shaft such that the rotational energy of the second output shaft is converted to electrical energy.