Generator assembly and bearing equipped with the same

Abstract

A generator assembly for harvesting energy in a bearing arrangement having a first ring and a second ring is provided. The generator assembly includes a plurality of coils attached to the first ring and configured to interact with a magnet ring with alternating magnetization directions attached to the second ring, and a plug connector for supplying power generated by the generator assembly to external devices. The coils are encapsulated and mounted in an outer carrier ring such that the winding axis is oriented in a radial direction of the bearing and the magnet ring is composed of plural permanent magnets attached to an inner carrier ring attached to the inner ring of the bearing.

Claims

1. A generator assembly for harvesting energy in a bearing arrangement having a first ring and a second ring and first and second axial sides, the generator assembly comprising: the generator having a first generator portion located on the first axial side, comprising: a first plurality of coils attached to the first ring and configured to interact with a first magnet ring with alternating magnetization directions attached to the second ring, and a plug connector for supplying power generated by the generator assembly to external devices, the generator having a second generator portion located on the second axial side, comprising: a second plurality of coils attached to the first ring and configured to interact with a second magnet ring with alternating magnetization directions attached to the second ring, wherein one of the first and second rings forms an outer ring having a radially outermost outer surface, the radially outermost outer surface of the outer ring defining a groove which extends from the first axial side of the bearing, helically about the radially outermost outer surface of the outer ring, to the second axial side of the bearing; and a conductor being located in the groove and connecting the first generator portion to the second generator portion.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

(1) FIG. 1 is a perspective view of a generator assembly according to a first embodiment the invention mounted to a bearing;

(2) FIG. 2 is a perspective groove of a bearing with parts of a generator assembly according to a second embodiment of the invention; and

(3) FIG. 3 is a perspective view of a generator assembly according to a third embodiment the invention mounted to a bearing.

DETAILED DESCRIPTION OF THE INVENTION

(4) FIG. 1 is a perspective view of a spherical roller bearing 10 equipped with a generator assembly according to the invention.

(5) The generator assembly is provided for harvesting energy in a bearing arrangement having an outer ring 12 as the first ring and an inner ring 14 as the second ring and a row of spherical rollers 16 accommodated in a rolling chamber between the first ring 12 and the second ring 14.

(6) The generator assembly includes a plurality of coils 18 attached to the outer ring 12 and configured to interact with a magnet ring 20 with alternating magnetization directions attached to the inner ring 14. The coils 18 are encapsulated and mounted in an outer carrier ring 22 such that the winding axis is oriented in a radial direction of the bearing 10 and the magnet ring 20 is composed of plural permanent magnets 24 attached to an inner carrier ring 26 attached to the inner ring 14 of the bearing 10.

(7) In order to provide a versatile power supply for electric and electronic external devices in machine applications, the generator assembly includes a plug connector 34 for supplying power generated by the generator assembly to external devices. The plug connector 34 is connected to the body of the bearing 10 by a wire 36 and includes a plastic housing 38 which may be configured to receive power electronics devices.

(8) The below description of the second and third embodiments of the invention is limited to the differences to the first embodiment of the invention for the sake of simplicity. For the same reason, the plug connector is omitted in FIG. 2.

(9) In cases where the power generated by generator means on one side of the bearing is needed on the other axial side of the bearing, the bearing as illustrated in FIG. 2 with the conductor connecting both sides for power transfer could be used without the plug connector as shown in FIG. 1. If the power is needed for external devices, the plug connector should be provided.

(10) FIG. 2 illustrates a second embodiment of the invention, wherein identical arrangements of coils 18 and magnets 24 are provided on both axial sides of the bearing 10, wherein only one of the sides is illustrated for the sake of simplicity. Specifically, a first portion 28 of the generator assembly including a first magnet ring 20 and a first row of coils 18 is arranged on a first axial side of the bearing 10 and a second portion (not Illustrated) of the generator assembly including a second magnet ring and a second row of coils is arranged on a second axial side of the bearing 10 opposite to the first axial side.

(11) In order connect the first portion 28 of the generator assembly with the second portion thereof; the generator assembly further includes a conductor 30 for connecting the first portion 28 of the generator assembly with the second portion of the generator assembly. The conductor 30 is illustrated in a configuration prior to being connected to the two portions of the generator assembly and prior to being encapsulated by overmolding or potting in FIG. 2 for reasons of visibility.

(12) The outer ring 12 of the bearing according to FIG. 2 is provided with a groove 32, wherein the groove accommodates the conductor 30. The conductor 30 is formed by a conductive flex print in a bottom portion of the groove 32, which is encapsulated to be protected. The groove 32 has a helicoidal shape, wherein a helix angle is set such that the conductor 30 extends over one round of over the ring, i.e. the tangent of the helix angle is equal to the ratio between width and circumference of the outer ring. In other embodiments of the invention, the helix angle of the groove is 45° or more.

(13) FIG. 3 is a perspective view of a generator assembly according to a third embodiment the invention mounted to a bearing 10. In the third embodiment of the invention, the bearing 10 includes a connector portion 40 with the plug connector 34, a coil portion 42 including the coils 18 and means (not illustrated) for transferring power from the connector portion to the coil portion, wherein the connector portion 40 is configured so as to be rotatable in relation to the coil portion 42 around the rotation axis of the bearing 10 in order to allow for a creeping rotation of the first ring 12.

(14) A body part 44 of the connector portion 40 is formed like an SNL spacer ring including a first inductor coil (not illustrated) interacting with a second, parallel and coaxial inductor coil (not illustrated) provided in the coil portion 42 of the generator assembly. This strongly interacting pair of coils is the means for transferring power from the connector portion 40 to the coil portion 42.

(15) In applications where creeping of the outer ring in a housing may occur, the coil portion 42 of the generator assembly will follow the creeping rotation of the outer ring 12 while the connector portion 40 can remain stationary thanks to the rotatable connection.

(16) Anti-rotation means, which should otherwise be provided in order to avoid stress on the connector plug 34 or the wire 36, can be dispensed with in the third embodiment of the invention.

(17) One further embodiment of the invention including such anti-rotation means for avoiding a creeping rotation of the bearing within a bearing housing uses the encapsulation of the conductor 30 for this purpose, which may be formed using elastomeric material and such that it slightly protrudes over the outer circumferential surface of the outer ring 12.

(18) In the above embodiments, the generator assembly may further include at least one inverter circuit for conditioning the power generated in the coils to a desired type of AC or DC voltage. In the preferred embodiment of the invention, at least a part of the inverter circuit is accommodated in the housing 38 of the plug connector 34. By providing different versions of inverter circuits in different versions of plug connectors 34, it is easy to realize different versions of the generator circuit, e.g. a 5V, 12V or 24V version.