Apparatus using magnets for harvesting energy on a metrology device
10329942 ยท 2019-06-25
Assignee
Inventors
Cpc classification
F01D5/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05B2250/312
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03G7/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/20
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F03B13/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K21/22
ELECTRICITY
F01D21/003
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05B2220/602
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05B2220/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05B2240/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D15/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03G7/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F01D15/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03B13/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K7/18
ELECTRICITY
H02K21/22
ELECTRICITY
F01D5/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D21/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03G7/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
An apparatus comprising a meter device with a rotating component configured to rotate in response to a flowing fluid, an indexing unit coupled with the meter device and configured to process signals from the meter device resulting in values for measured parameters of a flowing fluid, and an energy harvester coupled to the pair of impellers, the energy harvester comprising a first harvesting unit and a second harvesting unit that co-operate to generate an electrical signal, the first harvesting unit configured to co-rotate with the pair of impellers, the second harvesting unit comprising a hollow, magnetic core disposed proximate the first harvesting unit.
Claims
1. An apparatus, comprising: a meter device with a rotating component including a pair of impellers configured to rotate in response to a flowing fluid; an indexing unit coupled with the meter device and configured to process signals from the meter device resulting in values for measured parameters of a flowing fluid; and an energy harvester coupled to the rotating component, the energy harvester comprising a first harvesting unit and a second harvesting unit that co-operate to generate an electrical signal, the first harvesting unit configured to co-rotate with the pair of impellers, the second harvesting unit comprising a hollow, magnetic core disposed proximate the first harvesting unit, wherein the energy harvester comprises a field shaper disposed on the hollow, magnetic core, the field shaper configured to collapse magnetic flux lines towards an outer surface of the hollow, magnetic core.
2. The apparatus of claim 1, wherein the first harvesting unit comprises an annular, magnetic ring with magnetic poles diametrically disposed about an opening with a center axis.
3. The apparatus of claim 2, wherein the hollow, magnetic core comprises an elongate, cylindrical tube with a bore extending therethrough to form open ends, and wherein the elongate, cylindrical tube fits inside of the opening so as to orient the ends proximate the annular ring.
4. The apparatus of claim 1, wherein the field shaper comprises a bent wire with ends disposed in the hollow, magnetic core and a longitudinal segment outside of the hollow, magnetic core and coupled with the ends.
5. The apparatus of claim 1, wherein the field shaper comprises a plurality of bent wires, each having a longitudinal segment outside of the hollow, magnetic core and annularly spaced apart from one another about a longitudinal axis of the hollow, magnetic core.
6. The apparatus of claim 1, wherein the field shaper comprises a pair of magnetic end caps, one each disposed on ends of the hollow, magnetic core.
7. The apparatus of claim 1, wherein the hollow, magnetic core has open ends.
8. The apparatus of claim 1, wherein the hollow, magnetic core comprises a plurality of layers.
9. The apparatus of claim 1, wherein the first harvesting unit comprises multiple magnetic poles.
10. The apparatus of claim 1, wherein the first harvesting unit comprises a pair of magnetic poles diametrically opposed from one another.
11. The apparatus of claim 1, wherein the first harvesting unit forms an opening to receive the hollow, magnetic core.
12. The apparatus of claim 1, wherein the field shaper comprises a wire spaced apart from the outer surface of the hollow, magnetic core.
13. The apparatus of claim 1, wherein the field shaper comprises a plurality of wires spaced apart from the outer surface of the hollow, magnetic core.
14. A gas meter, comprising: a meter body comprising impellers configured to counter-rotate in response to material flow; and an energy harvester comprising: a first member comprising an annular ring magnet coupled with the impellers so as to co-rotate with the impellers, the annular ring magnet configured to generate a magnetic field; a second member comprising a magnetic core disposed proximate the magnetic field, the magnetic core forming a hollow tube; and a wire wound about the hollow tube so as to manifest an electrical signal in response to changes in the magnetic field relative to the hollow tube, wherein the hollow tube has a through bore forming a longitudinal axis that extends through diametrically opposed parts of the annular ring, and wherein the hollow tube has a peripheral wall that comprises a plurality of material layers that bound the longitudinal axis.
15. The gas meter of claim 14, wherein the hollow tube has open ends disposed proximate the annular ring magnet so that diametrically-opposed magnetic poles of the annular ring magnet pass in proximity to both open ends in response to rotation of the impellers.
16. The gas meter of claim 14, wherein the hollow tube is disposed inside of the annular ring magnet.
17. The gas meter of claim 14, further comprising leads coupled with the wire, wherein the leads conduct the electrical signal.
18. A gas meter, comprising: a meter body comprising impellers configured to counter-rotate in response to material flow; and an energy harvester comprising: a first member comprising an annular ring magnet coupled with the impellers so as to co-rotate with the impellers, the annular ring magnet configured to generate a magnetic field; a second member comprising a magnetic core disposed proximate the magnetic field, the magnetic core forming a hollow tube; and a wire wound about the hollow tube so as to manifest an electrical signal in response to changes in the magnetic field relative to the hollow tube; and a bent wire having ends extending into the hollow tube, wherein the ends are spaced apart from one another and a longitudinal segment outside of and spaced apart from the interior of the hollow tube.
19. The gas meter of claim 18, wherein the meter body comprises a central cylinder with end covers disposed on opposite ends, and wherein the annular ring magnet and the hollow tube are disposed in space formed by a recess in the end covers.
20. The gas meter of claim 19, further comprising: a bracket mounted to one of the end covers, the bracket supporting the magnetic core so as to arrange ends of the hollow tube inside of and proximate the magnet; and an extension cup with a peripheral wall forming an opening and a flexible tab, the opening and the tab configured to receive and secure the magnet in the extension cup.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Reference is now made briefly to the accompanying figures, in which:
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(16) Where applicable like reference characters designate identical or corresponding components and units throughout the several views, which are not to scale unless otherwise indicated. The embodiments disclosed herein may include elements that appear in one or more of the several views or in combinations of the several views. Moreover, methods are exemplary only and may be modified by, for example, reordering, adding, removing, and/or altering the individual stages.
DETAILED DESCRIPTION
(17) The embodiments disclosed herein employ structure to harvest energy in situ on gas meters and related metrology devices. These devices may quantify parameters (e.g., flow rate, volume, etc.) of fluids and solids, for example, using electro/mechanical means with rotating elements (e.g., impellers) that can generate pulses indicative of the flow. As described below, embodiments may employ magnetic devices that cooperate to generate power in response to rotation of the rotating elements on the device. These embodiments may use a hollow, tubular member (or core), however, which proves advantageous to reduce braking and other deleterious effects brought on by interaction with a rotating magnet in these types of devices. Other embodiments are within the scope of the subject matter of this disclosure.
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(19) As noted herein, the metering system 100 may embody a gas meter or like metrology hardware. This type of hardware may be configured to measure defined volumes of flowing gas. These measurements can be used to quantify (and often bill) consumers at residential, commercial, industrial, and municipal locations, but this does not foreclose use of the energy harvesting concepts on other hardware or for other applications. In one implementation, the first component 106 (also metrology component 106) may include a meter device 112 with a rotating component, for example co-rotating impellers, configured to rotate in response to the material (104). Although shown separate from the conduit 102, the meter device 112 may be configured to connect to the conduit 102, often in-line using flanges or fittings that are common for pipe connections. The second component 108 (also, processing component 108) may include an indexing unit 114 that can process signals from the meter device 112. These processes may calculate values for the measured parameters among other functions. As also shown, the third component 110 (also, energy harvester 110) may couple with the meter device 112. The energy harvester 110 may have a bifurcated structure with a pair of harvesting units (e.g., a first harvesting unit 116 and a second harvesting unit 118). The harvesting units 116, 118 can communicate with one another without physical contact, preferably to create a signal 120 in response to movement of elements of the meter device 112. The units 116, 118 may leverage a variety of technologies including photoelectric, inductive, capacitive, and ultrasonic technologies. Other technologies developed after filing of this application may also be acceptable for use in the metering system 100.
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(22) With reference also to
(23) The hollow body 154 of the core 138 has been found to improve performance of the harvesting component 110. The design is less susceptible to braking that may occur as the poles 130, 132 of the rotating annular ring 126 pass in close proximity to the ends 158, 160 of the body 154. In turn, the length L of body 154 can be set to maximize the number of windings 142 of the conductor 136. This feature permits the harvesting component 110 to more effectively generate the SAC. As an example, Table 1 below compares power achieved from a solid core design and the power achieved from the hollow body 154 disclosed herein.
(24) TABLE-US-00001 TABLE 1 Power Comparison Rotation Speed Solid Core Hollow Core 200 RPM 670 Watts 840 Watts 300 RPM 1,320 Watts 1650 Watts 400 RPM 2,370 Watts 2960 Watts 500 RPM 3,760 Watts 4700 Watts 600 RPM 5,290 Watts 6610 Watts 700 RPM 6,970 Watts 8710 Watts 800 RPM 8,380 Watts 10,470 Watts 900 RPM 10,820 Watts 13,520 Watts 1000 RPM 13,910 Watts 17,390 Watts 1100 RPM 16,520 Watts 20,650 Watts 1200 RPM 18,920 Watts 23,650 Watts 1300 RPM 23,330 Watts 29,160 Watts 1400 RPM 25,500 Watts 31,880 Watts 1500 RPM 29,150 Watts 36,420 Watts 1600 RPM 33,300 Watts 41,620 Watts 1700 RPM 36,240 Watts 45,300 Watts 1800 RPM 38,750 Watts 48,430 Watts 1900 RPM 41,360 Watts 51,700 Watts 2000 RPM 43,530 Watts 54,410 Watts 2100 RPM 46,020 Watts 57,520 Watts 2200 RPM 49,300 Watts 61,620 Watts 2500 RPM 55,430 Watts 69,290 Watts
(25) The power output of the hollow structure of the body 154 is seen in Table 1 to be significantly greater, up to 25%, effectively maximizing the available space within the similar-sized envelope as compared to the solid core design. By way of comparison, the spacing or gap distance of a prior art solid core sensor was approximately 0.030 inches less on each end, resulting in significantly less coils (approximately 2000 less turns) and less power generation.
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(33) The impellers 220 work in concert to displace a fixed volume of material 104 that transits the fluid coupling 210 between inlet/outlets 212. In one implementation, the impellers 220 counter-rotate in response to flow of material 104 (
(34) The back view of
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(37) As used herein, an element or function recited in the singular and proceeded with the word a or an should be understood as not excluding plural said elements or functions, unless such exclusion is explicitly recited. Furthermore, references to one embodiment of the claimed invention should not be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.
(38) This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
(39) In light of the foregoing discussion, the embodiments herein incorporate improvements that are useful to harvest energy from revolution of the impellers on gas meters and related metrology hardware. These devices often reside in remote areas that lack electrical power so as to place emphasis on battery power for energy. Powering the electronics by battery power alone presents two common problems. First, the battery life was finite so the batteries had to be periodically replaced according to a maintenance schedule. Second, sometimes batteries died prematurely and unexpectedly, requiring an expensive emergency field replacement. In this regard, the examples below include certain elements or clauses one or more of which may be combined with other elements and clauses describe embodiments contemplated within the scope and spirit of this disclosure.