Generator for powering a reel from a fluid flow

A generator is provided along a conduit that carries a man-made fluid flow. The generator generates electrical power that can be, e.g., used to charge a battery, rotate a reel, or to directly control a fluid flow control valve associated with the fluid flow. In the garden hose context, neither AC power nor frequent battery replacement is required because power from the generator can recharge the battery powering the valve and the reel.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to electricity generators and particularly to fluid-driven electricity generators.

2. Description of the Related Art

The use of conduits to carry fluids therethrough is well known in the art. For example, water hoses can be connected to a faucet on the outside of a house, the faucet having a traditional manual spigot or valve for turning the water flow on and off. A user can thus selectively allow pressurized water pumped from a well or supplied by a municipal water company to flow through the hose.

However, because hoses often extend many yards from the faucet, it is inconvenient for a user to have to return to the faucet to turn the water flow on and off. Manual devices, such as spray guns, are widely used to regulate water flow at the distal end of the hose so that the flow can be turned off and on without repeatedly returning to the faucet. However, it is undesirable to leave water turned on at the source when the hose is no longer in use for a number of reasons. Continual water pressure along the length of the hose tends to form leakage paths at joints between multiple lengths of hose, at the joint between the nozzle and the nozzle attachment, and at the joint between the hose and the faucet.

Electrical devices have also been developed to regulate water flow in hoses. For example, an electrically controllable valve responsive to remote control can be placed between the faucet and the hose. A remote control can then be operated to actuate the valve. A detailed description of such a remote control can be found in U.S. Provisional Application 60/455,229, filed Mar. 13, 2003, which is hereby incorporated by reference in its entirety.

Generators have been proposed for generating electricity from a flow of water in a conduit such as a hose or pipe. Various reeling mechanisms for reels not connected to a residential power grid are also known in the art. However, these mechanisms do not offer satisfactory means for powering the reeling of a hose. For example, these mechanisms either necessitate that the entire reel be in motion (e.g., a wheeled reel pulled behind a tractor) or that the water pressure be maintained at high levels at all times during which an operator could desire to spool or unspool the hose from/onto the reel drum. Accordingly, these prior art reeling mechanisms do not allow the reeling of a hose to be powered in situations where is it desirable for the entire reel to be stationary or where constant high water pressure is undesirable in the hose.

SUMMARY OF THE INVENTION

In accordance with a preferred embodiment, a system for spooling and unspooling a flexible conduit configured to contain a flow of a pressurized fluid is provided. The system includes a reel drum onto which the flexible conduit can be spooled and a generator. The generator is operatively connected to a flow path within the conduit. The generator is also configured to receive a pressurized fluid flow therethrough and convert kinetic energy of the pressurized fluid flow into electricity. A battery is operatively connected to the generator and is configured to receive and store the electricity. The system also includes a motor for selectively driving rotation of the reel drum. The motor is connected to the battery and is configured to receive electrical power from the battery.

In accordance with another preferred embodiment, a conduit managing system is provided including an electrically powered hose reel. The system also includes a fluid flow control device having a fluid flow path extending between an inlet and an outlet of the device. The fluid flow control device further includes an electrically actuated valve disposed in-line with the flow path. The valve is configured to selectively open or close the flow path. The control device also has electronics configured to actuate the valve. A generator is configured to convert the kinetic energy from a pressurized fluid flowing through the flow path into electricity. The system also includes an electrical circuit for delivering electricity from the generator to the fluid flow control device and the hose reel.

In accordance with yet another preferred embodiment, a hose control system is provided including a reel for spooling and unspooling a flexible fluid conduit. A motor is connected to the reel to drive rotation of the reel. An electrically actuated flow control device is configured to selectively allow a pressurized fluid flow therethrough. The system also includes a generator adapted to harness the energy of the pressurized fluid flow to electrically charge a battery connected to both the flow control device and the motor. The battery is configured to provide power to both the flow control device and the motor.

In accordance with another preferred embodiment, a method of spooling a hose is provided. A flow control device is connected to the hose. The device includes a flow path in communication with the hose, the device being configured to receive a pressurized fluid flow therethrough. The device further includes an electrically actuated valve in communication with the flow path. A generator is provided, at least a portion of the generator being disposed in the flow path. The generator is configured to convert kinetic energy of the pressurized fluid flow into electrical energy. A battery connected to the generator is charged with the electrical energy. An electrical connection from the battery to a hose reel is provided to electrically power rotation of the hose reel with the battery.

In accordance with another preferred embodiment, a method of reeling or unreeling a hose and regulating a pressurized fluid flow through the hose is provided. A flow control device connected to a hose is provided, the hose having a flow path. The energy of a pressurized fluid flow through the hose is harnessed to generate electricity. A battery is then charged with the electricity. The reeling or unreeling of the hose is powered with electricity from the battery. Electrical power from the battery is also provided to the flow control device to selectively allow flow through the flow path.

In accordance with another preferred embodiment, a method for electrically powering a reel from a pressurized fluid flow through a conduit is provided. The method includes providing a conduit defining a flow path configured to receive a pressurized fluid flow therethrough from a mechanical source. Energy of the pressurized fluid flow is harnessed to generate electricity. Rotation of the reel is then powered using the generated electricity.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Mechanically driven hose reels with electric valves for controlling fluid flow are known in the art. However, these reels do not teach generating electricity to power the rotation of the reel. For instance, U.S. Pat. No. 4,276,900 to Rosenqvist teaches an irrigation device employing a water-driven turbine connected to an electricity generator powering a valve in a water line. However, the Rosenqvist generator does not power the rotation of the hose reel. Instead, the water-driven turbine drives the rotation of the drum through a transmission link. Accordingly, the transmission link cannot drive rotation of the reel drum when there is little or no water pressure to drive the turbine. Preferred embodiments of the present invention address this problem by effectuating the rotation of a reel drum even when the water pressure is low, e.g., if the water source is turned off.

Generation of power from natural water flow is also well known in the art. For example, hydroelectric plants use the gravitational flow of water from a reservoir side of a dam to a body of water downstream of the dam to generate power. Said gravitational water flow strikes and turns blades of a turbine, which is attached to a generator by way of a shaft. The goal, of course, is generation of electrical energy from natural sources.

However, the inventors have realized that generation of electrical energy from flowing fluids can be useful, particularly in the context of controlling a reel, even when it is not an efficient manner in which to create electrical energy. In particular, there are situations in which it is difficult or impractical to supply electrical power, but in which there is a ready source of kinetic energy in the form of a flowing fluid. For example, the generators described herein harness the power of pressurized water flow from man-made sources. These man-made sources include water pumped from a well or made available by a municipal or local water company. A user normally accesses said pressurized or pumped water flow from man-made sources by turning on a faucet or the like. For example, the user can connect a hose to a faucet outside a house, the faucet having a traditional manual spigot or valve for turning the water flow on and off and selectively allowing the pressurized water to flow through the hose. Such pressurized water flow has power-generating potential that is generally not harnessed. In an alternate embodiment, the pressurized fluid powering the generator is pressurized air.

While illustrated in the context of pressurized water flow through garden hoses for household watering or washing applications, one of ordinary skill in the art will readily appreciate that the principles and advantages of the preferred embodiments are applicable to other fluid flows and products. For example, in addition to the illustrated liquid application, the fluid flow through a conduit (e.g., hose or pipe) can comprise compressed air for other applications. Additionally, the preferred embodiments can be used anywhere there is a fluid flow and the use of a separate power source is inconvenient or impractical.

FIG. 1shows a schematic view of one embodiment of a generator100. The generator100preferably comprises a housing2having an open end2aand configured to house at least a portion of an impeller10. The impeller10has a body12adapted to rotate within the housing2about an axis X that preferably passes through a center point13of the body12. In the illustrated embodiment, the body12has a circular cross-section. However, the cross-section of the body12can have other shapes, such as oval, square and polygonal.

The impeller10also comprises at least one paddle14connected to the body12and extending away from the body12. In the illustrated embodiment, the impeller10comprises a plurality of paddles14distributed about the body12circumference. Each paddle14preferably defines a length14afrom the body12to a free end14bof the paddle14. The paddles14are preferably integral with the body12. However, in one embodiment, the paddles14can be removably connected to the body12via, for example, rivets, screws, hooks or the like. In another embodiment, the paddles14can be permanently attached to the body12via, for example, an adhesive like a resin or the like.

The impeller10is preferably operatively connected to at least one electrical terminal20of the generator100. For example, the impeller10can connect to the at least one terminal20via a shaft (not shown). In the illustrated embodiment, the generator has two terminals20, a negative terminal22and a positive terminal24. However the generator100can have any number of terminals20. The terminals20are preferably configured to transmit electrical energy generated by the generator to at least one electrical object connected thereto. In the illustrated embodiment, the terminals20are connected to a battery25via electrical wires26. However, the terminals20can connect to other devices, such as an electrical motor (not shown) or an electrical actuator (not shown). Preferably, the terminals20and electrical wires26are kept dry, especially when used in a wet environment. For example, the terminals20and wires26can be housed in a housing (not shown) containing said electrical motor or electrical actuator.

In the preferred embodiment illustrated inFIG. 1, the housing2of the generator100connects to a conduit28so that the open end2aof the housing2aligns with an aperture28aon the surface28bof the conduit28. Preferably, the open end2ais generally the same size as the aperture28a.In the illustrated embodiment, the housing2is integral with the conduit28. However, in another embodiment, the housing2can be removably attached to the conduit28. For example, the housing2can comprise a section of hose or pipe (not shown) having connectors at its ends, each of said connectors being configured to connect the housing2to a conduit28. For example, the connector can be a threaded male end (not shown) configured to connect with a threaded female fitting (not shown) of the conduit28. The conduit28can be a hose, a pipe or the like.

As shown inFIG. 1, the impeller10is disposed in the housing2so that at least a portion of the length14aof the at least one paddle14extends into the conduit28when the housing2is connected to the conduit28. Preferably, only the paddles14extend into the conduit28, not the body12. The length14aof the at least one paddle14that extends into the conduit28is selected such that it generates sufficient power for the purposes of the application (e.g., to keep a battery charged for purposes of powering a reel or actuating a control valve), but not so much that the flow is slowed down to the extent that it is no longer useful for the intended purpose of the fluid flow. For most fluid flow applications, in which electrical energy is to be generated simply out of convenience to minimize the need to replace batteries or avoid providing AC current to a wet environment, preferably between about 70% and 95% of the flow's kinetic energy is converted to electrical energy, more preferably between about 85% and 95%. The typical household water pressure is 40–60 psi. In one preferred embodiment, a 5 psi drop in water pressure is caused by slowing the flow path and 80–90% of the 5 psi drop in water pressure is converted into electricity.

The conduit28is preferably adapted to carry a pressurized fluid flow F therethrough. For example, the conduit28can be a hose having the required material characteristics to carry a fluid flow pressurized to a desired amount. In one embodiment, the conduit28can be made of a hard plastic, such as polypropylene or polyethylene. In another embodiment, the conduit28can be made of a rubber or metal.

In one embodiment, the housing2, impeller body12, and paddles14of the generator100are made of a hard plastic. However, any material commonly used for making generators can be used. For example, in one embodiment, the housing2, impeller body12, and paddles14can be made of a metal or metal alloy, such as aluminum and stainless steel.

The pressurized fluid flow F is preferably from a mechanical source, such as a pump or the like, not sources that pressurize water via gravity. For example, the pressurized fluid flow F can be a liquid, such as water pumped from a well or delivered to a user from a municipal or local water system. However, the pressurized fluid flow F is not limited to liquids and can comprise other fluids, such as gases. In another embodiment, the pressurized fluid flow F can be compressed air from a compressor.

In operation, the pressurized fluid flow F exerts a force on a surface14cof the at least one paddle14. In the illustrated embodiment, the surface14cis generally planar. Preferably, the surface14cis oriented at an angle α relative to the fluid flow F configured to maximize the transmission of the force from the fluid flow F to the paddle14. The angle α varies as the impeller10preferably rotates. In the embodiment illustrated inFIG. 1, the angle α is about 90 degrees when the maximum portion of the length14aextends into the conduit28, so that the paddle14is generally orthogonal to the fluid flow F and receives the maximum amount of force from said fluid flow F. However, as the impeller10rotates, the angle α decreases, resulting in a decreased transmission of the force from the fluid flow F to the paddle14. But the rotation of the impeller10preferably rotates another paddle14into a position generally perpendicular to the fluid flow F, which then receives the maximum amount of force from said fluid flow F, as discussed above.

The force exerted by the fluid flow F preferably causes the paddle14and the body12to rotate about the axis X. The rotation of the body12is transformed into electrical energy in a manner well-known in the art and transmitted to the terminals20, as discussed above, to provide electrical energy to a variety of devices, such as batteries, electrical actuators and electric motors. Thus, an electrical path is provided from the generator, either directly to an electrical device associated with the fluid flow, or indirectly to such a device by way of a battery that stores the generated energy between operations of the electrical device.

FIGS. 2–3show a schematic of another embodiment of a generator200. The generator200comprises a turbine210extending along a length L between a first end210aand a second end210band having a body212. The body212is disposed in the conduit28, has a length L, and is preferably configured to rotate about an axis Y generally in-line with the pressurized fluid flow F. The body212is operatively connected to the terminals20of the generator200, via, for example, a shaft (not shown).

The turbine210also comprises at least one vane214connected to the body212and extending away from the body212. In the illustrated embodiment, the turbine210comprises a plurality of vanes214. Each vane214preferably defines a length214afrom the body212to an end214bof the vane214. In one embodiment, the end214bis a free end. In another embodiment, the end214bconnects to a housing202extending about the turbine210along the length L. Preferably, the housing202is cylindrical in shape. The length214ais preferably curved. The vanes214also preferably extend in curved fashion along the length L. For example, the vanes214can extend as spirals along the length L. Preferably, the vanes214are shaped and oriented to efficiently transmit a force from the fluid flow F to the vanes214.

The vanes214are preferably integral with the body212. However, in one embodiment, the vanes214can be removably connected to the body212via, for example, rivets, screws, hooks or the like. In another embodiment, the vanes214can be permanently attached to the body212via, for example, an adhesive, a resin or the like.

As illustrated inFIG. 2, the at least one vane214preferably defines a surface214dalong the length L of the vane214. The surface214dprojects a surface214ealong the axis Y generally orthogonal to the pressurized fluid flow F (seeFIG. 3). The surface214dis adapted to receive the force exerted thereon by the fluid flow F to efficiently transmit the linear force along axis Y from the fluid flow F to the rotation of the body212about the axis Y.

In one embodiment, the housing202, turbine body212, and vanes214of the generator200are made of a hard plastic. However, any material commonly used for making generators can be used. For example, in one embodiment, the housing202, turbine body212, and vanes214can be made of a metal or metal alloy, such as aluminum and stainless steel.

The force exerted by the fluid flow F preferably causes the at least one vane214and the body212to rotate about the axis Y. The rotation of the body212about the axis Y is transformed into electrical power in a manner well-known in the art and transmitted to the terminals20, as discussed above, to provide power to a variety of devices, such as batteries, electrical actuators and electric motors.

FIG. 4illustrates the use of the generator100,200in a flow control device300. The flow control device300preferably comprises a fluid flow path32extending between an inlet34and an outlet36. In one embodiment, the flow control device300can be connected between a hose (not shown), such as a garden hose, and a faucet (not shown). In a preferred embodiment, the flow control device300comprises the generator100,200. For example, at least a portion of the fluid flow path32can be defined by the conduit28(shown inFIGS. 1 and 2) to which the generator100,200connects.

The flow control device300also comprises an electrically actuated valve38disposed in-line with the flow path32and an associated electrical signal receiver40. For example, the valve38can be a motor-driven valve, pressure-activated valve, or solenoid valve. The skilled artisan will understand, in view of the disclosure herein, that there are a variety of different types of controllable (preferably electronically controllable) valves which can be employed with the embodiments disclosed herein. In one preferred embodiment, a solenoid valve and a pressure-activated valve are both employed, the pressure activated valve preferably reducing pressure within the conduit and, as a result, reducing power consumption when spooling or unspooling the conduit. The receiver40is preferably configured to receive an electromagnetic signal from, for example, a remote source. For example, the receiver40can receive the signal via an antenna42operatively connected thereto. Preferably, the receiver40communicates the signal via a line40bto actuate the valve38between an open position and a closed position. Accordingly, the valve38can be selectively operated to regulate flow through the flow path32. In one embodiment, the valve38is also capable of assuming one or more intermediate positions, i.e., positions that are between the completely open and completely closed positions, which allows for greater control of the fluid flow. In one embodiment, the valve38is continuously variable between its open and closed positions to preferably vary the size of a flow orifice (not shown) in the flow path32. For example, the valve38can be a spool valve.

In one embodiment, the receiver40can be connected to the battery25via at least one wire connection40a,wherein the battery25in turn connects to the terminals20(as shown inFIGS. 1 and 2) of the generator100,200. Accordingly, the generator100,200charges the battery25while fluid flows through the flow path32. The battery25in turn transmits power to the receiver40, which signals the actuator to actuate the valve38, as discussed above. In an alternate embodiment, the receiver40can connect directly to the terminals20of the generator100,200via the at least one wire connection40a.

FIG. 5illustrates the use of the generator100,200in a hose control apparatus400, including a hose reel device430. The hose reel device430includes an electric motor434configured to rotate a hose reel drum436. A first hose section416aof a hose416communicates fluid from the pressurized fluid source or faucet410to the hose reel device430. A second hose section416bwraps around the drum436and terminates at a distal end420in a hose nozzle422or attachment device. In one embodiment, the second hose section416bconnects to the first hose section416a.In another embodiment, a third hose section416cconnects the first hose section416ato the second hose section416b.The apparatus400can also include the receiver40and antenna42(FIG. 4) to receive remote commands for operating the reel device430.

In a preferred embodiment, at least a portion of the third hose section416ccan be the conduit28(seeFIGS. 1 and 2) to which the generator100,200connects, so that the generator100,200is disposed inside a hose reel housing432enclosing the motor434, the reel drum436and the third hose section416c.However, in other embodiments, the generator100,200can be connected to a portion of the hose416outside the housing432.

In one embodiment, the motor434can be connected to the battery25via at least one wire connection434a,wherein the battery25in turn connects to the terminals20(seeFIGS. 1 and 2) of the generator100,200via electrical wires26. Accordingly, the generator100,200charges the battery25, which in turn transmits power to the motor434to rotate the reel drum436. Preferably, the generator100,200charges the battery25at least enough to delay the need to remove the battery25to fully charge or replace it. The time required to replace the power consumption during a spooling cycle is dependent on a number of factors, including, e.g., water pressure, the total length or weight of the hose, the length of hose unspooled from the reel, the resistance of the hose to spooling or unspooling, etc. For example, if a 12V volt battery with a capacity of about 7 amp-hours is employed, it is expected that water pressure from an average household (e.g., about 40–60 psi) will replenish the power drained from the battery during the reeling of the entire length of a 100 ft. hose by running water through the generator for about 4–6 minutes. In an alternate embodiment, the motor434can connect directly to the terminals20via the at least one wire connection434a.

Further information on the flow controller300and the hose control apparatus400can be found in Applicant's U.S. Provisional Patent Application No. 60/455,229, filed Mar. 13, 2003.