Power harvesting bearing configuration

A power generating bearing assembly (100) comprising a bearing (120) retained by a bearing housing (110). The bearing housing (110) includes a bearing cooling passage system comprising at least one integrated liquid cooling passage (130) is integrated within the bearing housing (110). A turbine receiving bore (160) is formed through the bearing housing (110), penetrating the integrated liquid cooling segment (130). A turbine assembly (200) is inserted into the turbine receiving bore (160), positioning a turbine blade subassembly (230) of the turbine assembly (200) within the integrated liquid cooling passage (130), wherein fluid flowing within the integrated liquid cooling passage (130) causes the blade subassembly (230) to rotate. The rotation of the blade subassembly (230) rotates an electric power generator (collectively 222, 224, 226, 240, 242, 244, 246) to create electric power. The turbine assembly (200) can include an electro-magnetic subassembly mounting plate (248), wherein the turbine subassembly (202) is located on an interior surface of the mounting plate (248) and at least a portion of the power generating portion location on an exterior portion of the mounting plate (248).

BACKGROUND OF THE INVENTION

1. Technical Field of the Invention

The present invention relates to an apparatus and method for generating power utilizing a cooling system integrated into a bearing or bearing housing.

2. Background Art

Bearings are used to support many rotating objects. Bearings are commonly integrated into a variety of machines. The bearings are a key factor contributing to the reliability of the machine. The system designed commonly installs one or more bearing condition monitoring devices to ensure the bearings remain in working order. The majority of the condition monitoring devices requires low voltage electrical power for operation. Some systems include other components that also utilize electrical power.

Batteries provide a limited capacity, which dictates a limited supply and thus a limited run time. Obtaining power from a commercial utility source can be costly, particularly for remote installations. Transferring electrical power from a commercially available source can require running extensive and costly power cabling and support equipment. Maintenance of these systems must be considered. Replacement of batteries incurs both parts and labor costs. These concerns are aggravated for temporary installations.

A portion of the bearings generates a significant amount of heat. These bearings include heat dissipation or thermal transfer systems. One exemplary thermal transfer system includes one or more integrated liquid cooling passages. Liquid coolant is pumped through the integrated liquid cooling passages extracting heat from the bearing or bearing assembly.

Turbines are commonly used for a variety of applications. One application converts energy from a flowing liquid to electrical energy. A well-known example is a windmill. Another well-known example is a dam.

More compact, lower level power generators have been integrated into home appliances such as faucets, shower heads, and the like, where power is converted from the flowing water to electrical power, which is subsequently used to illuminate LED's.

A variety of parameters are monitored to continuously determine a condition of a bearing. The application of the bearing may limit the availability or ease of providing electrical power to the sensors used to monitor the condition of the bearing. What is desired is a power generating system that can be integrated into the bearing assembly to harvest power from the bearing assembly and utilize the harvested power to generate electrical energy.

DISCLOSURE OF THE INVENTION

The present invention is directed towards an apparatus and respective method for generating electrical energy utilizing a cooling system of a bearing or bearing assembly.

In a first aspect of the present invention, a power generating bearing assembly, the power generating bearing assembly comprising:

a bearing;

a bearing housing comprising:a bearing receptacle,at least one integrated liquid cooling passage; anda turbine installation port extending between an exterior surface of the bearing housing and penetrating one of the integrated liquid cooling passages, wherein the turbine installation port is substantially perpendicular to the integrated liquid cooling passage and a central axis of the turbine installation port is offset from a center of the penetrated integrated liquid cooling passage;

a turbine assembly comprising:a turbine casing,a turbine shaft assembled within the turbine casing,a turbine blade subassembly rotationally carried by the turbine shaft,a turbine fluid passage passing through the turbine casing, the turbine fluid passage being oriented perpendicular to a rotational axis of the turbine blade subassembly, a center of the turbine fluid passage being offset from a center of a diameter of the turbine casing, andan electrical generator in operational engagement with the turbine blade subassembly, wherein rotational motion of the turbine blade subassembly causes the electrical generator to generate electrical power;

wherein the turbine is inserted into the turbine installation port positioning the turbine fluid passage within the liquid cooling passage orienting the turbine blade subassembly to rotate about an axis that is perpendicular to a flow of fluid through the liquid cooling passage converting energy provided by fluid flowing through the liquid cooling passage to electrical energy.

In a second aspect, the turbine is installed orienting a rotational axis of the turbine substantially perpendicular to the direction of flow of the fluid.

In another aspect, an exterior surface of the turbine casing provides a seal for the turbine installation port.

In another aspect, a sealant material is placed between the exterior surface of the turbine casing and the turbine installation port to provides a seal therebetween.

In another aspect, the turbine casing and the turbine installation port comprise threaded surfaces enabling a threaded assembly therebetween.

In another aspect, the turbine further comprises an electrical conduit extending in electrical communication from the electrical generator.

In another aspect, the turbine casing is provided having a circular cross sectional shape.

In another aspect, the turbine casing is provided having a tubular cross sectional shape.

In another aspect, the turbine is installed aligning a rotational axis of the turbine assembly offset from a center of a diameter of the liquid cooling passage.

In another aspect, the turbine is installed aligning the longitudinal axis of the turbine blade subassembly offset from a center of a diameter of the liquid cooling passage.

In another aspect, the turbine is installed proximate a cooling system inlet port.

In another aspect, the turbine is installed proximate a cooling system discharge port.

In another aspect, an electro-magnetic subassembly mounting plate can be integrated into the turbine assembly to aid in the installation of the turbine assembly within the bearing housing. The electro-magnetic subassembly mounting plate can further provide the functionality of a seal.

In another aspect, the electrical power generated is utilized to provide power to a separate electrically powered device.

In another aspect, the electrical power generated is utilized to power at least one bearing condition monitoring sensor.

In another aspect, the electrical power generated is utilized to power at least one bearing condition monitoring sensor associated with the same bearing assembly.

In another aspect, the electrical power generated is utilized to power at least one bearing condition monitoring sensor associated with the same bearing assembly and at least one bearing condition monitoring sensor associated with a separate bearing assembly located proximate the power generating bearing assembly.

One advantage of the present invention is the ability to modify an existing liquid cooled bearing assembly to receive a turbine assembly. The conversion from a standard liquid cooled bearing assembly to a power harvesting bearing assembly can be accomplished by machining a bore through the bearing housing, wherein the bore penetrates the integrated liquid cooling passage. The turbine assembly can be retained in position using an electro-magnetic subassembly mounting plate. The configuration enables a simplistic conversion as well as a design that accommodates servicing.

Another advantage of the present invention is the ability to generate a continued electrical current using a cooling system of a bearing assembly. One or more sensors can be employed to monitor a condition of a bearing. The sensors are commonly operated using electrical power. The sensors can monitor a variety of parameters to continuously determine a condition of a bearing. Communication devices could be employed as a vehicle to transfer information to a remote monitoring facility. These communication devices are also operated using electrical power. It is not uncommon where a system utilizing a bearing would be located in a remote area where sourcing electrical power could be difficult. Bearings can be utilized on equipment deployed in remote locations. The application of the bearing may limit the availability or ease of providing electrical power to the sensors used to monitor the condition of the bearing. The inclusion of an electrical power-generating device within a bearing system eliminates the need for an external source of electrical power. Additionally, by integrating the turbine assembly into the cooling system, the electrical energy is not drawing energy from the rotation of the bearing or other rotating elements of the system. Therefore, the turbine assembly is not impacting the efficiency of the rotating elements of the system.

Another advantage of the present invention is the flexibility for the installation. The installation can be accomplished by machining a turbine receiving bore through any suitable location along the cooling integrated liquid cooling segments. The turbine assembly would then be seated within the bore, positioning the turbine blade subassembly within the flow region of the integrated liquid cooling segment.

Another advantage of the present invention is the acceptance of a wide variety of turbines or impellers for driving the generator. By fabricated a turbine casing having a diameter that is wider than the diameter of the integrated liquid cooling passage, the exposed portion of the turbine blade subassembly is limited to a semicircular section that is rotating in a direction parallel with the flow of the fluid. The portion of the turbine blade subassembly rotating towards the flowing fluid is offset from the flowing fluid, thus minimizing any impact therewith.

flowing fluid can Offsetting the fluid transfer channel reduces the impact of the impeller on the flow of the fluid.

The location of condition monitoring sensors could complicate any provisions for externally provided power for monitoring the condition of the bearing. The bearing(s) can be integrated into the equipment at a location that is difficult to access, particularly for wiring. The inclusion of a power generator within the bearing assembly optimizes a source for electrical power at a location proximate the sensors or other equipment requiring the electrical power. This significantly reduces a length of wiring required. The reduced wiring avoids any accidentally interference or abrasion by any rotational movements or other movements of components of the equipment.

Another advantage of the present invention is the ability to deploy a temporary system having an integrated turbine for portable, monitored systems. The solution enables a complete stand-alone wireless system.

MODES FOR CARRYING OUT THE INVENTION

A power harvesting bearing assembly100is illustrated inFIGS. 1 through 4. Details of a turbine assembly200are illustrated in the cross sectional views presented inFIGS. 3 and 4. A power harvesting bearing assembly100includes a bearing120retained within a bearing housing110by a bearing receptacle112. Bearing housings110are configured in a variety of form factors, having a multitude of optional configurations. One optional feature is an inclusion of an integrated bearing cooling passage system within the bearing housing110. The optional integrated bearing cooling passage system provides a thermal transfer system to remove heat generated by the rotation of the bearing and/or other rotating components in contact with the bearing. The integrated bearing cooling passage system includes an integrated liquid cooling segment130defining an integrated liquid cooling passage131for passing a fluid therethrough in accordance with a fluid flow138. The integrated bearing cooling system can include a single segment130or a series of coolant passage segments130. An exemplary cooling system port134is shown at each end of the exemplary integrated liquid cooling segment130, collectively forming an integrated bearing cooling system. One cooling system port134functions as a source port and the second cooling system port134functions as a return port. It is understood that the fluid flow138can flow in either direction, wherein the direction of flow would be determined by the installation. It is understood that the integrated bearing cooling system would additionally comprise a liquid coolant, a second heat exchanger to remove heat from the liquid coolant, and a pump for driving the liquid coolant through the integrated liquid cooling segments.

A turbine receiving bore160is formed within the bearing housing110by machining a bore towards and penetrating the integrated liquid cooling segment130. The desired location can be determined from the product design information, an X-Ray, higher technology such as acoustic sounding, and the like. In the exemplary embodiment, it is preferred that the turbine receiving bore160is offset from a center of a cooling passage diameter132spanning between the tangent edges of the integrated liquid cooling segment integrated liquid cooling passage131. The dimensions of the turbine receiving bore160are preferably suited for receiving the turbine casing210. It is preferred that the turbine casing210is fabricated having a circular exterior circumference, and the turbine receiving bore160is formed using a drilling process. The diameter of the turbine receiving bore160would be respective to the diameter of the turbine casing210to provide a fluid seal when the turbine casing210is installed within the turbine receiving bore160. It is understood that the exterior surface of the turbine casing210and the interior surface of the turbine receiving bore160could be threaded, enabling a threaded assembly between the two components. A sealant material can be placed about the threaded portions to enhance the seal therebetween.

The turbine assembly200can include an electro-magnetic subassembly mounting plate248. A portion or all of the turbine subassembly202and electro-magnetic subassembly240can be assembled to the electro-magnetic subassembly mounting plate248, simplifying the installation process. The turbine subassembly202would be inserted into the turbine receiving bore160in accordance with a turbine insertion208. The electro-magnetic subassembly mounting plate248would be detachable secured to an exterior surface of the bearing housing110. In one embodiment, the electro-magnetic subassembly mounting plate248can be detachable secured using a threaded fastener, such as screws, bolts, or any other threaded fastener (not shown but well understood by those skilled in the art).

A turbine assembly200is inserted within the turbine receiving bore160for harvesting power from fluid flowing through the integrated bearing cooling passage system. The turbine assembly200is oriented with an axis of rotation of each turbine blade subassembly230perpendicular to the fluid flow138. Details of the turbine assembly200are presented inFIG. 3and will be presented below.

The power harvesting bearing assembly100can include a condition sensor150or other electrically operated component. Electrical power is transferred from the turbine assembly200to the condition sensor150by connecting power supply conductors250,252to a condition sensor wiring152. The condition sensor wiring152provides an electrical communication channel between the condition sensor150and the power supply conductors250,252. It is understood that the turbine assembly200can provide electrical power to sensors150and other electrically operated component located in the general vicinity of the power harvesting bearing assembly100, including bearing sensors located on other bearing assemblies; communication devices (wired or wireless); alarms; data recording devices (including computers, magnetic tape drives, digital recording devices, disc recording devices, and the like); controllers, and the like.

The turbine assembly200comprises elements of any electricity generating turbine assembly known by those skilled in the art. The exemplary embodiment of the turbine assembly200presented herein illustrates one embodiment to describe various elements, the components inter-relation, and function.

The turbine assembly200includes at least one turbine blade subassembly230rotationally assembled within a turbine casing210. Each turbine blade subassembly230comprises a plurality of turbine blades232. The turbine blades232are shaped to rotationally drive the turbine blade subassembly230when subjected to the fluid flow138. The turbine blades232can be formed in any suitable shape and orientation, including angled, spiraling, linear233, and the like. An exemplary arched turbine blade232is presented inFIG. 4. The arched or other shaped blade configurations aid in generating a torque to initiate rotation of the turbine blade subassembly230. An exemplary linear turbine blade233is presented inFIG. 5. The offset of the fluid transfer channel215, as defined by the locations of the turbine casing fluid inlet port216and the turbine casing fluid discharge port218enables the use of the broad variety of blade configurations, wherein the blade configuration is not limited because of an offset exposure of the turbine blade subassembly230to the fluid flow138. The offset exposure of the turbine blade subassembly230to the fluid flow138generates a torque to initiate rotation of the turbine blade subassembly230. Other optional suitable blade configurations are known by those skilled in the art.

The turbine casing fluid inlet port216turbine casing fluid discharge port218collectively define the fluid transfer channel215. The turbine casing fluid inlet port216turbine casing fluid discharge port218can be formed through the turbine casing210, wherein one edge of the fluid transfer channel215is in proximate alignment with a rotational axis of the turbine blade subassembly230, as illustrated inFIGS. 4 and 5. In another configuration, the turbine casing fluid inlet port216and the turbine casing fluid discharge port218can be formed within one semicircular portion of a circumference of said turbine casing210.

The turbine blade subassembly230is assembled within the turbine casing210enabling the turbine blade subassembly230to rotate about a longitudinal axis of the turbine shaft220. It is preferred that the turbine blade subassembly230is affixed to the turbine shaft220, driving rotation of the turbine shaft220within the turbine casing210. The turbine shaft220can be supported by at least one turbine axle bushing212. The turbine axle bushing212can additionally provide functionality of a liquid seal. The turbine end of the turbine shaft220can be supported by a turbine axle bushing212of the turbine casing210or another feature acting as a bushing. It is understood that bearings can be used in place of the bushings to reduce friction when needed. Although the exemplary embodiment employs a bracket212in combination with a feature integrated into a turbine casing end wall211, it is understood that the turbine shaft220can be rotationally assembled within an interior of the turbine casing210using any suitable mounting configuration. A turbine friction reduction lining272can be inserted between the adjacent surface of the turbine blade subassembly230and the turbine casing end wall211. A magnet support member222is rotationally assembled within the turbine casing210. The magnet support member222is rotationally driven by a rotation of the turbine blade subassembly230, wherein the rotation is referenced as a turbine subassembly rotation260. A pair of rotated magnets or magnetic material224,226is carried by the magnet support member222. The first rotated magnet224is carried at a first end of the magnet support member222and the second rotated magnet226is carried at a second end of the magnet support member222. Alternatively, the magnet support member222can be fabricated of a magnetic material, wherein the rotated magnets224,226would be representative of the magnetic polarity of the magnet support member222. An electro-magnetic subassembly is secured within the turbine casing210. The electro-magnetic subassembly comprises an electrical coil241wrapped about a coil core242. A first coil core polarity244is carried at a first end of the coil core242and a second coil core polarity246is carried at a second end of the coil core242. Alternatively, the coil core242would be fabricated of a magnetic material, wherein the fixed magnets244,246would be representative of the magnetic polarity of the coil core242. The assembly aligns each of the pair of rotated magnets or magnetic material224,226with the pair of fixed magnets244,246. The magnets can be provided in opposing polarity to generate an alternating current. The rotation of the magnet support member222passes the rotated magnets or magnetic material224,226across the pair of fixed magnets244,246generating an alternating current. A pair of power supply conductors250,252transfers the electrical power generated from the electrical coil240to a connector (not shown) for connection with an electrically powered device, such as the condition sensor150. The turbine shaft220and magnet support member222can be fabricated of any suitable material. It is preferred that the turbine shaft220and magnet support member222are fabricated of non-magnetic materials, such as ceramic material, and the like.

A fluid transfer channel215is formed through the turbine casing210, enabling fluid to pass therethrough. A turbine casing fluid inlet port216is provided at a first end of the fluid transfer channel215and a turbine casing fluid discharge port218is formed at a second end of the fluid transfer channel215. Fluid would flow through the integrated liquid cooling segment integrated liquid cooling passage131in accordance with the fluid flow138. The fluid would enter the turbine casing fluid inlet port216, pass across the turbine blade subassembly230and exit through the turbine casing fluid discharge port218. As the fluid passes through the fluid transfer channel215, the fluid engages with the series of turbine blades232causing the turbine blade subassembly230to rotate about the longitudinal axis of the turbine shaft220. Each of the turbine blades232can be shaped to direct the rotation in a predetermined direction, as illustrated inFIG. 4. It is understood that the turbine blades232can be formed in any shape suitable for the fluid flow within the integrated liquid cooling segment integrated liquid cooling passage131.

The design of the fluid transfer channel215and respective fluid transition ports216,218can be symmetric, as illustrated inFIG. 4or asymmetric as illustrated inFIG. 5. The asymmetric fluid transition ports286,288would be offset to ensure a proper torque is generated and applied to the turbine blade subassembly230to initiate the turbine subassembly rotation260. A disadvantage of the offset ports286,288is that the offset can introduce resistance to the flow of the fluid. An advantage of the offset ports286,288is that the offset can enable the use of lower cost turbine blade assemblies230.

Teflon or any other friction reducing lining270can be employed between the circumference of the turbine blade subassembly230and an interior surface of the turbine casing210to enhance a seal therebetween without increasing friction. The distance between the rotated magnets224,226and the pair of fixed magnets244,246directly affects the operation and efficiency of the electrical coil240. The turbine shaft220is assembled within the turbine casing210to retain the dimensional relationship between the rotated magnets224,226and the pair of fixed magnets244,246. The friction reducing material, more specifically a turbine axle friction reducing element274, can be employed between a generator end of the turbine shaft220and the electro-magnetic subassembly mounting plate248. The friction reducing material, referred to as a magnetic interface friction reducing element276, can be employed between the rotated magnetic elements224,226and the fixed magnetic elements244,246.

A rectifier can be inserted in electrical communication with the system to convert the alternating current to direct current.

The turbine assembly200is inserted within the turbine receiving bore160machined through the bearing housing110and penetrating the integrated liquid cooling segment integrated liquid cooling passage131. The turbine receiving bore160is machined being offset from a center between the two edges of the integrated liquid cooling segment integrated liquid cooling passage131. In one exemplary embodiment, the turbine receiving bore160can be located aligning a central axis thereof with one of the edges of the integrated liquid cooling segment integrated liquid cooling passage131, as illustrated inFIG. 4. The turbine assembly200is inserted into the turbine receiving bore160, locating the fluid transfer channel215offset from the center of flow within the integrated liquid cooling segment integrated liquid cooling passage131. The turbine casing fluid inlet port216and turbine casing fluid discharge port218can be tapered (as illustrated respective to the turbine casing fluid inlet port216) or linear (as illustrated respective to the turbine casing fluid discharge port218). The turbine subassembly202is rotated aligning each of the turbine casing fluid ports216,218with the integrated liquid cooling segment integrated liquid cooling passage131. The turbine subassembly202can include a reference to identify the orientation of the turbine casing fluid ports216,218to aid in the alignment process. The exemplary embodiment enables the turbine subassembly202to utilize any of a wide variety of turbine blade232designs.

The turbine subassembly202can be retained within the turbine receiving bore160using any mechanical attachment configuration known by those skilled in the art. The exemplary embodiment utilizes an electro-magnetic subassembly mounting plate248. The electro-magnetic subassembly mounting plate248is fabricated of a non-magnetic material, enabling the magnetic flux to pass therethrough. The designer should consider the thickness of the electro-magnetic subassembly mounting plate248to optimize the interaction between the magnets. One suggested magnetic gap249is 5 mm. In a condition where the magnets are too close, the magnetic attraction will impact the rotation of the magnet support member222. In a condition where the magnets are too far apart, the magnetic attraction will not be sufficient enough to generate the necessary current within the electrical coil241to create the desired power output. The electro-magnetic subassembly240is attached to an exterior surface of the electro-magnetic subassembly mounting plate248. This configuration eliminates a requirement for passing the power supply conductors250,252from within an area exposed to fluid, thus eliminating any risk of a fluid leak related to a passage for the power supply conductors250,252.

The turbine casing210can be carried by an interior surface of the electro-magnetic subassembly mounting plate248. This configuration creates a single assembly, simplifying the installation and removal of the turbine assembly200from the bearing housing110.

The turbine receiving bore160can be sealed using any sealing process known by those skilled in the art. One exemplary process would be to insert a sealant between the exterior of the turbine casing210and the interior of the turbine receiving bore160. This can be a gasket sleeve, a liquid compound, and the like. The exterior of the turbine casing210and the interior of the turbine receiving bore160can be threaded, providing a threaded assembly interface. A sealant, such as pipe tape, threadlock, and the like can be employed within the threaded interface to seal the threaded joint. A seal can be placed between the interior (contacting) surface of the248electro-magnetic subassembly mounting plate248and the exterior surface of the bearing housing110. It is understood that more permanent joint compounds can be employed, although this option limits servicing options.

In operation, fluid flows through the integrated liquid cooling segment integrated liquid cooling passage131in accordance with the fluid flow138. The flowing fluid enters the fluid transfer channel215by passing through the turbine casing fluid inlet port216. The flowing fluid causes the turbine blade subassembly230to rotate. The rotation of the turbine blade subassembly230drives rotation of an electric generator. The electric generator can be of any known suitable form factor. The exemplary electric generator includes a pair of magnets224,226located at distal ends of the magnet support member222. The magnets224,226interact with a pair of fixed magnets244,246or polarized ends of a coil core242. Changes in the magnetic flux density resulting from the rotating magnets224,226passing the fixed magnets244,246creates a current in the electrical coil241. The current is transferred through a pair of power supply conductors250,252. The power supply conductors250,252are provided in electrical communication with electrically operated devices, such as the condition sensor150. It is understood that the electrical power generated by the electro-magnetic subassembly240can be used to power any electrically operated device capable of operating on the power output rating of the generator.

The design of the turbine assembly200can be optimized for efficiency based upon the application.

The components of the turbine assembly200can be treated for consideration of their working environment. Since the turbine assembly200will be subjected to flowing fluid, the electrical components are treated accordingly, such as being potted, coating with a conformal coating, and the like to avoid corrosion and/or premature failure to ensure long term reliability.

One skilled in the art can appreciate that the present invention can be adapted to a liquid or gas cooling system. The system can be operated using medium pressure and medium flow rates to harvest enough energy to power the condition sensor and other low power devices.