Pool cleaner generator module with magnetic coupling

• US 10,519,924 B2
• Filed: 07/24/2017
• Issued: 12/31/2019
• Est. Priority Date: 09/04/2012
• Status: Active Grant

• Current Assignee: Pentair Water Pool And Spa Incorporated (Pentair Plc (Ireland))
• Original Assignee: Pentair Water Pool And Spa Incorporated (Pentair Plc (Ireland))
• Inventors: Deery, Brian, Gopalan, Suresh
• Primary Examiner(s): Patel, Tulsidas C
• Assistant Examiner(s): Ortega, Joseph
• Application Number:
  US15/658,258
• Publication Number:
  US 20180010568A1
• Time in Patent Office: 890 Days
• CPC Class Codes: E04H 4/148 Lighting means
• CPC Class Codes: E04H 4/1654 Self-propelled cleaners
• CPC Class Codes: F03B 13/10 Submerged units incorporating electric generators or motors
• CPC Class Codes: F21L 13/02 with fluid drive
• CPC Class Codes: H02K 7/11 with dynamo-electric clutches
• CPC Class Codes: H02K 7/1823 structurally associated with turbines or similar engines
• CPC Class Codes: Y02E 10/20 Hydro energy

Abstract

A pool cleaner generator module with magnetic coupling. The generator module can include a housing, a paddle wheel, a magnetic follower, and a generator. The generator can power components of the pool cleaner, such as light emitting diode (LEDs). The housing can be removably coupled to the pool cleaner and can include a flow directing portion positioned in a fluid path of the pool cleaner. The paddle wheel can be located adjacent to the flow directing portion and can rotate in response to fluid flow through the fluid path. The generator can be magnetically coupled to the paddle wheel and can generate power through rotation of the paddle wheel. The LED can be coupled to the generator and can receive the generated power from the generator to illuminate an area adjacent to the pool cleaner.

Claims

1. A generator module for a swimming pool cleaner, comprising:

an outer housing having a paddle wheel end and a lead cover end, the outer housing configured to be coupled to a supply mast of the swimming pool cleaner;

a paddle wheel positioned outside the outer housing at the paddle wheel end of the outer housing and around a stationary drive shaft, the paddle wheel including a magnet section having a central cavity and at least one drive magnet arranged around the perimeter of the central cavity and rotating in response to fluid flow through the fluid path, the outer housing extending at least partially into the central cavity of the magnet section;

a generator positioned inside the outer housing and in communication with a driven shaft so that rotation of the driven shaft causes the generator to produce electric power; and

a magnetic follower coupled to the driven shaft and including at least one follower magnet, the magnetic follower being substantially encircled by the magnet section of the paddle wheel, the at least one follower magnet being magnetically coupled to the at least one drive magnet of the paddle wheel so that rotation of the paddle wheel causes rotation of the magnetic follower and the driven shaft.

2. The generator module of claim 1, further comprising a circuit board positioned inside the outer housing and powered by the generator.

3. The generator module of claim 1, further comprising at least one light emitting diode coupled to the generator, the at least one light emitting diode receiving power from the generator and illuminating an area adjacent to the swimming pool cleaner.

4. The generator module of claim 3, wherein the at least one light emitting diode is positioned within a light emitting diode housing.

5. The generator module of claim 3, further comprising at least one lead cable that connects the at least one light emitting diode to the generator module.

6. The generator module of claim 3, wherein the at least one light emitting diode includes control circuitry that controls at least one of illumination and color of the at least one light emitting diode.

7. The generator module of claim 3, wherein the at least one light emitting diode emits a first color according to a first operational condition of the pool cleaner and a second color according to a second operational condition of the pool cleaner.

8. The generator module of claim 7, wherein the first operational condition indicates that the swimming pool cleaner is working properly and the second operational condition indicates that the swimming pool cleaner has malfunctioned.

9. The generator module of claim 1, wherein the magnetic follower is positioned inside the outer housing.

10. The generator module of claim 1, wherein the outer housing is disposed between the supply mast of the swimming pool cleaner and a pool hose attachment adapter.

11. The generator module of claim 10, wherein the outer housing is coupled to the supply mast by a snap fit connection and the outer housing is coupled to the pool hose attachment adapter by a friction fit connection.

12. The generator module of claim 1, wherein the magnetic follower has a torque limit, and when the driven shaft rotates at a speed, the magnetic follower is configured to rotate at the same speed as the driven shaft until the torque limit is exceeded.

13. A generator module for a swimming pool cleaner, comprising:

an outer housing including a generator housing and a flow directing portion, the flow directing portion positioned in a fluid flow path of the swimming pool cleaner;

a paddle wheel positioned around a drive shaft, the paddle wheel including magnets embedded into the paddle wheel;

a generator enclosed within the generator housing and in communication with a driven shaft so that rotation of the driven shaft causes the generator to produce electric power;

electronic circuitry configured to be driven by an alternating electric current converted from an alternating magnetic field; and

at least one light emitting diode that emits light in a first manner if a first swimming pool cleaner operational condition is present and emits light in a second manner different from the first if a second swimming pool cleaner operational condition is present.

14. The generator module of claim 13, wherein the at least one light emitting diode being powered by the alternating electric current illuminates an area adjacent to the swimming pool cleaner.

15. The generator module of claim 14, wherein the electronic circuitry controls the at least one light emitting diode to illuminate in one of a single-color mode, a multi-color mode, and a color changing mode.

16. The generator module of claim 14, wherein the at least one light emitting diode is positioned within a light emitting diode housing.

17. A pool cleaner for a swimming pool or spa, the pool cleaner comprising:

a fluid flow path;

a light emitting diode positioned to direct light toward one of walls and a floor of the swimming pool or spa;

a generator module that powers the light emitting diode, the generator module including;

an outer housing including a generator housing with a paddle wheel end and a lead cover end, and a flow directing portion positioned in the fluid flow path, the outer housing configured to be coupled to a supply mast of the swimming pool cleaner,

a paddle wheel positioned around a stationary drive shaft, the paddle wheel including a magnet section having at least one drive magnet and rotating in response to fluid flow through the fluid path,

a generator enclosed within the generator housing by a lead cover on the lead cover end and in communication with a driven shaft so that rotation of the driven shaft causes the generator to produce electric power, and

a magnetic follower coupled to the driven shaft and including at least one follower magnet, the magnetic follower being substantially encircled by the magnet section of the paddle wheel, the at least one follower magnet being magnetically coupled to the at least one drive magnet of the paddle wheel so that rotation of the paddle wheel causes rotation of the magnetic follower and the driven shaft.

18. The pool cleaner of claim 17, further comprising a controller, wherein the generator module is coupled to the controller.

19. The pool cleaner of claim 17, wherein the magnetic follower has a torque limit, and when the driven shaft rotates at a speed, the magnetic follower is configured to rotate at the same speed as the driven shaft until the torque limit is exceeded.