Piston-mounted power generator, especially for telemetry systems

• US 5,459,360 A
• Filed: 01/14/1994
• Issued: 10/17/1995
• Est. Priority Date: 01/14/1994
• Status: Expired due to Fees

• Current Assignee: Cummins Incorporated
• Original Assignee: Cummins Incorporated
• Inventors: Archuleta, Steven A., Varo, Richard G.
• Primary Examiner(s): Stephan, Steven L.
• Assistant Examiner(s): JONES, JUDSON
• Application Number:
  US08/181,460
• Time in Patent Office: 641 Days
• Field of Search: 310/15, 310/17, 310/23, 310/24, 310/30, 310/34, 310/35, 310/14
• US Class Current: 310/24
• CPC Class Codes: F02B 63/041 Linear electric generators
• CPC Class Codes: G01M 15/02 Details or accessories of testing apparatus
• CPC Class Codes: G01M 15/048 by monitoring temperature
• CPC Class Codes: H02K 35/06 with moving flux distributors, and both coil systems and magnets stationary
• CPC Class Codes: H02K 7/14 Structural association with mechanical loads, e.g. with hand-held machine tools or fans with fan or impeller for cooling the machine H02K9/06

Abstract

A piston-mounted power generator has a piston-mounted magnet unit (1) formed of a coil (2) with a permanent magnet core (3) that is fitted with pole extensions (5, 6). The unit (1) is mounted to the piston skirt (8) with the pole extensions having a small clearance from the inner wall (10) of the piston cylinder formed by cylinder wall liner (12). Shallow grooves (14) are machined into the cylinder wall (10). The grooves (14) have a crescent-shaped longitudinal cross section, that extends circumferentially in the cylinder wall (10) for a distance that is only slightly longer than the width of the pole extensions. The width of each groove (14) is equal to the spacing between the pole extensions (5, 6) and the axial spacing between the adjacent pairs of grooves (14) is equal to the thickness of the pole extensions (5, 6). Electrical power is generated in the coil 2 by the rapid change in flux in the magnetic circuit linked through it as the effective gap between the poles and wall changes as the poles (5, 6) pass each of the grooves (14) and is maximized when the spacing of the poles and grooves results in the magnetic circuit being made and broken simultaneously at both poles. Transducers and telemetry modules (TTM) can be mounted within the interior of the piston and electrically connect to the coil to be powered thereby. To increase the power generated, the grooves (14'"'"') can be backfilled with a nonmagnetic material (15) by flame-spraying or the like. For special pistons, annular grooves can be used instead ones having the preferred crescent shape.

Claims

1. A piston-mounted power generator comprising a permanent magnet unit, having a coil and magnet with a pair of axially spaced pole extensions, mounted to a skirt of a reciprocating piston, and shallow grooves formed in a facing wall of a cylinder within which the piston is mounted for reciprocation and which have an axial spacing corresponding to that of said pole extensions of the magnet;

wherein said pole extensions have a radial clearance relative to the facing wall of the cylinder to enable a magnet circuit to be created through the cylinder wall from one pole extension to the other when each of the grooves is disposed between the pole extensions; and

wherein each of the grooves has a depth sufficient to break said magnet circuit when each groove radially overlies one of the pole extensions.

2. A piston-mounted power generator according to claim 1, wherein said grooves are crescent-shaped in longitudinal cross section.

3. A piston-mounted power generator according to claim 2, wherein said grooves are filled with a nonmagnetic material.

4. A piston-mounted power generator according to claim 1, wherein said grooves are annular.

5. A piston-mounted power generator according to claim 4, wherein said grooves are filled with a nonmagnetic material.

6. A piston-mounted power generator according to claim 1, wherein said grooves are filled with a nonmagnetic material.

7. A piston-mounted power generator according to claim 1, wherein a transducer and telemetry module is mounted within the piston and is electrically connected to the coil of the magnet unit so as to be powered thereby.

8. A piston-mounted power generator according to claim 7, wherein said grooves are crescent-shaped in longitudinal cross section.

9. A piston-mounted power generator according to claim 8, wherein said grooves are filled with a nonmagnetic material.

10. A piston-mounted power generator according to claim 7, wherein said grooves are annular.

11. A piston-mounted power generator according to claim 10, wherein said grooves are filled with a nonmagnetic material.

12. A piston-mounted power generator according to claim 1, wherein the magnet unit forms part of annular generator and telemetry module assembly, said assembly having a ting-shaped body which is mounted to the underside of the piston skin and within which said magnet unit and a transmitter are provided.

13. A piston-mounted power generator according to claim 12, wherein a thermocouple conditioner/switch unit is also provided within said ring-shaped body.

14. A piston-mounted power generator according to claim 12, further comprising a rectifier circuit having means for optimizing output voltage from the coil by minimizing source impedance.

15. A piston-mounted power generator according to claim 14, wherein said means for optimizing comprises a capacitor which forms a tuned circuit in conjunction with the inductance of the coil of the magnet unit at a mean pulse frequency which corresponds to an engine idle speed so as to form a resonant circuit with an overall impedance that is close to the DC resistance of the coil.

16. A piston-mounted power .generator according to claim 14, wherein said rectifier circuit comprises a diode bridge, at least one smoothing capacitor and a voltage regulator for rectification and regulation of coil output.

17. A piston-mounted power generator according to claim 1, further comprising a rectifier circuit having means for optimizing output voltage from the coil by minimizing source impedance.

18. A piston-mounted power generator according to claim 17, wherein said means for optimizing comprises a capacitor which forms a tuned circuit in conjunction with the inductance of the coil of the magnet unit at a mean pulse frequency which corresponds to an engine idle speed so as to form a resonant circuit with an overall impedance that is close to the DC resistance of the coil.

19. A piston-mounted power generator according to claim 17, wherein said rectifier circuit comprises a diode bridge, at least one smoothing capacitor and a voltage regulator for rectification and regulation of coil output.