Leakage flux generators and power equipment

Abstract

To provide a leakage flux power generation device and power equipment that are easy to install on power equipment, do not require wiring, space requirements, or battery replacement, have excellent power generation efficiency, and are highly versatile as they are compatible with various circuit boards equipped with power supply ICs of different operating voltages. [Solution] A leakage flux power generation device 10 is used attached to a power equipment equipped with a moving body that performs rotational or linear motion by electromagnetic force, and includes one or more windings 11B that generate an electromotive force by electromagnetic induction due to changes in leakage flux leaking from a rotary motor or linear motor, which is the power equipment, in conjunction with the rotational motion of the rotor or the linear motion of the sliding element, which is the moving body.

Description

Technical Field

[0001] The present invention relates to a leakage flux power generation device and a power equipment including the same.

Background Art

[0002] In recent years, with the development of information technology, by utilizing various sensors, communication devices, data processing devices, etc. and attaching these devices to various facilities and equipment, it has become possible to grasp the operating status, detect failures at an early stage, and predict failures using the acquired data. For example, in various facilities centered on infrastructure systems for performing air conditioning, water supply and drainage, etc., in order to maintain the stable operating state of power equipment such as motors and electromagnetic valves, a method of observing temperature fluctuations, presence or absence of vibration, etc. by attaching sensors to the power equipment has been adopted. Observation data obtained by sensors attached to power equipment is transmitted via a data communication circuit board, etc. to, for example, smartphones, tablet terminals, etc. and is used for monitoring the operating status of various facilities.

[0003] When attaching sensors to various power equipment as described above and installing a sensor drive circuit board, a data processing / communication circuit board, etc. together with them, generally, a commercial power supply or a battery is used as the driving power for operating them. However, when supplying the driving power for each of the above circuit boards from a commercial power supply, it becomes a factor for cost increase from the viewpoints of the labor of wiring and securing the wiring path. On the other hand, when using a battery for the above driving power, although the labor of wiring does not occur, there is a problem that the battery needs to be replaced at regular intervals. Therefore, in both cases where each driving power is supplied from a commercial power supply and where it is supplied from a battery, the burdens on both the users and providers of the power equipment are large.

[0004] In recent years, power generation devices have been proposed that utilize so-called energy harvesting technology, which uses vibrations and leakage magnetic flux generated incidentally during the operation of power equipment, to generate electricity while attached to the power equipment. When electricity generated using this method, which takes advantage of the installation environment, is used to operate the aforementioned sensor drive circuit boards and data processing / communication boards, installation becomes easy without the need for wiring from commercial power or securing space. Furthermore, by adopting the above technology, the hassle of battery replacement and other maintenance is eliminated, thus improving maintainability.

[0005] For example, Patent Document 1 discloses a vibration power generation device that can be attached to and used with machinery such as production machines or machine tools. According to the vibration power generation device described in Patent Document 1, a power generation element is excited in accordance with the vibration of the machinery, and power is extracted from a coil attached to a magnetostrictive plate provided on the power generation element. Furthermore, the vibration power generation device described in Patent Document 1 is provided with a frequency adjustment member attached to a frame joined to the power generation element, which adjusts the resonant frequency of the vibration power generation device.

[0006] Furthermore, Patent Document 2 discloses a magnetic field power generation device that is arranged on the outside of the housing of a power device and comprises a winding capable of generating electricity using leakage magnetic flux generated from multiphase wiring, and a holder for holding the winding, and is attached to the outer surface of the housing via the holder. Patent Document 2 states that with the above configuration, it is possible to generate electricity using leakage magnetic flux generated from multiphase wiring, and that by providing the magnetic field power generation device including the winding on the outside of the housing, it is possible to reduce the burden of maintenance work without having to process holes or other parts of the housing of the power device.

[0007] Furthermore, Patent Document 3 discloses a combined generator comprising a main generator having a ring-shaped magnet that rotates around the rotation axis of a shaft and a coil arranged opposite to the magnet, and a secondary generator that generates electricity from the leakage magnetic flux from the main generator to supplement the power generated by the main generator. Patent Document 3 states that the above configuration can provide a combined generator that can utilize the leakage magnetic flux of the magnet. [Prior art documents] [Patent Documents]

[0008] [Patent Document 1] Japanese Patent Publication No. 2021-153381 [Patent Document 2] Japanese Patent Publication No. 2019-068663 [Patent Document 3] Patent No. 6935909 [Overview of the project] [Problems that the invention aims to solve]

[0009] The semiconductor elements (power ICs) used in IoT communication devices such as the data communication boards mentioned above are designed to be optimized for the differences in impedance depending on the type of power source, such as photovoltaic, thermoelectric, or vibration-powered devices, and each has a different operating voltage. Therefore, it may become necessary to use different circuit boards depending on the power supply voltage, which could lead to increased costs.

[0010] The operating voltage range of power supply ICs like those described above varies greatly depending on the specifications, for example, 0.02~0.2V, 0.2~1.0V, 0.2~2V, 2~5.5V, etc. When a power generator is attached to power equipment and the generated power is supplied to the various circuit boards mentioned above, it is necessary to ensure at least the minimum operating voltage of the power supply ICs mentioned above, but there is a problem in that it is difficult to cover all voltage bands with a single type of power generator.

[0011] In the case of a resonant vibration type vibration power generation device like the one described in Patent Document 1, the configuration is such that it can only generate power at frequencies near the resonant frequency, which means that the specifications must be changed depending on the industrial equipment to which it is installed, resulting in a lack of versatility. Although the vibration power generation device described in Patent Document 1 is equipped with a frequency adjustment member, the adjustment range is limited because the resonant frequency mainly depends on the size and structure of the power generation element, thus limiting its ability to increase versatility. Furthermore, with a vibration power generation device configuration employing a resonant vibration type like the one in Patent Document 1, the output voltage is limited to a single voltage, which also contributes to its lack of versatility.

[0012] Furthermore, as in Patent Document 2, when using magnetic flux leaking from multilayer wiring for supplying power to power equipment, the leakage flux itself is very small, and therefore a large voltage cannot be obtained. For this reason, with a power generation method like that in Patent Document 2, there is a problem in that it becomes difficult to secure the minimum operating voltage of the various specifications of power supply ICs mentioned above.

[0013] Furthermore, in a combined generator like the one described in Patent Document 3, the shaft supporting the magnet rotates due to rotational force transmitted from the outside, and the power generated by the rotation of the magnet is extracted from the coil. As a result, the leakage magnetic flux acting on the auxiliary generator is relatively small. Therefore, as with Patent Document 2, there is a problem in that it is difficult to ensure the minimum operating voltage of power supply ICs of various specifications. In addition, in the case of the combined generator in Patent Document 2, the auxiliary generator is integrated with the main generator, so the specifications must be incorporated at the design stage. Therefore, it is not easy to add an auxiliary generator later, and for example, it is difficult to change the specifications of the auxiliary generator to accommodate various circuit boards that supply power, resulting in a lack of versatility and expandability.

[0014] Therefore, in order to apply power generation using energy harvesting technology that utilizes the installation environment to supply power to the various circuit boards described above, there was a strong need for a power generation device that is easy to attach to power equipment, etc., and has excellent power generation efficiency and versatility.

[0015] The present invention has been made in view of the above problems, and aims to provide a leakage flux power generation device that is easy to attach to power equipment, does not require wiring, space requirements, or battery replacement, has excellent power generation efficiency, is compatible with various types of circuit boards equipped with power supply ICs of different operating voltages, and is highly versatile, as well as power equipment to which this leakage flux power generation device is attached. [Means for solving the problem]

[0016] To solve the above problems, the inventors conducted extensive research. As a result, they found that by adopting a configuration that includes one or more windings capable of generating electricity through changes in leakage flux, and by attaching such a leakage flux power generation device to a power device having a moving body that performs rotational or linear motion due to electromagnetic force, excellent power generation efficiency can be obtained. Furthermore, they found that by optimizing the number of windings, etc., it becomes possible to accommodate various types of circuit boards equipped with power supply ICs of different operating voltages, thus completing the present invention.

[0017] In other words, the present invention provides a leakage flux power generation device for use attached to a power equipment equipped with a moving body that performs rotational or linear motion due to electromagnetic force, characterized in that it includes one or more windings that generate an electromotive force by electromagnetic induction due to changes in leakage flux leaking from the power equipment in conjunction with the rotational or linear motion of the moving body.

[0018] In the above embodiment, the leakage flux power generation device of the present invention can be configured such that the winding generates an electromotive force by electromagnetic induction due to a change in leakage flux leaking from one or both of the electromagnetic coils and permanent magnets that cause the moving body to rotate or move linearly, which are provided in the power equipment.

[0019] In the above embodiment, it is preferable that the leakage flux power generation device of the present invention further includes a core made of a soft magnetic material, the core of which is provided such that at least a portion is inserted into the internal space of the winding.

[0020] In the leakage magnetic flux power generation device of the present invention, in the above aspect, the core may be composed of a rod-shaped member, and one end of the core may be an attachment portion to the outer surface of the housing in the power equipment.

[0021] In the leakage magnetic flux power generation device of the present invention, in the above aspect, it is more preferable to adopt a configuration in which the core is composed of a U-shaped member when viewed from the front, and each of both ends of the core is an attachment portion to the outer surface of the housing in the power equipment.

[0022] In the leakage magnetic flux power generation device of the present invention, in the above aspect, a plurality of the windings may be provided, and at least a part of the core may be inserted so as to extend through the internal spaces of each of the plurality of windings, so that the plurality of windings are arranged in series.

[0023] In the leakage magnetic flux power generation device of the present invention, in the above aspect, both ends of the core may be attachment portions to positions where the change timing of the leakage magnetic flux is different with respect to the outer surface of the housing in the power equipment, respectively.

[0024] In the leakage magnetic flux power generation device of the present invention, in the above aspect, the plurality of windings may have the same or different impedances respectively, and each current generated by the plurality of windings may be output individually for each winding, or at least a part of the plurality of windings may be electrically connected in series or in parallel, so that they may be output comprehensively.

[0025] In the leakage magnetic flux power generation device of the present invention, in the above aspect, the power equipment may be a rotary motor having a rotor as the moving body, and the winding axis of the winding may be arranged so as to be orthogonal to the rotation direction of the rotor.

[0026] In the above embodiment, the leakage flux power generation device of the present invention may consist of a linear motor having a sliding element as the moving body, and the winding may be configured such that the winding axis of the winding is perpendicular to the direction of movement due to the linear motion of the sliding element.

[0027] The present invention provides a power device characterized by comprising a moving body that performs rotational or linear motion by electromagnetic force, and having one or more of the above-described leakage magnetic flux power generation devices according to the present invention attached to the outer surface of a housing on which the moving body is arranged. [Effects of the Invention]

[0028] The leakage flux power generation device of the present invention employs a configuration that includes one or more windings that generate an electromotive force by electromagnetic induction due to changes in leakage flux leaking from the moving body of a power device in conjunction with the rotational or linear motion of the moving body. As described above, by employing a configuration that includes one or more windings capable of generating electricity through changes in leakage flux, and by attaching such a leakage flux generator to power equipment, excellent power generation efficiency can be obtained. By optimizing the number of windings and other factors, it becomes possible to simultaneously supply power at multiple different voltages. Therefore, it is possible to realize a highly versatile leakage flux power generation device with a simple configuration that is easy to install on power equipment, does not require wiring, space allocation, or battery replacement, has excellent power generation efficiency, and is compatible with various boards equipped with power supply ICs of different operating voltages.

[0029] Furthermore, since the power equipment of the present invention is equipped with the leakage flux power generation device described above, the power efficiently generated by the leakage flux power generation device can be stably supplied to, for example, a sensor drive board or a data processing / communication board. Moreover, even if the various boards mentioned above are equipped with power supply ICs of different operating voltages, by optimizing the arrangement of windings in the leakage flux power generation device, it becomes possible to operate various boards while simultaneously supplying power of multiple different voltages. Therefore, power equipment with a variety of functions obtained through the operation of various circuit boards can be realized without requiring commercial power or batteries.

[0030] Other objects, features, and advantages of the present invention will become apparent from the following description of embodiments of the invention with reference to the accompanying drawings. [Brief explanation of the drawing]

[0031] [Figure 1] Figure 1 is a diagram illustrating one embodiment of the leakage flux power generation device and power equipment according to the present invention, and is a schematic perspective view showing an example of an overall configuration in which the leakage flux power generation device is attached to the outer surface of the housing of a rotary motor (power equipment). [Figure 2] Figure 2 is a diagram illustrating one embodiment of the leakage flux power generation device according to the present invention, and is an enlarged broken view showing an example of the leakage flux power generation device shown in Figure 1, in which a core made of a rod-shaped member is inserted into the internal space of the winding. [Figure 3] Figure 3 illustrates one embodiment of the leakage flux power generation device and power equipment according to the present invention. It is a schematic front view taken from the axial direction of the rotating shaft, showing an example of an overall configuration in which the leakage flux power generation device shown in Figure 2 is mounted on the outer surface of the housing of a rotary motor (power equipment). [Figure 4] Figure 4 is a diagram illustrating one embodiment of the leakage flux power generation device and power equipment according to the present invention, and is a schematic breakaway view from the front that shows another example of the overall configuration in which the leakage flux power generation device shown in Figure 2 is attached to the outer surface of the housing of a rotary motor (power equipment). [Figure 5] Figure 5 is a diagram illustrating one embodiment of the leakage flux power generation device according to the present invention, and is a schematic breakaway view showing an example in which a core made of a U-shaped member is inserted into the internal space of the winding. [Figure 6] Figure 6 is a diagram illustrating one embodiment of the leakage flux power generation device and power equipment according to the present invention, and is a schematic front view showing another example of the overall configuration in which the leakage flux power generation device shown in Figure 5 is attached to the outer surface of the housing of a rotary motor (power equipment). [Figure 7] Figure 7 illustrates one embodiment of the leakage flux power generation device and power equipment according to the present invention, and is a schematic front view showing another example of the overall configuration in which multiple leakage flux power generation devices, as shown in Figure 5, are mounted on the outer surface of the housing of a rotary motor (power equipment). [Figure 8] Figure 8 is a diagram illustrating one embodiment of a leakage flux power generation device according to the present invention, and is a schematic breakaway view showing an example in which a core made of a U-shaped member is inserted so as to extend through the internal space of multiple windings. [Figure 9] Figure 9 is a diagram illustrating one embodiment of the leakage flux power generation device according to the present invention, and is a schematic diagram showing a rod-shaped core provided in the leakage flux power generation device shown in the example in Figure 2. [Figure 10] Figure 10 is a diagram illustrating one embodiment of the leakage flux power generation device according to the present invention, and is a schematic diagram showing the relationship between the core, which consists of a U-shaped member, and the direction of the leakage flux, as provided in the leakage flux power generation device example shown in Figure 5. [Figure 11] Figure 11 illustrates one embodiment of the leakage flux power generation device according to the present invention, and is a schematic diagram showing another example of a core inserted into the internal space of the winding. [Figure 12] Figure 12 illustrates one embodiment of the leakage flux power generation device according to the present invention and is a schematic diagram showing another example of a core inserted into the internal space of the winding. [Figure 13] Figure 13 is a diagram illustrating one embodiment of the leakage flux power generation device and power equipment according to the present invention, and is a schematic diagram showing the relationship between a core consisting of a U-shaped member provided in the leakage flux power generation device example shown in Figure 5, the direction of the magnetic flux leaking from the AC synchronous motor (power equipment; rotary motor), and the timing of the change in this magnetic flux. [Figure 14] Figure 14 illustrates an embodiment of the leakage flux power generation device and power equipment according to the present invention. It is a graph showing the electromotive force waveform, comparing the voltage generated when the leakage flux power generation device is attached to the housing of an AC speed control motor (power equipment; rotary motor) with a sample of the leakage flux power generation device shown in Figure 2 and a sample of the leakage flux power generation device shown in Figure 5. [Figure 15] Figure 15 illustrates an embodiment of the leakage flux power generation device and power equipment according to the present invention. It is a graph showing the electromotive force waveform when the leakage flux power generation device shown in Figure 2 is mounted on the housing of an AC speed control motor (power equipment; rotary motor) and generates electricity, comparing the voltage for samples with high winding impedance and samples with low winding impedance. [Figure 16] Figure 16 illustrates an embodiment of the leakage flux power generation device and power equipment according to the present invention. It is a graph showing the electromotive force waveforms obtained by measuring and comparing the voltage generated when a sample of the leakage flux power generation device shown in Figure 2 is mounted on the housing of an AC speed control motor (power equipment; rotary motor) while changing the circuit speed (rotational speed) of the rotary motor. [Figure 17] Figure 17 illustrates an embodiment of the leakage flux power generation device and power equipment according to the present invention. It is a graph showing the electromotive force waveform obtained by measuring the voltage generated when a sample of the leakage flux power generation device shown in Figure 2 is mounted on the housing of a three-phase AC constant-speed induction motor (power equipment; rotary motor) and the power generation frequency is confirmed. [Figure 18] Figures 18(a) to 18(c) illustrate embodiments of the leakage flux power generation device and power equipment according to the present invention. The graphs show the electromotive force waveform obtained by measuring the voltage generated when a sample of the leakage flux power generation device shown in Figure 2 is mounted on the housing of a DC speed control motor (power equipment; rotary motor) while changing the rotation speed of the rotary motor, and confirming the power generation frequency. Figure 18(a) shows the case when the rotation speed is slow, Figure 18(b) shows the case when the rotation speed is medium, and Figure 18(c) shows the case when the rotation speed is fast. [Modes for carrying out the invention]

[0032] The following describes in detail embodiments of the leakage flux power generation device and power equipment equipped therewith according to the present invention, with appropriate reference to the drawings. In addition, the drawings used in the following description may be slightly enlarged for convenience in order to make the features of the leakage flux power generation device and power equipment of the present invention easier to understand, and the dimensional ratios of each component may differ from those of the actual product. Furthermore, the materials, dimensions, etc. exemplified in the following description are examples only, and the present invention is not limited to them, and can be implemented with appropriate modifications without changing the essence of the invention.

[0033] <Power equipment (power equipment to which leakage flux generators are installed)> The power equipment to which the leakage flux generator of this embodiment is attached will be described in detail, mainly with reference to Figures 1, 3, 4, 6, 7, and 13 as appropriate (Figures 2, 5, etc. will also be referenced as appropriate). The leakage flux power generation device of this embodiment (see reference numeral 10, etc. in Figure 1; hereinafter sometimes abbreviated as "power generation device") is used by being attached to a power device equipped with a moving body that performs rotational or linear motion due to electromagnetic force, as will be described in detail later, and generates an electromotive force in accordance with the change in leakage flux leaking from this power device. For this reason, in this specification (this embodiment), the detailed configuration of the power device and the mechanism by which magnetic flux leaks will be described first.

[0034] Figure 1 is a schematic perspective view showing an example of an overall configuration in which the power generation device 10 (see also Figure 2) is attached to the outer surface 31a of the housing 31 of the rotary motor (power equipment) 3. Figure 3 is a front view taken from the axial direction of the rotating shaft 36, showing an example of the overall configuration in which the power generation device 10 is attached to the outer surface 31a of the housing 31 of the rotating motor 3. Figure 4 is a broken view of another example of the overall configuration in which the power generation device 10 is attached to the outer surface 31a of the housing 31 of the rotary motor (power equipment) 3A, as seen from the axial direction of the rotating shaft 36, i.e., from the front side. Figure 6 is a front view from the axial direction of the rotating shaft 36, showing another example of the overall configuration in which the power generation device 10A (see also Figure 5) is attached to the outer surface 31a of the housing 31 of the rotating motor 3. Figure 7 is a front view taken from the axial direction of the rotating shaft 36, showing another example of the overall configuration in which multiple power generation devices 10A are attached to the outer surface 31a of the housing 31 of the rotating motor 3. Figure 13 is a schematic diagram showing the relationship between the core 13, which is a U-shaped member and is provided in the power generation device 10A, the direction of the leakage magnetic flux M leaking from the rotary motor (power equipment) 3B, which is an AC synchronous motor, and the timing of the change in the leakage magnetic flux M.

[0035] The rotary motor 3 shown in Figure 1 is an example of a power device to which the power generation device 10 of this embodiment can be attached, and has a rotor that rotates as a moving body (see also Figures 3 and 6 for details on the rotary motor 3). Although not shown in detail in Figure 1, the rotary motor 3 is equipped with a stator and a rotor, and the rotating shaft connected to the rotor (see reference numeral 36 in Figure 3, etc.) is provided to protrude to the outside, thereby enabling it to supply rotational force to the outside. As shown in Figure 1, the power generation device 10 of this embodiment is attached to the outer surface 31a of the housing 31 of the rotary motor 3. In the illustrated example, the power generation device 10 is attached near the top of the cylindrical, horizontally oriented housing 31. Furthermore, in the illustrated example, the rotary motor 3 is supported by the support base 2, thereby forming a power equipment system 1 consisting of the power generator 10, the rotary motor 3, and the support base 2.

[0036] In the example shown in Figure 1, the support base 2 is configured in the shape of a rectangular parallelepiped, with the rotary motor 3 installed on its upper surface. On the other hand, in the examples shown in Figures 3, 6, and 7, the support base 2 is shown as a roughly triangular shape in its longitudinal cross-section for the purpose of illustrating the rotary motors 3 and 3A. The support base 2 can be made of any metal material that can withstand the weight of power equipment such as a rotary motor and that can stably mount the power equipment.

[0037] Although the detailed structure of the rotary motor 3 is not shown in Figures 1, 3, 6, and 7, it is, for example, a brushless AC or DC motor equipped with an electromagnetic coil and a permanent magnet, with the stator side having the electromagnetic coil and the rotor side having the permanent magnet.

[0038] Detailed examples of AC motors include, for example, AC synchronous motors (see Figure 13), which will be described in detail later, as well as AC speed control motors and 3-phase AC constant-speed induction motors. Detailed examples of DC motors include, for instance, DC speed control motors. In addition to the brushless structure described above, DC motors also include those in which the stator side has permanent magnets and the rotor side has electromagnetic coils and a commutator, with current supplied from the brushes to the commutator.

[0039] As an example of the internal structure of a rotary motor, we will first explain the rotary motor 3A, which consists of a DC motor as shown in Figure 4. The cutaway view in Figure 4 shows the internal structure of the rotary motor 3A, and in the illustrated example, a power generation device 10, which will be described in detail later, is attached to the outer surface 31a of the housing 31. As shown in Figure 4, the rotary motor 3A has a stator 32 having multiple electromagnetic coils 32a and a rotor 33 having multiple permanent magnets 33a inside a roughly cylindrical housing 31, and a rotating shaft 36 for transmitting rotational force to the outside is positioned at the central axis of the rotor 33.

[0040] The stator 32 is mounted on the inner surface of the housing 31, opposite to the outer surface 31a. Multiple electromagnetic coils 32a constituting the stator 32 are mounted on the inner surface of the housing 31, and in the illustrated example, they are arranged at equal intervals at a total of nine locations. That is, the electromagnetic coils 32a in the illustrated example are arranged in a ring shape at 40° pitches in the circumferential direction of the inner surface of the housing 31.

[0041] The rotor 33 is positioned inside the stator 32, surrounded by the stator 32, and multiple permanent magnets 33a are arranged to face multiple electromagnetic coils 32a provided on the stator 32. The rotor 33 rotates around the rotation axis 36 due to the repeated magnetic attraction and repulsion generated between the multiple permanent magnets 33a and the energized multiple electromagnetic coils 32a. As a result, the rotary motor 3A transmits rotational force to the outside via the rotation axis 36.

[0042] In this embodiment, the rotary motor 3A, which is the power device, has a power generation device 10 detachably attached to the outer surface 31a of the housing 31. With this configuration, although the details will be described later, an electromotive force is generated in the power generation device 10 by electromagnetic induction in response to changes in the leakage magnetic flux (see also the symbol M in Figure 13) leaking from the rotor 33, which is a rotating body. In this way, the leakage magnetic flux leaking from the permanent magnet 33a changes with the rotation of the rotor 33, effectively generating an electromotive force in the power generation device 10. Therefore, efficient and stable power generation becomes possible by utilizing the leakage magnetic flux that would otherwise attenuate and disappear toward the outside of the rotary motor.

[0043] Next, as another example of the internal structure of a rotary motor, we will describe the rotary motor 3B, which consists of an AC synchronous motor as shown in Figure 13. The cutaway view in Figure 13 shows the internal structure of the rotary motor 3B, and in the illustrated example, the core 13, which is included in the power generation device described in detail later, is attached to the outer surface 31a of the housing 31. As shown in Figure 13, the rotary motor 3B has a stator 35 with multiple electromagnetic coils 35a, 35b, and 35c, and a rotor 34 made of a single permanent magnet, all housed in a roughly cylindrical casing 31. Although not shown in Figure 13, a rotating shaft for transmitting rotational force to the outside is positioned at the center axis of the rotor 34.

[0044] The stator 35 is mounted on the inner surface of the housing 31 opposite to the outer surface 31a, similar to the case of the rotary motor 3A shown in Figure 4. The multiple electromagnetic coils 35a, 35b, and 35c that constitute the stator 35 are mounted in multiple locations on the inner surface of the housing 31. In the illustrated example, the electromagnetic coils 35a, 35b, and 35c are arranged in pairs facing each other, for a total of six locations at equal intervals. That is, the electromagnetic coils 35a, 35a, 35b, 35b, and 35c, 35c in the illustrated example are arranged in a ring shape at 60° pitches in the circumferential direction of the inner surface of the housing 31. Furthermore, the two electromagnetic coils 35a, 35a, 35b, 35b, and 35c, 35c are each configured to generate a pair of S-pole and N-pole magnetic fields.

[0045] The rotor 34 is positioned inside the stator 35, surrounded by the stator 35, and in the illustrated example, it is composed of a single, roughly plate-shaped permanent magnet. In the illustrated example, the rotor 34 has two outer ends, which are the south and north poles of the permanent magnet, and these are positioned to face the multiple electromagnetic coils 35a, 35b, and 35c provided on the stator 35. The rotor 34 rotates around a rotation axis (not shown) due to the repeated attraction and repulsion of magnetic MF generated between the south and north poles of the rotor and the energized multiple electromagnetic coils 35a, 35b, and 35c. As a result, the rotary motor 3B transmits rotational force to the outside via the rotation axis.

[0046] In this embodiment, the rotary motor 3B, which is the power device, has a power generation device detachably attached to the outer surface 31a of the housing 31, similar to the case of the rotary motor 3A described above. In Figure 13, for illustrative purposes, only the U-shaped core 13 in plan view that constitutes the power generation device is shown. With this configuration, the rotary motor 3B, as described above, generates an electromotive force in the power generation device (see also power generation device 10A shown in Figure 5), which includes the core 13, through electromagnetic induction in response to changes in the leakage magnetic flux M leaking from the rotor 34, which is the rotating body. This enables efficient and stable power generation utilizing the leakage magnetic flux M.

[0047] Even if the power source, a rotary motor, is a DC motor with electromagnetic coils and a commutator arranged on the rotor side, it is possible to generate an electromotive force in the power generation device through electromagnetic induction corresponding to changes in leakage flux leaking from the electromagnetic coils on the rotor. Such changes in leakage flux depend on the power generation period (power generation frequency), i.e., the rotational speed, of the rotary motor.

[0048] In this embodiment, a rotary motor having a rotor, which is a moving body, is used as an example of a power device to which the leakage flux power generation device is attached. However, the power devices in this invention are not limited to this. In this invention, in addition to rotary motors, various power devices that operate by electromagnetic force and are expected to leak magnetic flux can be used as power devices, such as linear motors having a linearly moving slide element as a moving body, or electromagnetic solenoids. In any of these power devices, it is possible to attach and use the leakage flux power generation device, which will be described in detail later.

[0049] Furthermore, while the examples shown in Figures 1, 3, 6, and 7 illustrate how a power equipment system (see reference numeral 1 in Figure 1) is configured by mounting a rotary motor (3, 3A) to a support base 2, this support base 2 is not essential. For example, the support base 2 can be omitted by placing mounting fixtures or the like at the installation location of the rotary motor.

[0050] The rotary motor, which is the power device of this embodiment, only needs to have one or more of the above-described power generation devices attached to it, and the number of devices to be attached can be determined while taking into account the operating voltage (current) of the various circuit boards that require power supply from the power generation devices. For example, in the examples shown in Figures 1 and 3, one power generation device 10 is attached to the outer surface 31a of the housing 31 of the rotary motor 3, but in the example shown in Figure 7, three power generation devices 10A are attached to the outer surface 31a of the housing 31 of the rotary motor 3. In this way, by attaching multiple power generation devices to the rotary motor 3, it becomes possible to supply power to various circuit boards that operate at high voltage or high current, and by using multiple power generation devices individually or in combination as appropriate, it also becomes possible to supply power corresponding to multiple operating voltages and operating currents.

[0051] <Leakage magnetic flux power generation device> The configuration of the leakage flux power generation device (power generation device) of this embodiment will be described in detail, mainly with reference to Figures 2, 5, 8 to 12 (Figures 1, 3, 4, 6, 7, and 13, which describe the power equipment to which the power generation device is attached, will also be referred to as appropriate). Figure 2 is a diagram illustrating the power generation device 10 of this embodiment, and is a broken view showing an example in which a core 12 made of a rod-shaped member is inserted into the internal space 11C of the winding unit 11 (winding 11B) shown in Figure 1. Figure 5 is a diagram illustrating the power generation device 10A of this embodiment, and is a broken view showing an example in which a core 13 made of a U-shaped member is inserted into the internal space of the winding unit 11. Figure 8 is a diagram illustrating the power generation device 10A of this embodiment, and is a broken view showing an example in which a core 13 made of a U-shaped member is inserted so as to span the internal spaces 11C, 11C of a plurality of winding units 11, 11. Figure 9 is a schematic diagram showing a rod-shaped core 12, which is provided in the power generation device 10 of the example shown in Figure 2, on its own. Figure 10 is a schematic diagram showing the relationship between the core 13, which consists of a U-shaped member, and the direction of the leakage magnetic flux M, as provided in the power generation device 10A shown in Figure 5.

[0052] The power generation device of this embodiment is used when attached to a power device equipped with a moving body that performs rotational or linear motion due to electromagnetic force. Furthermore, the power generation device of this embodiment is configured to include one or more windings that generate an electromotive force by electromagnetic induction due to changes in leakage magnetic flux leaking from power equipment in conjunction with the rotational or linear motion of a moving body.

[0053] In other words, the power generation device 10 of this embodiment, shown in detail in Figure 2, is used by being attached to a rotary motor (see reference numeral 3 in Figure 3 or reference numeral 3A in Figure 4), which is a power device equipped with a rotor (see reference numeral 33 in Figure 4) as a moving body that performs rotational motion by electromagnetic force, as shown in the example in Figure 3 or Figure 4. In the illustrated example, the power generation device 10 is attached to the outer surface 31a of the housing 31 of the rotary motors 3 and 3A. Furthermore, the power generation device 10 of this embodiment is generally configured to include a winding unit 11 (winding 11B) that generates an electromotive force by electromagnetic induction due to the change in leakage magnetic flux leaking from the rotary motor 3A in conjunction with the rotational motion of the rotor 33 illustrated in Figure 4. In the example shown in Figure 4, a rod-shaped core 12 is inserted into the internal space 11C of the winding unit 11, and one end 12a of the core 12 is used as a mounting portion to the outer surface 31a of the housing 31 of the rotary motor 3. In addition, although not shown in Figures 1, 3, 4, etc., one end 12a of the core 12 is attached to the outer surface 31a of the housing 31 of the rotary motors 3, 3A by methods such as bolts, jigs, or adhesive.

[0054] The winding unit 11 consists of a coil bobbin 11A and a winding 11B that is wound around the coil bobbin 11A.

[0055] The coil bobbin 11A is a bobbin-shaped member with a cylindrical body 11a and flanges 11c formed at both ends, and functions as a core for winding the winding wire 11B. In addition, an axial hole 11b is formed inside the body 11a, and this axial hole 11b secures a cylindrical internal space 11C into which the core 12, which will be described in detail later, can be inserted. The material of the coil bobbin 11A is not particularly limited; any resin material with excellent heat resistance and electrical resistance, commonly used in electromagnetic coils, can be used without any restrictions. It is also possible to use metal materials with excellent heat resistance and mechanical strength properties.

[0056] The winding 11B is wound around the body 11a of the coil bobbin 11A and has the effect of generating an electromotive force by electromagnetic induction due to the change in leakage magnetic flux leaking from the rotary motor 3 described above. Furthermore, the winding 11B is wound around the body 11a by the flange 11c so as not to protrude from it.

[0057] The number of turns (turns) n of winding 11B is not particularly limited and is preferably set appropriately while taking into account the strength of the magnetic flux expected to leak from power equipment such as a rotary motor. On the other hand, depending on the structure of the power equipment, the leakage magnetic flux leaking to the outside of the housing may be weaker, so in such cases it is preferable to set the number of turns n of winding 11B to be larger.

[0058] Here, the voltage generated by electromagnetic induction in winding 11B can be expressed by the following equation (1). That is, it is known that the voltage of the electromotive force due to electromagnetic induction is proportional to the number of turns n. e=-n(Δφ / Δt) [V] ·····(1) However, in equation (1) above, e is the voltage (V), n is the number of turns of winding 11B, and Δφ / Δt is the change in magnetic flux of winding 11B per unit time.

[0059] The wire material constituting the winding 11B is not particularly limited, and any enameled wire commonly used for windings in power generation devices utilizing electromagnetic induction can be used without any restrictions.

[0060] As described above, the core 12 is provided so as to be inserted, at least a portion of it, into the internal space 11C secured by the shaft hole 11b in the coil bobbin 11A that constitutes the winding unit 11, and in the examples shown in Figures 2 and 9, it is a rod-shaped member formed in the shape of a round bar. Although not shown in Figure 2, the core 12 can be fixed inside the shaft hole 11b of the coil bobbin 11A by fixing means such as adhesive or adhesive tape.

[0061] The core 12 converges the leakage magnetic flux in the internal space 11C of the winding unit 11 (winding 11B), increasing the magnetic flux density and thereby improving the power generation efficiency of the winding 11B. Furthermore, by providing the core 12, the leakage magnetic flux leaking from the rotating motor can be efficiently guided to the winding 11B, so even if the leakage magnetic flux leaking from the rotating motor is relatively weak, sufficient power generation efficiency can be obtained. Furthermore, the core 12 provided in the power generation device 10 of this embodiment functions as a mounting part in the power generation device 10, as one end 12a is attached to the outer surface 31a of the housing 31 of the rotary motor 3, which is a power device.

[0062] The material of the core 12 is not particularly limited, but it is preferably a soft magnetic material with high magnetic permeability and low coercivity, and more preferably a soft magnetic material with high saturation magnetic flux density. Examples of such soft magnetic materials include iron-nickel alloys, iron-cobalt alloys, iron-chromium alloys, and amorphous metals. These alloy materials are also preferred as core materials because they have excellent workability and are easy to process into desired shapes.

[0063] Furthermore, the core is not limited to a linear rod-shaped member as shown in Figure 2, etc., and it is even more preferable to have a shape that can more efficiently capture leakage flux and suppress the protrusion size from the rotating motor, which is a power device. Such a core shape will be described in detail later, but for example, a U-shaped shape when viewed from the front, as shown in Figure 5, etc., can be cited.

[0064] Furthermore, the cross-sectional shape of the core is not limited to the roughly circular shape shown as the end face shape in Figures 2 and 9. The cross-sectional shape of the core can be determined while taking into account the amplification efficiency of the leakage flux change, which will be discussed later. In addition to the circular shape mentioned above, it is also possible to use various shapes such as a triangular, square, or polygonal cross-section.

[0065] The power generation device 10, shown in detail in Figure 2, generates electromotive force through electromagnetic induction caused by changes in leakage magnetic flux. This will be explained using the example of a case where the power generation device 10 is attached to a rotary motor 3A, which is a DC motor, as shown in Figure 4.

[0066] First, the rotor 33 of the rotary motor 3A rotates around the rotation axis 36 in the direction R indicated by the arrow in Figure 4, as current is supplied to the electromagnetic coils 32a of the stator 32. At this time, as the rotor 33 rotates due to the repeated attraction and repulsion of the magnetic field generated by the multiple electromagnetic coils 32a and the magnetic field generated between the multiple permanent magnets 33a, a change occurs in the leakage magnetic flux (see also the symbol M shown in Figure 13) leaking out of the housing 31 from the multiple permanent magnets 33a of the rotor 33 and / or the multiple electromagnetic coils 32a of the stator 32. The winding 11B of the power generation device 10 attached to the outer surface 31a of the housing 31 captures this change in leakage magnetic flux, generating an electromotive force by electromagnetic induction in the winding 11B. That is, the winding 11B generates electricity by electromagnetic induction due to the change in leakage magnetic flux leaking from one or both of the electromagnetic coils 32a and permanent magnets 33a of the rotary motor 3A.

[0067] The electricity generated by the above-described power generation process is output externally from the power generation device 10 via lead wires (not shown). This electricity can be supplied to various sensor drive circuit boards, data processing and communication boards, etc., which are attached to a rotary motor (not shown), for example, as driving power to operate these boards.

[0068] It should be noted that the power generation device of this embodiment is not limited to the configuration illustrated in Figure 2, etc. In this embodiment, in order to amplify the magnetic flux change in the core, for example, by arranging multiple end faces of the core facing the leakage magnetic flux leaking from the rotating motor, and attaching the rotating motor in such a way that the change in leakage magnetic flux occurs at different timings at each end face, it is possible to amplify the change in magnetic flux in the core.

[0069] In other words, in this embodiment, as shown in the example power generation device 10A in Figures 5 and 6, the power generation device can be configured to include a core 13 made of a U-shaped member in front view, with one end 13a and the other end 13b, located at both ends of the core 13, serving as mounting parts for the outer surface 31a of the housing 31 of the rotary motor 3. The core 13 in the illustrated example is a so-called yoke structure core having a horizontal part 13A and two vertical parts 13B extending approximately vertically from both ends of the horizontal part 13A.

[0070] Then, one end 13a and the other end 13b of the core 13 are attached to the outer surface 31a of the housing 31 of the rotary motor 3, respectively. Here, it is more preferable, from the viewpoint of amplifying the magnetic flux change in the core and improving power generation efficiency, that one end 13a and the other end 13b of the core 13 are each attached at positions where the timing of the change in leakage magnetic flux is different, as described above.

[0071] In other words, if the power generation device 10A (see core 13 in Figure 5) is arranged such that the timing of the changes in the leakage magnetic flux M toward one end 13a and the leakage magnetic flux M toward the other end 13b are different, then the effect of amplifying the magnetic flux changes described above can be obtained. This makes it possible to further improve the power generation efficiency of the power generation device 10A.

[0072] To explain in more detail with reference to the example shown in Figure 13, first, as the rotor 34 rotates, the south pole and north pole of the rotor 34 alternately move closer to and further away from one end 13a or the other end 13b, which are located on each of the two vertical sections 13B in the core 13. In this way, the alternate movement of different magnetic poles closer to and further away from one end 13a and the other end 13b causes the leakage flux M captured at one end 13a and the other end 13b to alternately change. Consequently, the change in leakage flux M propagating through the core 13 from one end 13a and the other end 13b is amplified, and the electromotive force in the winding 11B shown in Figure 5 also increases, making more efficient power generation possible.

[0073] Furthermore, the power generation device of this embodiment can also be used by attaching multiple units to a rotary motor 3, which is a power device, as shown in the example in Figure 7. In the illustrated example, a total of three power generation devices 10A are attached to the outer surface 31a of the housing 31 of the rotary motor 3, and the horizontal portion 13A of the core 13 and the winding shaft of the winding 11B (winding unit 11: see Figure 6) of each core 13 are oriented along the rotation direction R of the rotary motor 3, with one end 13a and the other end 13b of the core 13 attached to the outer surface 31a of the housing 31. Also, in the illustrated example, the three power generation devices 10A are arranged at equal intervals along the rotation direction R of the rotary motor 3.

[0074] As illustrated in Figure 7, when multiple power generators 10A are attached to the rotary motor 3, for example, for a circuit board with a relatively high operating voltage, a high voltage power can be supplied by connecting two or three power generators 10A in series and outputting them together. Also, for example, for a circuit board with a relatively high operating current, a high current power can be supplied by electrically connecting two or three power generators 10A in parallel and outputting them together. On the other hand, for circuit boards with a relatively low operating voltage (or operating current), it is sufficient to supply power from a single 10A power generator.

[0075] In Figure 7, an example is shown in which three power generators 10A are attached to the outer surface 31a of the housing 31 of the rotary motor 3. However, the number of power generators used is not particularly limited; for example, a configuration using two power generators is possible, or a configuration using four or more power generators is also possible. Furthermore, when multiple power generators are installed on the rotary motor 3, the arrangement is not limited to the arrangement along the rotation direction R as shown in the example. Taking into consideration the surrounding space of the rotary motor 3, for example, they may be arranged in parallel in a direction perpendicular to the rotation direction R, or in a spiral arrangement. Moreover, in this embodiment, it is sufficient for each power generator 10A attached to the rotary motor 3 to be able to capture changes in leakage magnetic flux, so it is not limited to the aligned arrangement described above.

[0076] Furthermore, in this embodiment, as shown in the example power generator 10B in Figure 8, it is also possible to adopt a configuration in which multiple windings 11B are provided, and at least a part of the core 13 is inserted so as to span the internal space of each of the multiple windings 11B, thereby arranging the multiple windings 11B in series. In the illustrated example power generator 10B, two winding units 11 having windings 11B are provided, and the horizontal portion 13A of the core 13 is inserted so as to span the internal space 11C of each of the two winding units 11. In the illustrated example power generator 10B, one end 13a and the other end 13b of the vertical portions 13B, 13B of the core 13 are configured to be attachable to the outer surface of the housing of the rotary motor.

[0077] According to the power generation device 10B illustrated in Figure 8, with the above configuration, for example, by arranging multiple winding units 11 each having windings 11B with the same or different impedances, and appropriately changing the electrical connection paths of the multiple winding units 11 (windings 11B), it becomes possible to supply power of different voltages without providing a voltage adjustment circuit or the like. In other words, in the power generation device 10B, it becomes possible to output either the combined potential of two windings 11B, 11B electrically connected in series or parallel, or the potential at the midpoint of the windings 11B, 11B, i.e., the potential of a single winding 11B.

[0078] Furthermore, with the above configuration, for example, the output voltage can be appropriately changed by using multiple windings 11B with the same impedance, making it possible to drive multiple various circuit boards with different drive voltages with a single power generator.

[0079] Although the power generator 10B shown in Figure 8 has two windings 11B arranged in series, the number of windings 11B is not limited to this, and for example, three or more windings 11B may be arranged in series.

[0080] The mounting direction of the power generation devices 10A and 10B in this embodiment to the outer surface 31a of the housing 31 of the rotary motor is not particularly limited. On the other hand, in order to efficiently capture the leakage magnetic flux leaking from the rotary motor and generate power efficiently, it is more preferable to position the power generation devices such that the horizontal portion 13A of the core 13 and the winding axis of the winding 11B provided in the power generation devices 10A and 10B are aligned with the rotation direction (see reference numeral R) of the rotor (see reference numeral 33 in Figure 4) of the rotary motor.

[0081] According to the power generation devices 10, 10A, and 10B of this embodiment, the above configuration allows them to be used as AC power sources for driving boards with different operating voltages, such as drive boards for various sensors installed to observe the state of power equipment such as rotary motors, or data processing and communication boards.

[0082] Furthermore, according to the power generation devices 10, 10A, and 10B of this embodiment, they can be attached to general equipment such as rotary motors using bolts in a so-called "plug-and-play" manner, and together with the sensor drive boards that receive the power supply, they can be installed with simple work. As a result, the power generation devices and various boards can be easily installed without the need for wiring or securing space. At the same time, the hassle of battery replacement is eliminated, thus improving maintainability. Consequently, it becomes possible to easily acquire operating information of power equipment such as rotary motors from various sensors with a simple configuration, and the workload of the user is also reduced.

[0083] On the other hand, the power generation device of this embodiment does not generate electricity when the rotating motor, which is the power source, is stationary, because no change in leakage magnetic flux occurs. Therefore, it also offers excellent safety when the power source is not in use.

[0084] In this embodiment, in addition to Figure 1, examples of mounting the power generation device on the outer surface of the housing of a rotary motor, which is a power device, as shown in Figures 3 and 4, are given for explanation, but the invention is not limited to these examples. The mounting position of the power generation device in a rotary motor is not particularly limited as long as it is a position in which leakage magnetic flux can be efficiently captured. For example, the power generation device may be mounted on or near the stator inside the rotary motor.

[0085] Furthermore, although detailed illustrations are omitted, when the power generation device of this embodiment is attached to a power equipment consisting of a linear motor having a sliding element as a moving body, the mounting direction of the power generation device to the linear motor is not particularly limited. On the other hand, as with the rotary motor, in order to efficiently capture the leakage flux leaking from the linear motor and generate power efficiently, it is more preferable to position the power generation device such that the horizontal portion of the core, which is U-shaped in plan view, and the winding axis of the windings are aligned with the direction of movement due to the linear motion of the sliding element.

[0086] Furthermore, in this embodiment, it is also possible to adopt a configuration that includes, for example, a battery (not shown) for storing electricity generated by a power generation device using leakage flux. By adopting this configuration, it becomes possible to construct a wireless temperature sensor by using the power stored in the battery to drive, for example, a rotating motor or a temperature sensor in its vicinity. Furthermore, the power stored in the battery can also be used as a power source to detect the status of power equipment during a power outage, making it possible to construct a device that is resilient to disasters and other emergencies.

[0087] <Effects and Effects> As described above, the leakage flux power generation devices (power generation devices) 10, 10A, and 10B of this embodiment employ a configuration that includes a winding 11B that generates an electromotive force by electromagnetic induction due to changes in leakage flux leaking from power equipment such as rotary motors 3, 3A, and 3B in conjunction with the rotational motion of the rotor, which is a moving body. By adopting a configuration that includes a winding 11B capable of generating an electromotive force due to changes in leakage flux and attaching the power generation devices 10, 10A, and 10B to rotary motors 3, 3A, and 3B, excellent power generation efficiency can be obtained, and by optimizing the arrangement of the windings 11B, it becomes possible to supply power of multiple different voltages simultaneously. Therefore, it is easy to attach to power equipment such as rotary motors 3, 3A, and 3B, and it is possible to realize power generation devices 10, 10A, and 10B with a simple configuration that have excellent power generation efficiency and are highly versatile, as they can be used with various boards equipped with power supply ICs of different operating voltages, without the hassle of wiring, space requirements, or battery replacement.

[0088] Furthermore, according to the power equipment of this embodiment, since it consists of rotary motors 3, 3A, 3B, etc., to which the power generation devices 10, 10A, 10B according to the present invention described above are attached, the power efficiently generated by the power generation devices 10, 10A, 10B can be stably supplied to, for example, sensor drive boards and data processing / communication boards. Moreover, even if the above-mentioned various boards are equipped with power supply ICs of different operating voltages, by optimizing the arrangement of windings 11B provided in the power generation devices 10, 10A, 10B, it becomes possible to operate various boards while simultaneously supplying power of multiple different voltages. Therefore, power equipment with a variety of functions obtained through the operation of various circuit boards can be realized without requiring commercial power or batteries.

[0089] <Modified version of the present invention> Although embodiments of the present invention have been described in detail above, the leakage flux power generation device and power equipment of the present invention are not limited to the embodiments described above, and can be implemented with various changes and modifications as long as they do not depart from the principles of the present invention and the scope of the appended claims.

[0090] For example, in the above embodiment, a power generation device 10 is provided which has a core 12 made of a rod-shaped member that is round as shown in Figure 2, and power generation devices 10A and 10B are provided which have a core 13 made of a U-shaped member when viewed from the front as shown in Figure 5 or Figure 8. However, the general shape of the core that is inserted into the internal space 11C of the winding unit 11 is not limited to these shapes. For example, the power generation device may be constructed using a core 14 that is roughly E-shaped in a front view, as shown in Figure 11, or it may be constructed using a core 15 that is rounded in a roughly C-shape in a front view, as shown in Figure 12. In other words, the shape of the core provided in the power generation device can be appropriately designed, taking into consideration, for example, the shape of the power equipment (such as a rotary motor or linear motor) to which it is mounted, and the direction of the leakage magnetic flux.

[0091] Furthermore, while the above embodiment mainly describes a configuration in which a core is inserted into the internal space of the winding (winding unit) and the end of this core is attached to a rotary motor, which is a power device, the power generation device according to the present invention can also employ a configuration in which the core is omitted. In such cases, although not shown in the figures, for example, a mounting jig that can be attached to the outer surface of the housing of the rotary motor while holding the winding (winding unit), or adhesive tape, etc., can be used. Furthermore, when adopting a configuration that generates electromotive force using only windings without a core, as described above, from the viewpoint of power generation efficiency, the leakage magnetic flux leaking from the power equipment needs to pass through in the direction of the winding axis. Therefore, when adopting such a configuration, it is preferable to mount the power generation device so that the winding axis of the windings is perpendicular to the direction of rotation of the rotor in a rotary motor, or the direction of movement due to the linear motion of the slide in a linear motor.

[0092] Furthermore, the power generation device according to the present invention may also be configured to include a power generation indicator (not shown) for displaying the amount of power generated in the windings, for the purpose of confirming the power generation status of the power generation device. Such a power generation indicator functions as a direct power generation monitor that is directly connected to or integrated with the power generation device. Specifically, as the power generation indicator, for example, an LED electrically connected to the windings of the power generation device can be used. By configuring the power generation indicator from an LED, it becomes possible for the user to visually check the brightness and easily grasp the approximate amount of power generated, and it also has the advantage of being inexpensive to configure without requiring complex circuits. [Examples]

[0093] The present invention will be described in more detail below with reference to embodiments of the leakage flux power generation device and power equipment of the present invention. However, the configuration of the leakage flux power generation device and power equipment of the present invention is not limited to the specifications and conditions described in the following embodiments.

[0094] <Example 1> In Example 1, the power generation devices 10 and 10A shown in Figure 2 or Figure 5 were manufactured using the method and conditions described below, and these power generation devices 10 and 10A were attached to the outer surface 31a of the housing 31 of the rotary motor 3B shown in Figure 13, respectively (see also the power generation device 10A attached to the rotary motor 3 in Figure 6). Then, by measuring the amount of power generated by leakage magnetic flux when the rotary motor 3B was rotated under predetermined conditions using the method described below, we investigated the difference in power generation due to different core shapes (structures).

[0095] [1] Method and conditions for manufacturing a power generation device In Example 1, a winding unit 11, in which a winding 11B is wound around a coil bobbin 11A, and cores 12 and 13 inserted into the internal space 11C of the winding unit 11 (winding 11B), were manufactured according to the specifications shown below. (1) Winding (common to 10A and 10A generators) • Wire type: UEW (Polyurethane copper wire (enameled wire)) Wire diameter: φ0.16mm Impedance: 9.8 (ohm) • Number of turns: n = 160 turns (evenly wound around the body of the coil bobbin) (2) Coil bobbin (same as above) • Outer diameter of fuselage 11a: 17.0 mm • Inner width between flanges 11c: 5.0mm • Inner diameter of shaft hole 11b (internal space 11C): 15.0 mm (3) Core (a) Core 12 (rod-shaped member; see power generation device 10 shown in Figures 2 and 9, etc.) • Cross-sectional shape: circular ·Diameter:φ10mm • Length: 55mm • Material: Permalloy B (Fe-45Ni) (b) Core 13 (U-shaped member; see power generation device 10A shown in Figures 5 and 6) • Cross-sectional shape: circular ·Diameter φ: 10mm Length: Horizontal section 35mm, Vertical section 10mm • Material: Permalloy B (Fe-45Ni)

[0096] [2] Rotary motor (power equipment) In Example 1, an AC speed control motor (Oriental Motor Co., Ltd.: M590-001C; single-phase) was prepared as the rotary motor 3B (Figure 13), which is the power device. Then, the power generation device 10 or power generation device 10A described in [2] above was individually attached to the outer surface 31a of the housing 31 of the rotary motor 3B (see also Figures 3 and 5). In this case, as shown in the example in Figure 3, one end 12a of the core 12 of the power generation device 10 was attached to the outer surface 31a of the housing 31 of the rotary motor 3B(3) in such an upright position. Furthermore, for the power generation device 10A, one end 13a and the other end 13b of the core 13 are attached to the outer surface 31a of the housing 31 of the rotary motor 3B, in such a configuration that the winding shaft of the winding 11B and the horizontal portion 13A of the core 13 are aligned with the rotational direction of the rotor 34 (see also Figure 6). In the above, each of the cores 12 and 13 was attached and fixed to the outer surface 31a of the housing 31 of the rotary motor 3B using adhesive tape.

[0097] [3]Measurement method Using the power generators 10 and 10A attached to the rotary motor 3B as described above, the electromotive force waveform was obtained using an oscilloscope (KEYSIGHT; model number: DSOX1204G) based on the relationship between the measured voltage (V) and the rotation time (sec) of the rotary motor 3B, for the power generated by electromagnetic induction due to leakage flux. In this case, the rotation speed of the rotary motor 3B was set to 1400 rpm (rotation output: 100%). The electromotive force waveforms described above are shown in the graph in Figure 14.

[0098] [4] Test results In the electromotive force waveform shown in the graph of Figure 14, the voltage generated by the power generator 10 and the voltage generated by the power generator 10A are shown in a way that allows for comparison of waveforms on the same time axis (rotation time). As shown in the graph in Figure 14, it was confirmed that the power generator 10A, which has a U-shaped core (yoke structure) in plan view, can obtain approximately 1.5 times the voltage in terms of power ratio when the load terminals are open, compared to the power generator 10, which has a round bar-shaped core 12.

[0099] From the results of Example 1, it was confirmed that when a configuration is adopted in which a core is placed in the internal space of the winding as a power generation device, the amount of power generated is greater compared to the case in which the core is rounded, by making the shape of the core U-shape when viewed from the front, and optimizing the orientation of the horizontal part of the core and the winding axis of the winding. In other words, as shown in Figure 6, the example employs a U-shaped core 13 in front view, and the horizontal portion 13A of the core and the winding axis of the winding are positioned in line with the rotation direction of the rotor provided in the rotary motor, while one end 13a and the other end 13b of the core 13 are attached to the outer surface 31a of the housing 31. By adopting this configuration, it was confirmed that a higher voltage can be obtained compared to the case where one end 12a of the core 12 is attached to the outer surface 31a of the housing 31, such as in the example power generation device 10 shown in Figure 3, where the longitudinal direction of the round bar-shaped core 12 and the winding axis of the winding are oriented perpendicular to the rotation direction of the rotor. This is thought to be because by attaching both ends of the core to the housing of the rotary motor and arranging the rotation direction of the rotary motor with the horizontal portion of the core and the winding axis of the winding in the above-mentioned relationship, changes in magnetic flux leaking from the electromagnetic coil and permanent magnet of the rotary motor can be efficiently captured, thereby increasing the power generation efficiency.

[0100] Furthermore, in Example 1, using the above-described power generator 10A, an experiment was also conducted in which the horizontal portion 13A of the core 13 and the winding axis of the winding 11B were mounted on the outer surface 31a of the housing 31 of the rotary motor 3B in such a configuration that they were perpendicular to the rotation direction of the rotor 34 (see the symbol R in Figures 3 and 6), and the electromotive force waveform was obtained in the same manner as above. As a result, it was confirmed that a higher voltage could be obtained when the horizontal portion 13A of the core 13 and the winding axis of the winding 11B were arranged along the rotation direction of the rotor 34, compared to when the horizontal portion 13A and the winding axis were arranged perpendicular to the rotation direction.

[0101] Thus, in Example 1, it was confirmed that the electromotive force changes significantly depending on the shape and orientation of the core (the direction of the winding axis). Specifically, it was confirmed that the electromotive force is increased when a U-shaped core is used in a front view, and the longitudinal direction (horizontal part) of the core and the winding axis of the winding are arranged along the direction of rotation of the rotor in the rotary motor, while it is difficult to generate electricity when the horizontal part of the core and the winding axis of the winding are perpendicular to the direction of rotation of the rotor in the rotary motor. On the other hand, when a round bar-shaped core is used and only one end of the core is attached to the outer surface of the housing of the rotary motor, the longitudinal direction of the core and the winding axis of the winding are arranged perpendicular to the direction of rotation of the rotor, but power generation is still possible even in such an arrangement. However, in this configuration, the amount of power generated is smaller compared to the case described above, where a U-shaped core is used in a front view, and the horizontal part of the core and the winding axis of the winding are arranged along the direction of rotation of the rotor.

[0102] Furthermore, in Example 1, the electromotive force waveform shown in the graph of Figure 14 confirmed that when the power generation device of the present invention is attached to an AC motor and used, an electromotive force is generated in the winding due to the leakage magnetic flux from the electromagnetic coil provided in the stator and the permanent magnet provided in the rotor.

[0103] Furthermore, in Example 1, although detailed illustrations are omitted, an experiment was also conducted to obtain the electromotive force waveform when the core 12 was removed from the power generation device 10 shown in Figure 2 and the individual winding unit 11 was attached to the rotary motor 3B with adhesive tape. As a result, it was confirmed that by adopting a configuration in which the core 12 for magnetic flux convergence is inserted into the internal space 11C of the winding unit 11, the electromotive force from the winding 11B is approximately doubled compared to when the core is not provided.

[0104] <Example 2> In Example 2, using the power generation device 10 shown in Figure 2 as a base, and although detailed illustrations are omitted, a power generation device was fabricated in which a core 12 was inserted through the internal space 11C of two winding units 11, and the windings 11B were arranged in series, and this was attached to the outer surface 31a of the housing 31 of the rotary motor 3B shown in Figure 13. In this case, by adjusting the number of turns n of the winding 11B provided in each of the two winding units 11, each winding unit 11 was manufactured such that the impedance of the winding 11B provided in one winding unit 11 was 9.8 (ohm) and the impedance of the winding 11B provided in the other winding unit 11 was 170 (ohm). That is, in Example 2, the number of turns n of the winding 11B was adjusted while also taking into account the relationship expressed by the following equation {e=-n(Δφ / Δt)[V]} (see equation (1) explained earlier).

[0105] In Example 2, as the power source, the rotary motor 3B, was the same AC speed control motor (Oriental Motor Co., Ltd.: M590-001C) as in Example 1. Next, one end 12a of the core 12 provided in the power generation device 10 having the two winding units 11 described above was attached to the outer surface 31a of the housing 31 of the rotary motor 3B such that the longitudinal direction of the core 12 and the winding axis of the winding 11B are perpendicular to the rotation direction R of the rotor 33.

[0106] Then, using the same conditions and methods as in Example 1, electromotive force waveforms indicating the amount of power generated by leakage flux when the rotary motor 3B was rotated under predetermined conditions were obtained for each of the two windings 11B with different impedances, and these results are shown in the graph in Figure 15.

[0107] In the electromotive force waveform shown in the graph of Figure 15, the voltage of the power generated by one winding unit 11 equipped with a low-impedance (9.8 ohm) winding 11B and the voltage of the power generated by the other winding unit 11 equipped with a high-impedance (170 ohm) winding 11B are shown to be compared on the same time axis (rotation time). As shown in the graph in Figure 15, it was confirmed that the winding unit 11 equipped with a high-impedance (170 ohm) winding 11B can obtain a higher voltage compared to the winding unit 11 equipped with a low-impedance (9.8 ohm) winding 11B.

[0108] Furthermore, in Example 2, the above experiment confirmed that the output (voltage, current) can be adjusted by equipping multiple windings of the same specifications and connecting them electrically in series or parallel. Furthermore, in Example 2, it was confirmed that multiple adjacent windings did not affect each other's output characteristics.

[0109] Therefore, it became clear that by configuring the power generation device to have multiple windings with different impedances, i.e., multiple windings with different numbers of turns (n), it is possible to simultaneously supply power at multiple different voltages. In other words, since a single power generation device (power supply) can simultaneously output power at various voltages and currents, it is clear that it is possible to simultaneously operate, for example, multiple IoT communication devices with different product specifications.

[0110] <Example 3> In Example 3, a device similar to that in Example 1 was prepared, with the power generation device 10 shown in Figure 2 attached to the outer surface 31a of the housing 31 of the rotary motor 3B shown in Figure 13 (see also Figure 3). Then, except that the voltage measurement was performed while varying the rotation speed (rotational velocity) of the rotary motor 3B to 100%, 80%, and 50% of the maximum output, an electromotive force waveform indicating the amount of power generated by leakage flux was obtained under the same conditions and methods as in Example 1, and the results are shown in the graph in Figure 16.

[0111] In the electromotive force waveform shown in the graph of Figure 16, the voltages measured at each rotational speed are shown so that they can be compared as waveforms on the same time axis (rotational time). As shown in the graph in Figure 16, regardless of the rotational speed of the rotary motor 3B, the power generation frequency was 50Hz, the same as the frequency of the commercial power supply that drove the rotary motor 3B. On the other hand, the electromotive force waveform shown in the graph in Figure 16 confirms that the voltage increases and the amount of power generated increases as the rotational speed increases.

[0112] In Example 3, it was confirmed that the electromotive force waveform, i.e., the intensity of the leakage magnetic flux, remained almost unchanged when the rotational speed of the rotary motor was in the range of low speed (50%) to medium speed (80%). Furthermore, in Example 3, when only the power supply for the rotating motor 3B was turned on and the motor remained in a non-rotating state, no output was observed from the winding 11B. From this, it can be concluded that the magnetic flux leaking from a non-rotating AC motor changes only slightly. On the other hand, within the above rotational speed range, although output from winding 11B was confirmed, the voltage was relatively low. From this, it can be inferred that when the rotational speed of the AC motor is medium or below, the leakage flux consists only of the magnetic field of the electromagnetic coil in the stator. Furthermore, it can be confirmed that the output voltage from winding 11B increases when the rotational speed of motor 3B exceeds a medium speed (80%). From this, it can be inferred that when the rotational speed of motor 3B is high, leakage flux is generated not only from the magnetic field in the stator but also from the magnetic field of the rotor.

[0113] The results from Example 3 confirmed that the frequency of power generated using the magnetic flux leaking from the rotary motor was the same as the frequency of the commercial power supply driving the rotary motor.

[0114] <Example 4> In Example 4, a sample of the power generation device 10 shown in Figure 2 was first prepared. Next, one end 12a of the core 12 provided in the power generation device 10 was attached to the outer surface of the housing of an AC induction motor (3-phase; 4-pole; maximum 400W) provided in a dust collector installed in a factory, in the same manner as in Example 1 (see also Figure 1, etc.). Then, the rotation speed of the rotary motor was kept constant at 1410 rpm, and the electromotive force waveform indicating the amount of power generated by leakage flux was obtained under the same conditions and methods as in Example 1, and the results are shown in the graph in Figure 17.

[0115] As shown in the graph in Figure 17, the power generation frequency of the power generation device 10 attached to the rotary motor, which consists of an AC induction motor, was 50 Hz, the same as the frequency of the commercial power supply that drove the rotary motor, similar to the results in Example 3. This is thought to be a power generation period that depends on the change in the magnetic field generated by the electromagnetic coil inside the AC induction motor.

[0116] <Example 5> In Example 5, a sample of the power generation device 10, as shown in Figure 2, was first prepared. Next, one end 12a of the core 12 provided in the power generation device 10 was attached to the outer surface 31a of the housing 31 of the rotary motor 3A shown in Figure 4 (see also the power generation device 10 attached to the rotary motor 3 in Figure 3). The rotary motor 3A prepared in Example 5 is a DC speed control motor (PWM control: pulse width modulation) with a 9-slot and 6-pole structure as shown in Figure 4, and has a maximum applied voltage of 10V and a maximum rotational speed of 15200rpm under no load.

[0117] Then, the rotation speed of the rotary motor 3A was varied approximately to low speed, medium speed, and high speed relative to the maximum rotation speed mentioned above, and electromotive force waveforms indicating the amount of power generated and the power generation frequency due to leakage flux were obtained under the same conditions and methods as in Example 1, etc., and these results are shown in the graphs of Figures 18(a) to (c). Here, Figure 18(a) shows the electromotive force waveform when the rotation speed is slow (low speed), Figure 12(b) shows the waveform when the rotation speed is medium (medium speed), and Figure 12(c) shows the waveform when the rotation speed is fast (high speed).

[0118] As is clear from the graphs in Figures 18(a), 18(b), and 18(c), as the rotational speed of the rotary motor 3B increases, the power generation period (power generation frequency) also shortens, but the maximum voltage remains almost constant. From this, it can be seen that, for example, in power generation from leakage flux from a DC motor with permanent magnets on the rotor side, the power generation period depends on the rotational speed of the DC motor, while the amount of leakage flux is constant regardless of the rotational speed, so the maximum voltage remains at the same level regardless of the rotational speed.

[0119] <Regarding the installation of a power generator on an AC synchronous motor> In the embodiments described above, no experiments were conducted using an AC synchronous motor as the rotating motor (power device). On the other hand, an AC synchronous motor has a structure in which permanent magnets are arranged on the rotor, and the rotor is rotated by changing the frequency of the current applied to the electromagnetic coils arranged on the stator, so its operating principle is the same as that of a DC motor. For this reason, it can be estimated that the power generation frequency when the power generation device of the present invention is attached to an AC synchronous motor and power is generated by leakage flux will also depend on the rotational speed, and it is thought that efficient power generation is possible, similar to when the power generation device is attached to a DC motor. [Industrial applicability]

[0120] As described above, the leakage flux power generation device of the present invention is easy to attach to power equipment, does not require wiring, space management, or battery replacement, has excellent power generation efficiency, and is highly versatile as it can be used with various types of boards equipped with power supply ICs of different operating voltages. Therefore, the leakage flux power generation device of the present invention is extremely useful in applications that drive boards with different operating voltages, such as drive boards for various sensors installed to observe the state of these power equipment, or data processing and communication boards, by being attached to power equipment such as rotary motors or linear motors. [Explanation of Symbols]

[0121] 1…Power equipment system 2…Support stand 3, 3A, 3B... Rotary motor (power equipment) 31…Cabinet 31a…External surface 32…Stata 32a... Electromagnetic coil 33...Rota 33a...Permanent magnet 34…Rotor (permanent magnet) 35…Status 35a, 35b, 35c... Electromagnetic coils 36…Rotation axis R...Direction of rotation M...Leakage magnetic flux MF…Magnetic 10, 10A, 10B... Leakage flux generator (power generator) 11...Winding unit 11A... Coil bobbin 11a... Torso 11b... shaft hole 11c…Flange 11B...winding 11C…Internal space 12... Cores 12a... One end (mounting part) 12b...the other end 13... Core 13A…Horizontal part 13B…Vertical part 13a…one end 13b...the other end 14, 15… Core

Claims

1. A leakage flux generator used in attachment to power equipment equipped with a moving body that performs rotational or linear motion due to electromagnetic force, A leakage flux power generation device characterized by including one or more windings that generate an electromotive force by electromagnetic induction due to changes in leakage magnetic flux leaking from the power equipment in conjunction with the rotational or linear motion of the moving body.

2. The leakage flux power generation device according to claim 1, characterized in that the winding generates an electromotive force by electromagnetic induction due to a change in leakage flux leaking from one or both of the electromagnetic coil and permanent magnets that cause the moving body to rotate or move linearly, which are provided in the power equipment.

3. Furthermore, the leakage flux power generation device according to claim 1 or 2 is characterized by comprising a core made of a soft magnetic material, provided such that at least a portion of it is inserted into the internal space of the winding.

4. The leakage flux power generation device according to claim 3, characterized in that the core is made of a rod-shaped member, and one end of the core is a mounting portion for the outer surface of the housing of the power equipment.

5. The leakage flux power generation device according to claim 3, characterized in that the core consists of a U-shaped member when viewed from the front, and each of the ends of the core is a mounting portion for the outer surface of the housing of the power equipment.

6. The leakage flux power generation device according to claim 3, characterized in that a plurality of windings are provided, and at least a portion of the core is inserted through the internal space of each of the plurality of windings, thereby arranging the plurality of windings in series.

7. The leakage flux power generation device according to claim 5, characterized in that both ends of the core are mounting portions located at positions where the timing of the change in the leakage flux is different from that of the outer surface of the housing in the power equipment.

8. Each of the windings has the same or different impedances. The leakage flux generator according to claim 6, characterized in that the current generated in each of the multiple windings is output individually for each winding, or is output collectively by at least a portion of the multiple windings being electrically connected in series or parallel.

9. The aforementioned power equipment consists of a rotary motor having a rotor as the moving body, The leakage flux power generation device according to claim 1 or 2, characterized in that the winding axis of the winding is arranged to be perpendicular to the rotation direction of the rotor.

10. The power equipment consists of a linear motor having a sliding element as the moving body, The leakage flux power generation device according to claim 1 or 2, characterized in that the winding axis of the winding is arranged to be perpendicular to the direction of movement due to the linear motion of the slide mover.

11. A power device comprising a moving body that performs rotational or linear motion by electromagnetic force, wherein one or more leakage flux power generation devices described in claim 1 or claim 2 are attached to the outer surface of a housing on which the moving body is arranged.

12. A power device comprising a moving body that performs rotational or linear motion by electromagnetic force, wherein one or more leakage flux power generation devices described in claim 3 are attached to the outer surface of a housing on which the moving body is arranged.

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