Leakage magnetic flux power generation device and power apparatus

Abstract

Provided are: a leakage magnetic flux power generation device which can be easily attached to a power apparatus, is excellent in power generation efficiency without needing to ensure labor and space for wiring, carry out battery replacement, and the like, can handle with various substrates on which power supply ICs having different operating voltages are mounted, and is excellent in versatility; and a power apparatus. Namely, the present invention is a leakage magnetic flux power generation device 10 used by being attached to a power apparatus comprising a moving body that performs rotational motion or linear motion by electromagnetic force. The leakage magnetic flux power generation device includes one or more windings 11B that generate electromotive force by electromagnetic induction due to a change in leakage magnetic flux leaking from a rotary motor or a linear motor, which is the power apparatus, in conjunction with the linear motion of a slide mover or the rotational motion of a rotor, which is the moving body.

Description

Leakage flux generators and power equipment

[0001] The present invention relates to a leakage flux power generation device and power equipment equipped therewith.

[0002] In recent years, with the advancement of information technology, various sensors, communication devices, and data processing devices have been utilized and attached to various equipment and machinery. This has made it possible to understand the operating status, detect and predict failures early using the acquired data. For example, in various facilities, mainly infrastructure systems for air conditioning and water supply and drainage, sensors are attached to power equipment such as motors and solenoid valves to observe temperature fluctuations and vibrations in order to maintain the stable operation of these power equipment. The observation data obtained from sensors attached to power equipment is transmitted via data communication boards to devices such as smartphones and tablet terminals, and is used to monitor the operating status of various facilities.

[0003] When sensors are attached to various power equipment as described above, and sensor drive circuit boards, data processing and communication boards, etc., are installed along with them, commercial power or batteries are generally used to power them. However, supplying power for each of the above boards from commercial power increases costs due to the effort of wiring and the need to secure wiring routes. On the other hand, using batteries for the power supply eliminates the effort of wiring, but it has the problem of requiring battery replacement at regular intervals. Therefore, whether the power for each drive is supplied from commercial power or from batteries, the burden on both the user and the provider of the power equipment is significant.

[0004] Here, in recent years, so-called energy harvesting technologies that utilize vibrations, leakage magnetic fluxes, etc. that are generated secondarily along with the operation of power equipment have been adopted, and power generation devices that generate electricity while being attached to power equipment have also been proposed. In this way, when the power generated by the method that utilizes the installation environment is used for operations such as the above-described sensor drive circuit board or data processing / communication board, it can be easily installed without the need for the labor and space for wiring from the commercial power supply. Further, by adopting the above technology, the labor of battery replacement, etc. can also be omitted, so it is considered that the maintainability, etc. can be improved.

[0005] For example, Patent Document 1 discloses a vibration power generation device that can be attached and used to a machine device such as a production machine or a machine tool. According to the vibration power generation device described in Patent Document 1, a power generation element is vibrated along with the vibration of the machine device, and power is taken out from a coil attached to a magnetostrictive plate provided in the power generation element. Further, in the vibration power generation device described in Patent Document 1, a frequency adjustment member that is attached to a frame joined to the power generation element and adjusts the resonance frequency of the vibration power generation device is provided.

[0006] Further, Patent Document 2 discloses a magnetic field power generation device having a winding that is arranged outside the housing of an electric power device and can be electrified by leakage magnetic fluxes generated from a multi-phase wiring, and a holding body that holds the winding, and is attached to the outer surface of the housing via this holding body. Patent Document 2 describes that with the above configuration, it is possible to generate electricity using the leakage magnetic fluxes generated from the multi-phase wiring, and by providing the magnetic field power generation device including the winding outside the housing, it is possible to reduce the work burden of maintenance, etc. without machining holes or the like in the housing of the electric 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.

[0008] Japanese Patent Publication No. 2021-153381 Japanese Patent Publication No. 2019-068663 Japanese Patent Publication No. 6935909

[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 to 0.2V, 0.2 to 1.0V, 0.2 to 2V, 2 to 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.

[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 above embodiment, the leakage flux power generation device of the present invention can adopt a configuration in which the core is made of a rod-shaped member, and one end of the core is used as a mounting portion for the outer surface of the housing of the power equipment.

[0021] In the above embodiment of the leakage flux power generation device of the present invention, it is more preferable that the core is made of a U-shaped member when viewed from the front, and that each of the ends of the core is a mounting portion for the outer surface of the housing of the power equipment.

[0022] In the above embodiment, the leakage flux power generation device of the present invention may employ a configuration in which a plurality of windings are provided, and at least a portion of the core is inserted so as to span the internal space of each of the plurality of windings, thereby arranging the plurality of windings in series.

[0023] In the above embodiment, the leakage flux power generation device of the present invention may employ a configuration in which 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 of the power equipment.

[0024] In the above embodiment, the leakage flux power generation device of the present invention may employ a configuration in which the multiple windings each have the same or different impedances, and the current generated in each of the multiple windings is output individually for each winding, or at least a portion of the multiple windings are electrically connected in series or parallel to output a total current.

[0025] In the above embodiment, the leakage flux power generation device of the present invention may consist of a rotary motor having a rotor as the moving body, and the winding may be configured such that the winding axis of the winding is perpendicular 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, wherein one or more leakage flux power generation devices according to the present invention are attached to the outer surface of a housing on which the moving body is arranged.

[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 due to changes in leakage flux, and by attaching such a leakage flux power generation device to a power device, excellent power generation efficiency can be obtained. By optimizing the arrangement of the windings, it becomes possible to supply power of multiple different voltages simultaneously. Therefore, it is easy to attach to power devices, and a leakage flux power generation device with excellent power generation efficiency and versatility that can be used with various boards equipped with power supply ICs of different operating voltages can be realized in a simple configuration without the need for wiring, space requirements, or battery replacement.

[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 by the operation of various 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.

[0031] 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 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 a 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 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 seen 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 attached to the outer surface of the housing of a rotary motor (power equipment). 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 broken view seen from the front, showing another example of an 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 is a diagram illustrating one embodiment of the leakage flux power generation device according to the present invention, and is a schematic breakaway diagram showing an example in which a core made of a U-shaped member is inserted into the internal space of the winding. 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 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 multiple leakage flux power generation devices shown in Figure 5 are attached to the outer surface of the housing of a rotary motor (power equipment). Figure 8 is a diagram illustrating one embodiment of the leakage flux power generation device according to the present invention, and is a schematic breakaway diagram showing an example in which a core made of a U-shaped member is inserted so as to span the internal space of multiple windings. 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 Figure 2 by itself. 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 a core made of a U-shaped member provided in the leakage flux power generation device example shown in Figure 5 and the direction of the leakage flux.Figure 11 is a diagram illustrating 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 is a diagram illustrating 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 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 made of a U-shaped member provided in the leakage flux power generation device example shown in Figure 5, the direction of magnetic flux leaking from an AC synchronous motor (power equipment; rotary motor), and the timing of the change in this magnetic flux. Figure 14 is a diagram illustrating an embodiment of the leakage flux power generation device and power equipment according to the present invention, and is a graph showing the electromotive force waveform when 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) is compared between a sample of the leakage flux power generation device example shown in Figure 2 and a sample of the leakage flux power generation device example shown in Figure 5. 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 the example in Figure 2 is mounted on the housing of an AC speed control motor (power equipment; rotary motor) and generates electricity, comparing samples with high and low winding impedance. 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 waveform when the voltage generated by 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) and generated electricity, while changing the circuit speed (rotational speed) of the rotary motor, and comparing the results. 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 when the voltage generated by 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 generation frequency is confirmed.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.

[0032] The following describes embodiments of the leakage flux power generation device and power equipment equipped therewith according to the present invention, with reference to the drawings as appropriate. Note that, for convenience, the drawings used in the following description may show slightly enlarged versions of characteristic parts 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 components. Furthermore, the materials, dimensions, etc., exemplified in the following description are merely examples, and the present invention is not limited to these; it can be implemented with appropriate modifications without altering its essence.

[0033] <Power Equipment (Power Equipment to which the Leakage Flux Generator is Attached)> 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 referred to as appropriate). The leakage flux generator of this embodiment (see reference numeral 10, etc. in Figure 1; hereinafter it may be abbreviated as the generator) will be used by being attached to one or more power equipment 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 equipment. For this reason, in this specification (this embodiment), the detailed configuration of the power equipment and the mechanism of magnetic flux leakage 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 an overall configuration in which the power generation device 10 is attached to the outer surface 31a of the housing 31 of the rotary motor 3. Figure 4 is a broken view taken from the axial direction of the rotating shaft 36, i.e., the front side, showing another example of an 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. Figure 6 is a front view taken from the axial direction of the rotating shaft 36, showing another example of an 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 rotary motor 3. Figure 7 is a front view taken from the axial direction of the rotating shaft 36, showing another example of an overall configuration in which multiple power generation devices 10A are attached to the outer surface 31a of the housing 31 of the rotary 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 detailed illustration is omitted in Figure 1, the rotary motor 3 is equipped with a stator and a rotor inside, and a 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, and in the illustrated example, the power generation device 10 is attached near the top of the cylindrical, horizontally oriented housing 31. In the illustrated example, the rotary motor 3 is supported by a support base 2, so that the power device system 1 consisting of the power generation device 10, the rotary motor 3 and the support base 2 is formed.

[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 rotary motors 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 three-phase AC constant-speed induction motors. Detailed examples of DC motors include, for example, 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 describe the rotary motor 3A, which consists of a DC motor as shown in Figure 4. The broken diagram 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 is equipped with a stator 32 having a plurality of electromagnetic coils 32a and a rotor 33 having a plurality of permanent magnets 33a inside a housing 31 which is roughly cylindrical, 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 so as to surround it, 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 multiple energized 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 reference numeral 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 towards the outside of the rotary motor.

[0043] Next, as another example of the internal structure of the rotary motor, a rotary motor 3B composed of an AC synchronous motor shown in FIG. 13 will be described. The broken view of FIG. 13 shows the internal structure of the rotary motor 3B. In the illustrated example, the core 13 included in the power generation device, which will be described in detail later, is attached to the outer surface 31a of the housing 31. As shown in FIG. 13, the rotary motor 3B includes a stator 35 having a plurality of electromagnetic coils 35a, 35b, 35c and a rotor 34 composed of a single permanent magnet inside a housing 31 having a substantially cylindrical shape. Although not shown in FIG. 13, a rotary shaft for transmitting a rotational force to the outside is arranged at the position of the central axis of the rotor 34.

[0044] The stator 35 is attached to the inner surface of the housing 31 on the side opposite to the outer surface 31a, similar to the case of the rotary motor 3A shown in FIG. 4. The plurality of electromagnetic coils 35a, 35b, 35c constituting the stator 35 are attached in plurality to the inner surface of the housing 31. In the illustrated example, the electromagnetic coils 35a, 35b, 35c are arranged in pairs so as to face each other at two locations each, and are arranged at equal intervals at a total of six locations. That is, the electromagnetic coils 35a, 35a, the electromagnetic coils 35b, 35b, and the electromagnetic coils 35c, 35c in the illustrated example are arranged annularly at a 60° pitch in the circumferential direction of the inner surface of the housing 31. Further, the electromagnetic coils 35a, 35a provided at two locations each, the electromagnetic coils 35b, 35b, and the electromagnetic coils 35c, 35c are each configured to generate magnetic fields of S pole and N pole as a pair.

[0045] The rotor 34 is arranged inside the stator 35 so as to be surrounded by the stator 35. In the illustrated example, the rotor 34 is composed of a single substantially plate-shaped permanent magnet. In the illustrated example of the rotor 34, two outer peripheral end portions are respectively the S pole and the N pole of the permanent magnet, and are arranged so as to face a plurality of electromagnetic coils 35a, 35b, 35c provided in the stator 35. The rotor 34 rotates about a rotation axis (not shown) by repeating attraction and repulsion of the magnetic MF generated between the above-described S pole side and N pole side and the plurality of energized electromagnetic coils 35a, 35b, 35c. Thereby, the rotary motor 3B transmits a rotational force to the outside by the rotary shaft.

[0046] The rotary motor 3B, which is the power device of this embodiment, is the same as the above-described rotary motor 3A in that a power generation device is detachably attached to the outer surface 31a of the housing 31. In FIG. 13, for the sake of illustration, only the U-shaped core 13 of the power generation device in a plan view is shown. With such a configuration, similar to the above, the rotary motor 3B can effectively generate an electromotive force in the power generation device (see also the power generation device 10A shown in FIG. 5) by electromagnetic induction according to the change in the leakage magnetic flux M leaking from the rotor 34, which is a rotating body. Therefore, efficient and stable power generation utilizing the leakage magnetic flux M becomes possible.

[0047] Here, even when the rotary motor, which is the power device, is a DC motor having a configuration in which an electromagnetic coil and a commutator are arranged on the rotor side, it is possible to generate an electromotive force in the power generation device by electromagnetic induction according to the change in the leakage magnetic flux leaking from the electromagnetic coil arranged on the rotor. The change in the leakage magnetic flux as described above occurs depending on the power generation cycle (power generation frequency), that is, the rotation speed, in the rotary motor.

[0048] In this embodiment, as the power device to which the leakage magnetic flux power generation device is attached, a rotary motor having a rotor as a moving body is exemplified and described. However, the power device in the present invention is not limited to this. In the present invention, as the power device, in addition to the rotary motor, for example, a linear motor having a slide mover that linearly moves as a moving body, or an electromagnetic solenoid, etc., which operates by electromagnetic force and has magnetic flux leakage expected, can be exemplified as various power devices. In any of the power devices, it is possible to attach and use a leakage magnetic flux power generation device, the details of which will be described later. <​​​​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 Flux Power Generator> The configuration of the leakage flux power generator (power generator) 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 generator is attached, will also be referred to as appropriate). Figure 2 is a diagram illustrating the power generator 10 of this embodiment, and is a broken diagram 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 generator 10A of this embodiment, and is a broken diagram showing an example in which a core 13 made of a U-shaped member is inserted into the internal space 11 of the winding unit 11. Figure 8 is a diagram illustrating the power generator 10A of this embodiment, and is a broken diagram 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 the rod-shaped core 12 provided in the power generator 10 of the example shown in Figure 2, by itself. Figure 10 is a schematic diagram showing the relationship between the core 13, which is made 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 equipment equipped with a moving body that undergoes rotational or linear motion due to electromagnetic force. 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 the power equipment in conjunction with the rotational or linear motion of the 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. 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. Furthermore, 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 means of 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. 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, and resin materials with excellent heat resistance and electrical resistance, which are commonly used in electromagnetic coils, can be used without any restrictions, and metal materials with excellent heat resistance and mechanical strength properties can also be used.

[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 that it does not protrude from the body 11a.

[0057] The number of turns (turns) n of the winding 11B is not particularly limited, and it is preferable to set it 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 weak, so in such cases, it is preferable to set the number of turns n of the 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 the above equation (1), e is the voltage (V), n is the number of turns in 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 of 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 weak, sufficient power generation efficiency can be obtained. Moreover, 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 rotating 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 preferable 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 described 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 magnetism generated by the multiple electromagnetic coils 32a and the magnetism 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 from the power generation device 10 to the outside 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, for example, in response to the leakage magnetic flux leaking from the rotating motor, a configuration is adopted in which multiple end faces of the core are arranged facing the leakage magnetic flux, and the rotation motor is attached in such a way that the change in leakage magnetic flux occurs at different timings at each end face, thereby amplifying 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 have 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 the one end 13a and the other end 13b of the core 13 are 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 change 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 change 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, as different magnetic poles alternately move closer to and further away from one end 13a and the other end 13b, the leakage magnetic flux M captured at one end 13a and the other end 13b changes alternately. Consequently, the change in leakage magnetic 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 one end 13a and the other end 13b of the core 13 are attached to the outer surface 31a of the housing 31, with the horizontal portion 13A of the core 13 and the winding shaft of the winding 11B (winding unit 11: see Figure 6) oriented along the rotation direction R of the rotary motor 3. 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, 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, 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 a circuit board with a relatively low operating voltage (or operating current), it is sufficient to supply power output from a single power generator 10A.

[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. That is, 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 generation device 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 for the power generation devices 10A and 10B of this embodiment when they are attached 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 serve as the power source for the drive, 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 this. 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 provided 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 a battery (not shown) for storing electricity generated by a power generation device using leakage flux. By adopting such a configuration, it is possible to construct a wireless temperature sensor by using the electricity stored in the battery to drive a rotating motor or a temperature sensor in its vicinity. In addition, the electricity stored in the battery can also be used as a power source for detecting the status of power equipment during a power outage, for example, making it possible to construct a device that is resilient to disasters.

[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 which 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 which can generate electricity 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 a power generation device 10, 10A, and 10B can be realized in a simple configuration that is highly versatile, has excellent power generation efficiency, and is compatible with various boards equipped with power supply ICs of different operating voltages, without requiring wiring work, space allocation, 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 with 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 at multiple different voltages.Therefore, power equipment with a variety of functions obtained by the operation of various boards can be realized without requiring commercial power or batteries.

[0089] <Modifications of the 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 principle 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 with a core 12 made of a rod-shaped member that is rounded as shown in Figure 2, and power generation devices 10A and 10B are provided with a core 13 made of a U-shaped member in front view 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, a power generation device may be configured using a core 14 that is roughly E-shaped in front view as shown in Figure 11, or a power generation device may be configured using a core 15 that is rounded in front view and roughly C-shaped as shown in Figure 12. In other words, the shape of the core provided in the power generation device can be appropriately designed while taking into consideration, for example, the shape of the power equipment (rotary motor or linear motor, etc.) to which it is mounted, the direction of the leakage magnetic flux, etc.

[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, it is also possible to adopt a configuration in which the core is omitted in the power generation device according to the present invention. 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. Note that when adopting a configuration in which the core is omitted and electromotive force is generated only by the winding, from the viewpoint of power generation efficiency, the leakage magnetic flux leaking from the power device needs to pass through in the direction of the winding axis of the winding. Therefore, when adopting such a configuration, it is preferable to mount the power generation device so that the winding axis of the winding is perpendicular to the direction of rotation of the rotor in the rotary motor, or the direction of movement due to the linear motion of the slide in the 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, the user can 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.

[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, 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 power generation device 10A attached to 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, the difference in power generation due to different core shapes (structures) was investigated.

[0095] [1] Method and Conditions for Manufacturing a Power Generator In Embodiment 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 power generators 10 and 10A) ・Wire type: UEW (polyurethane copper wire (enameled wire)) ・Wire diameter: φ0.16 mm ・Impedance: 9.8 (ohm) ・Number of turns: n = 160 turns (uniformly wound around the body of the coil bobbin) (2) Coil bobbin (same as above) ・Outer diameter of body 11a: 17.0 mm ・Inner dimension between flanges 11c: 5.0 mm ・Inner diameter of shaft hole 11b (internal space 11C): 15.0 mm (3) Core (a) Core 12 (rod-shaped member; refer to power generator 10 shown in Figures 2 and 9, etc.) ・Cross-sectional shape: circular ・Diameter: φ10 mm ・Length: 55 mm ・Material: Permalloy B (Fe-45Ni) (b) Core 13 (U-shaped member; refer to power generator 10A shown in Figures 5 and 6) ・Cross-sectional shape: circular ・Diameter φ: 10mm ・Length: horizontal part 35mm, vertical part 10mm ・Material: Permalloy B (Fe-45Ni)

[0096] [2] Rotating Motor (Power Equipment) In Embodiment 1, an AC speed control motor (Oriental Motor Co., Ltd.: M590-001C; single-phase) was prepared as the rotating motor 3B (Figure 13), which is the power equipment. 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 rotating motor 3B (see also Figures 3 and 5). In this case, for the power generation device 10, one end 12a of the core 12 was attached to the outer surface 31a of the housing 31 of the rotating motor 3B (3) in an upright position, as shown in the example in Figure 3. For the power generation device 10A, one end 13a and the other end 13b of the core 13 were attached to the outer surface 31a of the housing 31 of the rotating motor 3B in an arrangement such that the winding shaft of the winding 11B and the horizontal part 13A of the core 13 are aligned with the rotation 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 generator 10 and power generator 10A attached to the rotary motor 3B as described above, the electromotive force waveform was obtained using an oscilloscope (KEYSIGHT Corporation; model number: DSOX1204G) for the power generated by electromagnetic induction due to leakage magnetic flux, based on the relationship between the measured voltage (V) and the rotation time (sec) of the rotary motor 3B. At this time, the rotation speed of the rotary motor 3B was set to 1400 rpm (rotation output: 100%). The electromotive force waveform is 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 so that they can be compared on the same time axis (rotation time). As shown in the graph of Figure 14, it was confirmed that the power generator 10A, which has a U-shaped (yoke structure) core 13 in plan view, can obtain a voltage approximately 1.5 times higher in terms of power ratio when the load terminal is 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 power generation device employs a configuration in which a core is placed in the internal space of the winding, the amount of power generated is greater compared to the case in which the core is round bar-shaped, by making the core U-shaped in a front view and optimizing the orientation of the horizontal portion of the core and the winding axis of the winding. Specifically, in the example shown in Figure 6, a U-shaped core 13 is employed in a 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 such a configuration, it was confirmed that a higher voltage can be obtained compared to the case in the power generation device 10 example shown in Figure 3, where one end 12a of the core 12 is attached to the outer surface 31a of the housing 31 so that the longitudinal direction of the round bar-shaped core 12 and the winding axis of the winding are 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 coils and permanent magnets of the rotary motor can be efficiently captured, thereby increasing power generation efficiency.

[0100] Furthermore, in Example 1, using the above-described power generation device 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 described 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] In addition, 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 manufactured in which a core 12 was inserted through the internal space 11C of two winding units 11, and 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. At this time, by adjusting the number of turns n of the windings 11B provided in the two winding units 11, each winding unit 11 was manufactured so 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 windings 11B was adjusted while also taking into consideration the relationship expressed by the following equation {e = -n(Δφ / Δt) [V]} (see equation (1) explained earlier).

[0105] In Embodiment 2, as the power source, a rotary motor 3B, was prepared, which was an AC speed control motor (M590-001C manufactured by Oriental Motor Co., Ltd.), similar to that in Embodiment 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 magnetic 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 of Figure 15, it was confirmed that the winding unit 11 equipped with the high-impedance (170 ohm) winding 11B can obtain a higher voltage than the winding unit 11 equipped with the 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. In addition, Example 2 confirmed that multiple adjacent windings do 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, the same setup as 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). 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, except that the voltage measurement was performed while the rotation speed (rotational velocity) of the rotary motor 3B was varied to 100%, 80%, and 50% of the maximum output, and the results are shown in the graph in Figure 16.

[0111] The electromotive force waveforms shown in the graph of Figure 16 show the voltages measured at each rotational speed, allowing for comparison of waveforms on the same time axis (rotational time). As shown in the graph of Figure 16, the power generation frequency was 50 Hz, the same as the frequency of the commercial power supply that drove the rotary motor 3B, regardless of the rotational speed of the rotary motor 3B. On the other hand, from the electromotive force waveforms shown in the graph of Figure 16, it was also confirmed that the voltage increased and the amount of power generated increased as the rotational speed increased.

[0112] In Example 3, it was confirmed that the electromotive force waveform, i.e., the intensity of the leakage flux, hardly changed when the rotation speed of the rotary motor was in the range of low speed (50%) to medium speed (80%). Also, in Example 3, when only the power supply of the rotary motor 3B was turned on and the motor was kept in a non-rotating state, no output was observed from the winding 11B. From this, it is considered that the magnetic flux leaking from a non-rotating AC motor changes little. On the other hand, although output from the winding 11B was observed in the above rotation speed range, the voltage was low. From this, it is considered that when the rotation speed of the AC motor is medium speed or lower, the leakage flux consists only of the magnetic field of the electromagnetic coil in the stator. Furthermore, when the rotation speed of the rotary motor 3B exceeds medium speed (80%), it was confirmed that the output voltage from the winding 11B increased. From this, it is considered that when the rotation speed of the rotary motor 3B is high, the 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, first, a sample of the power generation device 10 as shown in Figure 2 was fabricated. 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 poles; maximum 400 W) provided in a dust collector installed in a factory, in the same manner as in Example 1 (see also Figure 1, etc.). The rotation speed of the rotary motor was kept constant at 1410 rpm, and an electromotive force waveform indicating the amount of power generated by leakage magnetic 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, first, a sample of the power generation device 10 as shown in Figure 2 was fabricated. 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) having a 9-slot and 6-pole structure as shown in Figure 4, with 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, medium, and high speeds 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 magnetic 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 decreases, but the maximum voltage remains almost constant. From this, it can be seen that, for example, in power generation using 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 case of attaching a power generation device to an AC synchronous motor> In the above embodiments, no experiments were conducted using an AC synchronous motor as the rotating motor (power equipment). 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 the 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 magnetic 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.

[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 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.

[0121] 1…Power equipment system 2…Support base 3, 3A, 3B…Rotating motor (power equipment) 31…Housing 31a…Outer surface 32…Stator 32a…Electromagnetic coil 33…Rotor 33a…Permanent magnet 34…Rotor (permanent magnet) 35…Stator 35a, 35b, 35c…Electromagnetic coil 36…Rotation shaft R…Rotation direction M…Leakage flux MF…Magnetic field 10, 10A, 10B…Leakage flux power generation device (power generation device) 11…Winding unit 11A…Coil bobbin 11a…Body 11b…Shaft hole 11c…Flange 11B…Winding 11C…Internal space 12…Core 12a…One end (mounting part) 12b…Other end 13…Core 13A…Horizontal part 13B…Vertical part 13a…One end 13b…Other end 14, 15... Core

Claims

1. A leakage flux power generation device used in attachment 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.

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 coils and permanent magnets that cause the moving body to rotate or move linearly, which are provided in the power equipment.

3. The leakage flux power generation device according to claim 1 or 2, further 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 so as to span 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. The leakage flux generator according to claim 6, wherein each of the multiple windings has the same or different impedance, and the current generated by 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 leakage flux power generation device according to claim 1 or 2, characterized in that the power equipment comprises a rotary motor having a rotor as the moving body, and the windings are arranged such that the winding axis of the windings is perpendicular to the rotation direction of the rotor.

10. The leakage flux power generation device according to claim 1 or 2, wherein the power equipment comprises a linear motor having a sliding element as the moving body, and the winding is arranged such that the winding axis of the winding is perpendicular to the direction of movement due to the linear motion of the sliding element.

11. A power device comprising a moving body that performs rotational or linear motion by electromagnetic force, wherein one or more leakage flux generating 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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