patent_id
stringlengths 7
8
| description
stringlengths 125
2.47M
| length
int64 125
2.47M
|
|---|---|---|
11859700 | DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Referring now to the drawings, there is seen inFIGS.1through4a non-backdrivable self-locking gear system embodiment referred to herein as the “output ring gear system” and indicated generally by the reference numeral10. This embodiment has a fixed spur gear and output spur gear arrangement in a gearbox13configuration and mounted to a back plate17via a mount paddle6(FIG.6). Back plate17abuts a winch15on one side and on the other side may be connected to a gear support plate14through a series of bolts11. Gear support plate14supports and substantially protects gearbox13from the surrounding environment during operation. Output ring gear system10may also be mounted within a cast or fabricated box for safety purposes and/or conventionality. Motor16is mounted to a motor plate9. Motor16rotates a sprocket18via shaft20. Sprocket18rotates a timing belt22that, in conjunction with the input motor16, sprocket18, and shaft20, makes up the primary motor input of the output ring gear system10. A plurality of teeth on the underside of timing belt22mesh with the teeth18′ of sprocket18and the teeth12′ on the external side of an input ring gear12of a gearbox13, which is mounted to a drive shaft32of gear system10. Drive shaft32connects to winch15on which a cord connected to a load may be wound (not shown). When shaft20rotates sprocket18, timing belt22causes input ring gear12to rotate around the longitudinal axis X-X of the drive shaft32(FIG.6) in a synchronous relationship with shaft20. Rotating input ring gear12in this manner may effectively be quieter than rotating input ring gear12by other previously-known configurations (e.g., a sun gear connected to input ring gear12or any internal components therein) known to generate substantial amounts of mechanical noise. Rotation of input ring gear12moreover causes the internal components (discussed below) of gearbox13to rotate. In other embodiments of output ring gear system10, timing belt22may be a timing chain or a plurality of timing gears (interposed between sprocket18and input ring gear12). For example,FIG.9illustrates a double sided polymer timing belt122which may be metal reinforced (e.g., steel or KEVLAR) in meshing engagement with sprocket18and input ring gear12. In another embodiment seen in FIG.10, a roller chain timing belt124is in meshing engagement with sprocket18and input ring gear12. In yet another embodiment seen inFIG.11, sprocket18is in direct meshing engagement with input ring gear12. In still another embodiment seen inFIG.12, at least one timing gear126is in meshing engagement with sprocket18and input ring gear12. Other gear system10embodiments may be configured to comprise a plurality of input ring gears12, positioned such that each may be driven by a single primary motor input (e.g., timing belt, sprocket, and motor configuration). It should be appreciated that motor16may, for example, be a NEMA (National Electrical Manufacturers' Association) “C-Faced” motor. However, motor16may also be replaced with a manual operation device (e.g., crank and lever configurations) for rotation of the sprocket18via shaft20. It should be further understood that the primary motor input may be embodied to comprise other components and configurations (e.g., pinion, annular gear, etc.). Other embodiments of gear system10may even further include multiple motor inputs. Referring now toFIGS.5through7, the input ring gear12in conjunction with ring plates29,31define the housing of gearbox13. To effectively encapsulate the internal components of gearbox13, ring plates29,31are joined to input ring gear12via a series of bolts8. A seal is created between ring gear12and ring plate29by the O-ring seal36and dynamic O-ring seal35. On the opposite side, another seal is created between ring gear12and ring plate31by a second O-ring seal33and dynamic O-ring seal39. It should be appreciated that the seals of input ring gear12may also be embodied as a shaft seal and dynamic shaft seal. During construction of the gearbox13, a volume of lubricant is placed in and around the gearbox's internal components. As such, when gearbox13rotates, lubricant is flung around (e.g. outward from output shaft42and the ball bearing rings34) so as to self-lubricate the self-contained internal components of gearbox13and allow the internal components to remain continuously deposited with lubrication. This allows for a continuous operation of gear system10, for example, without the need for certain routine, burdensome maintenance. Within the central opening of input ring gear12are planet locking gears24,26, output spur gear28, and fixed spur gear30. Output spur gear28is rotatably mounted on drive shaft32, in a radially inward, concentric relation to ring gear12, and is in meshing engagement with planet locking gears24,26. Output spur gear28further includes output shaft42, which is hollow to allow the output spur gear28to be mounted around drive shaft32. Fixed spur gear30is fixedly mounted over output shaft42via mount paddle6, adjacent to output spur gear28on the side thereof opposite ring plate31. Fixed spur gear30is also in meshing engagement with planet locking gears24,26. One or more ball bearing rings34may be positioned on output shaft42, in between output shaft42and fixed spur gear30, to facilitate rotation of output spur gear28relative to fixed spur gear30. An additional ball bearing ring34may be positioned on fixed spur gear30to facilitate rotation of gearbox13with respect thereto. In other gear system10embodiments, input ring gear12may extend in a perpendicular, spaced relation to drive shaft32(e.g. via miter gears). The first and second planet locking gears24,26are rotatably mounted within ring gear12. Planet gears24,26rotate about their own respective mounting axes37,41. Mounting axes37,41are created by orifices23,27in ring plates29,31, when the ring plates29,31are mounted to ring gear12. Second planet gear26is in 180° off-set relation with respect to first planet gear24, about the full 360° circumference of ring gear12. The planet gears teeth24′,26′ mesh with the spur gear teeth28′,30′ (shown inFIG.8) causing planet gears24,26to rotate about their respective mounting axes37,41while being revolved around the 360° circumference of spur gears28,30by ring gear12. One or more planet gear ball bearing rings19may be positioned on planet gears24,26to facilitate rotation of planet gears24,26about mounting axes37,41. Fixed spur gear30has N number of gear teeth30′, shown as an involute form geometry. Output spur gear28has a substantially similar pitch diameter as the fixed spur gear30but with N+/−X number of gear teeth28′ (e.g., two fewer teeth than the fixed spur gear30), shown as a modified involute form geometry. In the simplest embodiment, the tooth orientation28′ is involute with the spacing between teeth adjusted to take up the space from the removal of the 2 teeth. For example, the difference in tooth spacing for 53/51 teeth and approximately 8 inch diameter ring gear is approximately 0.008″ per tooth. Orienting the output and fixed spur gear teeth28′,30′ in this manner forces gear teeth28′,30′ to substantially align at the point in which they meshingly engage with planet gear teeth24′,26′. However, beyond this point, gear teeth28′,30′ begin to separate until becoming fully separated at the point about the full 360° circumference of the spur gears28,30furthest from where meshing engagement occurs. For example, when gearbox13comprises two planet gears24,26, the point of furthest gear teeth28′,30′ separation occurs at the two locations about the full 360° circumference directly between both points where meshing engagement takes place. Since output spur gear28has 2 fewer teeth and fixed spur gear30remains stationary, each revolution of the planet gears24,26about the 360° circumference of fixed spur gear30yields a rotational advancement of output spur gear28by 2 teeth. As follows, rotation of shaft20causes rotation of ring gear12which causes rotation of planet gears24,26which therefore cause rotation of output spur gear28which ultimately causes rotation of drive shaft32. It is appreciated that the tooth numbers and ratios listed above are an example and are therefore not to be construed as limiting the invention. It will be further appreciated that the gearing concept may be scaled up or down in size of gears, number of gear teeth, number of gears, and/or gear configuration. FIG.8is a schematic diagram illustrating the basic relationship between the output and fixed spur gears28,30, respectively, with respect to planet locking gears24,26. When rotational force is applied directly to output spur gear28via output shaft42, the gear will create an “Applied Load” force to rotate planet gears24,26on fixed spur gear30. However, since fixed spur gear30is fixed, it will create an equal, countervailing “Reacted Load” force against such a rotation. With “Applied Load” and “Reacted Load” forces being applied on both sides, planet gear teeth24′,26′ become frictionally wedged in between the fixed and output spur gear teeth28′,30′, causing planet gears24,26to lock in place. Once locked, planet gear teeth24′,26′ will halt the rotational advancement of output spur gear28. Additionally, when the general configuration comprises 2 planet gears 180 degrees apart, any gear twisting (due to shear action between gear teeth) will be in equal and opposite directions on each planet gear and become neutralized. Back rotation of gear box13is therefore only made possible through a force of backward rotation made directly to ring gear12. If a cable connecting a load to the winch15happens to break, for example, gear box13will not be able to back drive and allow any portion of the cable to retreat back into winch15. Planetary drive configurations can also be noisy due to sliding and scuffing between the teeth of the output and fixed spur gears28′,30′ and those of the planet gears24′,26′. Undue friction is created when output spur gear teeth wedge the planet gear teeth, discussed above. To reduce such sliding, scuffing, and undue friction, the output and fixed spur gear teeth28′,30′ and planet gear teeth24′,26′ are configured to comprise an angularly complimenting, noise-dampening pressure angle46(also known as the “angle of obliquity”). While the pressure angles of most common stock gears are around 141/2°, 20°, or 22°, the output and fixed gear pressure angles are most preferably made to be approximately 35°. This pressure angle configuration provides for lower backlash, smoother operation, and less sensitivity to manufacturing flaws. More specifically, the larger angles allow for the fixed and output spur gear teeth28′,30′ to slide easily in between the planet gear teeth24′,26′ with more rolling and less scuffing than previous pressure angles. This may also generally be accomplished by larger pressure angles that range from approximately 20° to 45°. FIGS.9-12show alternate embodiments of connection between the motor16and primary input gear12. It should be appreciated that the gears, shafts, and housings of the output ring gear system10may be made from, but are limited to, metals, plastics, composites, ceramics, woods, plywood, castings, metal powders, metal or plastic extrusions, or punched blanks. The various components of the output ring gear system10may be manufactured by, for example, laser cutting processes, water jet cutting processes, punch and die, fine-blanking, roll forming, investment cast, or laminated layers of materials (e.g. sheet metal, plastic, paper), or 3D printing processes. While the invention has been described with reference to preferred embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof to adapt to particular situations without departing from the scope of the invention. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope and spirit of the appended claims. | 12,213 |
11859701 | The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. Referring toFIGS.1and2, first to third forms of a powertrain for an electric vehicle according to one form of the present disclosure commonly include: a planetary gear PG having three rotating elements (i.e., first, second and third rotating elements), where the first rotating element is connected to a first shaft A1and the second rotating element is connected to a second shaft A2; a first motor MG1installed to selectively supply power to the first shaft A1at two or more gear ratios; and a second motor MG2installed to selectively supply power to the first shaft A1and the second shaft A2. The third rotating element of the planetary gear PG may be connected to a third shaft A3, and may be selectively connected to a transmission housing CS. In addition, two rotating elements randomly selected from among the three rotating elements of the planetary gear PG may be connected to each other, such that the entire planetary gear PG can be rotated integrally. Here, when the first shaft A1is regarded as an input shaft to which power may be transmitted from the first motor MG1and the second motor MG2and the second shaft A2is regarded as an output shaft to which power may be transmitted from the second motor MG2and from which shifted power may be output, the present disclosure may considered to be configured such that power that the first motor MG1provides to the input shaft in an adjusted manner and power that the second motor MG2provides to the input shaft or the output shaft may be readjusted using the planetary gear PG before being output to the output shaft. For reference, all of the first shaft A1, the second shaft A2, and the third shaft A3are concentrically disposed as rotating shafts of the rotating elements of the planetary gear PG. The first rotating element of the planetary gear PG may be referred to as being a sun gear S, the second rotating element of the planetary gear PG may be referred to as being a carrier C, and the third rotating element of the planetary gear PG may be referred to as being a ring gear R. For reference, the second shaft A2in the drawings is expressed as OUT, and is shown to function as an output shaft to which power is output. Forms of the present disclosure commonly include a third shift assembly S3fixing the third rotating element of the planetary gear PG to the transmission housing CS or connecting the third rotating element of the planetary gear PG to the second shaft A2by a linear displacement along the axial direction of the first shaft A1. The third rotating element of the planetary gear PG is connected to the second rotating element via the second shaft A2, such that all of the rotating elements of the planetary gear PG may rotate integrally. All of the rotating elements of the planetary gear PG may be configured to rotate integrally when the third shaft A3is connected to the second shaft A2as described above and when the third shaft A3is connected to the first shaft A1or the first shaft A1and the second shaft A2are connected. The third shift assembly S3may include, for example, a friction clutch able to produce a linear displacement by sliding linearly along the axial direction while the rotation thereof is restrained by the third shaft A3, so as to switch between a state in which the third rotating element of the planetary gear PG connected to the third shaft A3is connected to the transmission housing CS and a state in which the third rotating element is connected to the second shaft A2. In the first form illustrated inFIG.1, a first shift assembly S1is provided between the first motor MG1and the first shaft A1to switch between a state in which power provided by the first motor MG1is transmitted directly to the first shaft A1and a state in which power provided by the first motor MG1is shifted by a gear train before being transmitted to the first shaft A1. Specifically, the first motor MG1is disposed such that the rotating shaft thereof is coaxial with the first shaft A1, the first shift assembly S1includes a gear engagement unit, a hub and a sleeve of which are disposed on the rotating shaft of the first motor MG1, a first gear G1including a clutch gear engageable with the sleeve of the gear engagement unit is rotatably disposed on the rotating shaft of the first motor MG1, and a second gear G2including a clutch gear engageable with the sleeve of the gear engagement unit is disposed on the first shaft A1such that the rotation of the second gear G2is restrained. Accordingly, the first shift assembly S1includes the gear engagement unit substantially provided on the rotating shaft of the first motor MG1, the clutch gear of the first gear G1, the clutch gear of the second gear G2, and the like. In addition, a third gear G3in external engagement with the first gear G1and a fourth gear G4in external engagement with the second gear G2are coaxially connected to each other. Accordingly, when the sleeve of the first shift assembly S1is engaged with the clutch gear of the first gear G1, power provided by the first motor MG1is transmitted to the first shaft A1sequentially through the first gear G1, the third gear G3, the fourth gear G4, and the second gear G2. When the sleeve of the first shift assembly S1is engaged with the clutch gear of the second gear G2, power provided by the first motor MG1is transmitted directly to the first shaft A1. As a result, the power provided by the first motor MG1can be transmitted to the first shaft A1at different shift ratios. In addition, the second form illustrated inFIG.2differs from the first form, in that the first shift assembly S1is disposed between the first motor MG1and the first shaft A1such that power provided by the first motor MG1can be transmitted to the first shaft A1through one gear of two external engagement gears having different gear ratios. Here, the first shift assembly S1includes the gear engagement unit, the hub and the sleeve of which are disposed on the rotating shaft of the first motor MG1. The first gear G1and the second gear G2are rotatably provided on both sides of the hub. The third gear G3in external engagement with the first gear G1and the fourth gear G4in external engagement with the second gear G2are coaxially connected to each other. A fifth gear G5is disposed on the shaft of the third gear G3and the fourth gear G4such that the rotation of the fifth gear G5is restrained. A sixth gear G6in external engagement with the fifth gear G5is disposed on the first shaft A1such that the rotation of the sixth gear G6is restrained. Accordingly, when the sleeve of the first shift assembly S1is engaged with the clutch gear of the first gear G1, power provided by the first motor MG1is transmitted to the first shaft A1through the first gear G1, the third gear G3, the fifth gear G5, and the sixth gear G6. When the sleeve of the first shift assembly S1is engaged with the clutch gear of the second gear G2, power provided by the first motor MG1is transmitted to the first shaft A1via the second gear G2, the fourth gear G4, the fifth gear G5, and the sixth gear G6. As a result, the power provided by the first motor MG1can be transmitted to the first shaft A1at different shift ratios. For reference, an additional pair of external engagement gears configured in the same manner as a pair of external engagement gears including the first gear G1and the third gear G3or a pair of external engagement gears including the second gear G2and the fourth gear G4, as well as, an additional transmission connecting the further pair of external engagement gears to the first motor MG1, may be provided. Power provided by the first motor MG1may be transmitted at another shift ratio before being input to the first shaft A1through the fifth gear G5and the sixth gear G6. In addition, a seventh gear G7is connected to the first shaft A1such that the rotation of the seventh gear G7is restrained. An eighth gear G8is connected to the second shaft A2such that the rotation of the eighth gear G8is restrained. A ninth gear G9in external engagement with the seventh gear G7and a tenth gear G10in external engagement with the eighth gear G8are disposed coaxially with each other. The second motor MG2is disposed to be connectable to the first shaft A1and the second shaft A2via the second shift assembly S2disposed between the ninth gear G9and the tenth gear G10. For reference, the seventh gear G7to the tenth gear G10and the second shift assembly S2are common components of both the first form and the second form. The second shift assembly S2includes the gear engagement unit, the hub and the sleeve of which are disposed on the rotating shaft of the ninth gear G9and the tenth gear G10. Since the ninth gear G9and the tenth gear G10are respectively provided with a clutch gear in engagement with the sleeve of the gear engagement unit, the second shift assembly S2substantially includes the gear engagement unit provided on the rotating shaft of the ninth gear G9and the tenth gear G10, the clutch gear of the ninth gear G9, and the clutch gear of the tenth gear G10. In addition, the second motor MG2is coaxially disposed on the first shaft A1. The second motor MG2is configured such that power provided by the second motor MG2is transmitted to the first shaft A1or the second shaft A2through an eleventh gear G11disposed concentrically on the first shaft A1and a twelfth gear G12in external engagement with the eleventh gear G11to be coaxial with the ninth gear G9and the tenth gear G10. Accordingly, when the sleeve of the second shift assembly S2is engaged with the clutch gear of the ninth gear G9, power provided by the second motor MG2is transmitted to the first shaft A1through the eleventh gear G11, the twelfth gear G12, the ninth gear G9, and the seventh gear G7. When the sleeve of the second shift assembly S2is engaged with the clutch gear of the tenth gear G10, power provided by the second motor MG2is transmitted to the second shaft A2through the eleventh gear G11, the twelfth gear G12, the tenth gear G10, and the eighth gear G8. FIG.3is a table illustrating operating modes of first to third forms of the powertrain for an electric vehicle according to the present disclosure, in which a total of six gear stages are provided. For reference, in the shift assemblies, “a” indicates a configuration in which the sleeve of the first shift assembly S1connects or disconnects the clutch gear of the first gear G1to and from power, “b” indicates a configuration in which the sleeve of the first shift assembly S1connects or disconnects the clutch gear of the second gear G2to and from power, “c” indicates a configuration in which the sleeve of the second shift assembly S2connects or disconnects the clutch gear of the ninth gear G9to and from power, “d” indicates a configuration in which the sleeve of the second shift assembly S2connects or disconnects the clutch gear of the tenth gear G10to and from power, “e” indicates the third shift assembly S3being configured to connect or disconnect the third rotating element of the planetary gear PG to or from the transmission housing CS, and “f” indicates the third shift assembly S3being configured to connect or disconnect the third rotating element of the planetary gear PG to or from the second shaft A2. With reference to the form illustrated inFIG.1, gear stages and gear shifting of the powertrain for an electric vehicle according to the present disclosure will be described. In the form illustrated inFIG.2, gear shifting is performed substantially in the same manner. The first gear stage is realized by fixing the third rotating element of the planetary gear PG to the transmission housing CS, engaging the sleeve of the first shift assembly S1with the clutch gear of the first gear G1, and engaging the sleeve of the second shift assembly S2with the clutch gear of the ninth gear G9. Here, power provided by the first motor MG1is transmitted to the first shaft A1through the first gear G1, the third gear G3, the fourth gear G4, and the second gear G2. Power provided by the second motor MG2is transmitted to the first shaft A1through the eleventh gear G11, the twelfth gear G12, the ninth gear G9, and the seventh gear G7. Accordingly, both the power provided by the first motor MG1and the power provided by the second motor MG2may be transmitted to the first shaft A1. Driving in the first gear may be realized using one motor of the two motors, depending on the driving condition of the vehicle. Power transmitted to the first shaft A1as described above is input from the first shaft A1to the sun gear S, i.e. the first rotating element, and is reduced by the carrier C, i.e. the second rotating element, before being output to the second shaft A2, since a ring gear R, i.e. the third rotating element of the planetary gear PG, is fixed to the transmission housing CS by the third shift assembly S3. The second shaft A2is connected to one or more driving wheels via a separate differential device or the like, such that the vehicle can be propelled by power transferred as above. Gear shifting from the first gear stage to the second gear stage is performed by disengaging the sleeve of the first shift assembly S1from the clutch gear of the first gear G1and engaging the sleeve of the first shift assembly S1with the clutch gear of the second gear G2. In this case, in a state in which the torque of the first motor MG1is reduced while the second motor MG2is allowed to continuously supply power, the sleeve of the first shift assembly S1is disengaged to be in the neutral position and then is engaged with the clutch gear of the second gear G2, so that the gear shifting can be performed smoothly without torque interruption or shift shock. That is, even in a state in which the sleeve of the first shift assembly S1is disengaged to be in the neutral position, the power provided by the second motor MG2is continuously supplied to the first shaft A1, so that torque can be continuously transmitted to one or more driving wheels to prevent torque interruption. During the disengagement and engagement of the sleeve of the first shift assembly S1, the torque of the first motor MG1can be reduced or completely canceled. Consequently, the sleeve of the first shift assembly S1can be smoothly and softly disengaged and engaged, so that excellent shifting feel can be obtained. In the second gear stage realized as above, the power provided by the first motor MG1is transmitted to the first shaft A1directly through the sleeve of the first shift assembly S1and the second gear G2and reduced by the planetary gear PG before being output to the second shaft A2. Gear shifting from the second gear stage to the third gear stage is performed by disengaging the sleeve of the second shift assembly S2from the clutch gear of the ninth gear G9and engaging the sleeve of the second shift assembly S2with clutch gear of the tenth gear G10. Likewise, in a state in which the torque of the second motor MG2is reduced or released while the first motor MG1is allowed to continuously supply power to the first shaft A1, the sleeve of the second shift assembly S2is disengaged from the clutch gear of the ninth gear G9to be in the neutral position and then is engaged with the clutch gear of the tenth gear G10, so that the gear shifting can be performed smoothly without torque interruption or shift shock. Consequently, the sleeve of the second shift assembly S2is smoothly converted from a state in which the sleeve is engaged with the clutch gear of the ninth gear G9to a state in which the sleeve is engaged with the clutch gear of the tenth gear G10while the power provided by the first motor MG1is being continuously supplied to the driving wheels, so that the gear shifting to the third gear stage is completed. In the third gear stage, power provided by the first motor MG1is input to the sun gear S of the planetary gear PG through the first shaft A1, and power provided by the second motor MG2is input to the carrier C of the planetary gear PG through the second shaft A2. Referring toFIG.3, the fourth to sixth gear stages are realized in a state in which the third shift assembly S3has connected the third rotating element of the planetary gear PG to the second shaft A2. That is, in the first to third gear stages, the third shift assembly S3fixes the ring gear R, i.e. the third rotating element of the planetary gear PG, to the transmission housing CS, such that the power input to the first rotating element of the planetary gear PG is reduced before being output to the carrier C, i.e. the second rotating element, and the second shaft A2. In the fourth to sixth gear stages, the third shift assembly S3connects the third rotating element of the planetary gear PG to the second rotating element via the second shaft A2, such that the power input to the planetary gear PG is output without reduction or increase in speed. For gear shifting from the third gear stage to the fourth gear stage, canceling the torque of the first motor MG1and controlling the first shift assembly S1to be in the neutral position are performed from a state in which the third shift assembly S3has fixed the third rotating element of the planetary gear PG to the transmission housing CS in the third gear stage, the third rotating element of the planetary gear PG is connected to the second shaft A2via the third shift assembly S3, and then the first shift assembly S1is controlled to be engaged with the clutch gear of the first gear G1from the neutral position. In this manner, power provided by the first motor MG1is transmitted to the driving wheels, thereby completing the gear shifting. During the gear shifting, the power provided by the second motor MG2is continuously provided to the driving wheels through the second shaft A2, thereby preventing torque interruption. Afterwards, gear shifting from the fourth gear stage to the fifth gear stage is performed. In a state in which the first motor MG1is continuously transmitting power to the driving wheels, the torque of the second motor MG2is reduced, and the sleeve of the second shift assembly S2is disengaged from the clutch gear of the tenth gear G10and then is engaged with the clutch gear of the ninth gear G9. In addition, gear shifting from the fifth gear stage to the sixth gear stage is performed. In a state in which the second motor MG2is continuously supplying power to the driving wheels, the sleeve of the first shift assembly S1is disengaged from the clutch gear of the first gear G1and then is engaged with the clutch gear of the second gear G2. As described above, also in the gear shifting from the fourth gear stage to the fifth gear stage and the gear shifting from the fifth gear stage to the sixth gear stage, shifting can be performed in a state in which one more of the first motor MG1and the second motor MG2can continuously transmit power to the driving wheels, thereby preventing torque interruption and obtaining smooth shifting feel. In addition, since the powertrain for an electric vehicle according to the present disclosure is basically configured to transmit power provided by the motor to the driving wheels using a related-art automated manual transmission (AMT), superior power transfer efficiency is obtained. In particular, in the sixth gear stage, i.e. the highest gear stage, power provided by the first motor MG1is transmitted directly to the first shaft A1, and all of the rotating elements of the planetary gear PG are restrained by each other, such that the first shaft A1rotates integrally with the second shaft A2. As a result, the powertrain according to the present disclosure can output the power provided by the first motor MG1without gear shifting, thereby achieving significantly high power transfer efficiency and increasing or maximizing fuel efficiency of an electric vehicle. For reference,FIG.4is a modified form of the first form illustrated inFIG.1. In the form illustrated inFIG.4, the second motor MG2and gears connected to the second motor MG2are moved to the right of the planetary gear PG. In addition, an output gear OG is provided on the carrier C of the planetary gear PG, and a ring gear RG of a differential DF is engaged directly with the output gear OG. In the first to third forms, the first shift assembly S1and the second shift assembly S2are provided in common. In contrast, a fourth form ofFIG.5, a fifth form ofFIG.6, a sixth form ofFIG.8, and a seventh form ofFIG.9are forms in which only one shift assembly similar to the first shift assembly S1or the second shift assembly S2is provided. First, referring to the fourth and fifth forms, the two forms are configured in common to include: a planetary gear PG having three rotating elements, a first rotating element of which is connected to a first shaft A1, a second rotating element of which is connected to a second shaft A2, and a third rotating element of which is selectively connected to a transmission housing CS; a first motor MG1installed to supply power to the first shaft A1at all times; and a second motor MG2installed to selectively supply power to the first shaft A1and the second shaft A2. Any two rotating elements of the three rotating elements of the planetary gear PG may be selectively connected to each other, such that the entire planetary gear PG can be rotated integrally. The first rotating element of the planetary gear PG is a sun gear S, the second rotating element of the planetary gear PG is a carrier C, and the third rotating element of the planetary gear PG is a ring gear R. A seventh gear G7is installed on the first shaft A1in a restrained state, and an eighth gear G8is installed on the second shaft A2in a restrained state. A ninth gear G9in external engagement with the seventh gear G7and a tenth gear G10in external engagement with the eighth gear G8are coaxially installed. The second motor MG2is installed to be connected to the first shaft A1and the second shaft A2by the second shift assembly S2install between the ninth gear G9and the tenth gear G10. The second shift assembly S2includes a gear engagement unit in which a hub and a sleeve are provided on the rotating shaft of the ninth gear G9and the tenth gear G10. The second motor MG2is coaxially installed on the first shaft A1, and power of the second motor MG2is configured to be transmitted to the first shaft A1or the second shaft A2by an eleventh gear G11, which is coaxially installed on the first shaft A1, and a twelfth gear G12that is in external engagement with the eleventh gear G11and is coaxially installed on the ninth gear G9and the tenth gear G10. These forms are configured to include a third shift assembly S3configured such that the third rotating element of the planetary gear PG is fixed to the transmission housing CS or is connected to the second shaft A2by linear displacement following an axial direction of the first shaft A1. That is, the fourth and fifth forms are forms configured to use only the second shift assembly S2of the first to third forms, are nearly similar to the first to third forms with regard to the other configuration and operations, and can realize a total of four gear stages as illustrated inFIG.7. FIGS.8and9illustrate sixth and seventh forms of the present disclosure respectively, and include in common: a planetary gear including three rotating elements, among which a first rotating element is connected to a first shaft, a second rotating element is connected to a second shaft, and a third rotating element is connected to a third shaft; a first motor installed to supply power to the first shaft at all times; and a second motor installed to selectively supply power to the first and second shafts. The third shaft is fixably installed on a transmission housing, and any two shafts among the first, second, and third shafts are configured to restrain each other. The first rotating element of the planetary gear is a sun gear, the second rotating element is a carrier, and the third rotating element is a ring gear. In the sixth form ofFIG.8, a first shift assembly is provided between the second motor and the second shaft to switch between a state in which power of the second motor is directly transmitted to the second shaft and a state in which the power of the second motor is shifted by a gear train and is transmitted to the first shaft. That is, the second motor is disposed such that a rotating shaft thereof is coaxial with the second shaft; the first shift assembly includes a gear engagement unit, a hub and a sleeve of which are provided on the rotating shaft of the second motor; a first gear including a clutch gear engageable with the sleeve of the gear engagement unit is rotatably installed on the rotating shaft of the second motor; the clutch gear engageable with the sleeve of the gear engagement unit is installed on the second shaft in a state in which rotation of the clutch gear is restrained; and a second gear installed on the first shaft to receive the power of the second motor in a state in which rotation of the second gear is restrained. Further, a third gear engaged externally with the first gear and a fourth gear engaged externally with the second gear are coaxially connected to each other. Therefore, in a state in which the sleeve of the first shift assembly S1is moved to the left side in the drawing, the power of the second motor MG2is transmitted to the first shaft A1through the first gear G1, a third gear G3, a fourth gear G4, and the second gear G2in turn. In a state in which the sleeve of the first shift assembly S1is moved to the right side in the drawing, the power of the second motor MG2can be transmitted to the second shaft A2without a change. In some forms of the present form, a third shift assembly S3is provided. The third shift assembly S3is configured such that the third rotating element of the planetary gear PG is fixed to the transmission housing CS or is connected to the second shaft A2by linear displacement following an axial direction of the first shaft A1. Meanwhile, in the seventh form ofFIG.9, a first shift assembly is provided between the second motor and the first shaft to switch between a state in which power of the second motor is directly transmitted to the first shaft and a state in which the power of the second motor is shifted by a gear train and is transmitted to the second shaft. The second motor is disposed such that a rotating shaft thereof is coaxial with the first shaft; the first shift assembly includes a gear engagement unit, a hub and a sleeve of which are provided on the rotating shaft of the second motor; a first gear including a clutch gear engageable with the sleeve of the gear engagement unit is rotatably installed on the rotating shaft of the second motor; the clutch gear engageable with the sleeve of the gear engagement unit is installed on the first shaft in a state in which rotation of the clutch gear is restrained; and a second gear installed on the second shaft to receive the power of the second motor in a state in which rotation of the second gear is restrained. Further, a third gear engaged externally with the first gear and a fourth gear engaged externally with the second gear are coaxially connected to each other. Therefore, in a state in which the sleeve of the first shift assembly S1is moved to the left side in the drawing, the power of the second motor MG2is directly transmitted to the first shaft A1. In a state in which the sleeve of the first shift assembly S1is moved to the right side in the drawing, the power of the second motor MG2is transmitted to the second shaft A2by shifting of the first gear G1, a third gear G3, a fourth gear G4, and the second gear G2. In some forms of the present disclosure, a third shift assembly S3is provided on the planetary gear PG. The third shift assembly S3is configured such that the third rotating element of the planetary gear PG is fixed to the transmission housing CS or is connected to the second shaft A2by linear displacement following an axial direction of the first shaft A1. Although the exemplary forms of the present disclosure have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the present disclosure. | 28,843 |
11859702 | DETAILED DESCRIPTION FIG.1is a partial cross-sectional view of a torque converter including a lock-up device according to the present preferred embodiment. InFIG.1, an engine (not shown in the drawing) is disposed on the left side, whereas a transmission (not shown in the drawing) is disposed on the right side. It should be noted that line O-O depicted inFIG.1indicates a common rotational axis for the torque converter, the lock-up device, and a flow channel structure. In the following explanation, the term “axial direction” refers to an extending direction of the rotational axis O. On the other hand, the term “circumferential direction” refers to a circumferential direction of an imaginary circle about the rotational axis O, whereas the term “radial direction” refers to a radial direction of the imaginary circle about the rotational axis O. Yet on the other hand, the term “thickness direction” means a thickness direction of each of plates composing the flow channel structure. It should be noted that in the present preferred embodiment, the thickness direction extends along the axial direction and is therefore defined as identical to the axial direction. [Entire Configuration of Torque Converter] The torque converter (100) is a device for transmitting a torque from an engine-side crankshaft (not shown in the drawings) to an input shaft101of the transmission. As shown inFIG.1, the torque converter100includes a front cover11, a torque converter body12, and the lock-up device (10). The front cover11is fixed to an input-side member. The front cover11is a substantially disc-shaped member and includes an outer tubular portion111, protruding toward the transmission, in the outer peripheral part thereof. The torque converter body12is composed of three types of bladed wheels (an impeller13, a turbine14, and a stator15). The impeller13includes an impeller shell131, a plurality of impeller blades132, and an impeller hub133. The impeller shell131is fixed to the outer tubular portion111of the front cover11by welding or so forth. The impeller blades132are fixed to the inner surface of the impeller shell131. The impeller hub133is fixed to the inner peripheral end of the impeller shell131. The turbine14is disposed in opposition to the impeller13within a fluid chamber. The turbine14includes a turbine shell141, a plurality of turbine blades142, and a turbine hub143. The turbine blades142are fixed to the inner surface of the turbine shell141. The turbine hub143is fixed to the inner peripheral end of the turbine shell141. The turbine hub143includes a flange portion143aextending radially outward. The flange portion143areceives the inner peripheral end of the turbine shell141fixed thereto by a plurality of rivets (not shown in the drawings), welding, or so forth. The turbine hub143is provided with a spline hole that the input shaft101of the transmission is engaged. The turbine hub143includes a plurality of sixth through holes143b. The sixth through holes143baxially penetrate the flange portion143a. The sixth through holes143bare disposed apart from each other at intervals in the circumferential direction. The stator15is disposed between the impeller13and the turbine14and is configured to regulate the flow of hydraulic oil returning from the turbine14to the impeller13. The stator15includes a stator carrier151and a plurality of stator blades152. The stator carrier151is supported by a stationary shaft105through a one-way clutch102. Thrust bearings103and104are provided axially on both sides of the stator carrier151. The stator blades152are provided on the outer peripheral surface of the stator carrier151. [Lock-Up Device] As shown inFIG.2, the lock-up device10is disposed axially between the front cover11and the turbine14. The lock-up device10includes the flow channel structure (2), a clutch part5, a piston6, a chamber plate7, and a damper part8. Besides, the lock-up device10includes a first fluid chamber C1, a second fluid chamber C2, a third fluid chamber C3, and a fourth fluid chamber C4. <Flow Channel Structure> FIG.3is a front view of the flow channel structure2;FIG.4is a cross-sectional view taken along line IV-IV inFIG.3;FIG.5is a cross-sectional view taken along line V-V inFIG.3. As shown inFIGS.3to5, the flow channel structure2forms a first flow channel for making the first and second fluid chambers C1and C2communicate with each other therethrough. Besides, the flow channel structure2also forms a second flow channel for making the third and fourth fluid chambers C3and C4communicate with each other therethrough. The flow channel structure2is disposed radially between the turbine hub143and both the clutch part5and the piston6. The flow channel structure2includes a first plate21, a second plate22, and a third plate23. The first and second plates21and22are fixed to the third plate23. The first, second, and third plates21,22, and23are unitarily rotated with each other. The flow channel structure2is disposed in a rotatable manner. The flow channel structure2is fixed to the front cover11and is unitarily rotated therewith. Besides, the flow channel structure2is immovable in the axial direction. The inner peripheral surface of the flow channel structure2is in contact with the outer peripheral surface of the turbine hub143. It should be noted that a fourth seal member143cis disposed between the flow channel structure2and the turbine hub143. The fourth seal member143cis disposed in a groove circumferentially extending on the outer peripheral surface of the turbine hub143. The flow channel structure2is rotatable relative to the turbine hub143. The first plate21has an annular shape. The first plate21is fixed to the front cover11. In other words, the first plate21is unitarily rotated with the front cover11. The first plate21includes a plurality of first through holes21aand a plurality of third through holes21b. It should be noted that in the present preferred embodiment, the first plate21includes a pair of first through holes21aand a pair of third through holes21b. The pair of first through holes21ais disposed on the opposite sides from each other about the rotational axis O. Likewise, the pair of third through holes21bis disposed on the opposite sides from each other about the rotational axis O. The first through holes21aare disposed radially inside the third through holes21b. The first through holes21aand the third through holes21bare disposed at a phase difference of 90 degrees in the circumferential direction. The first through holes21apenetrate the first plate21in the thickness direction. The first through holes21aopen to the first fluid chamber C1. The third through holes21bpenetrate the first plate21in the thickness direction. The third through holes21bopen to the third fluid chamber C3. The first plate21includes a first annular portion21cand a first tubular portion21d. The first annular portion21cand the first tubular portion21dcompose a single plate. The first through holes21aand the third through holes21bare provided in the first annular portion21c. The first tubular portion21daxially extends from the outer peripheral end of the first annular portion21c. When described in detail, the first tubular portion21dextends from the first annular portion21ctoward the front cover11. It should be noted that the first tubular portion21dis formed by axially bending the outer peripheral part of the first plate21by stamping or so forth. The first tubular portion21dincludes a plurality of grooves21e. The grooves21eextend in the axial direction. The grooves21eare disposed apart from each other at intervals in the circumferential direction. The second plate22has an annular shape. The second plate22includes a plurality of second through holes22aand a plurality of fourth through holes22b. It should be noted that in the present preferred embodiment, the second plate22includes a pair of second through holes22aand a pair of fourth through holes22b. In the present preferred embodiment, the second through holes22aare equal in number to the first through holes21a. Likewise, the fourth through holes22bare equal in number to the third through holes21b. The pair of second through holes22ais disposed on the opposite sides from each other about the rotational axis O. Likewise, the pair of fourth through holes22bis disposed on the opposite sides from each other about the rotational axis O. The second through holes22aand the fourth through holes22bare disposed at a phase difference of 90 degrees in the circumferential direction. The second through holes22aare disposed radially outside the fourth through holes22b. The second through holes22aare identical in circumferential position to the first through holes21aThe first through holes21aare disposed radially inside the second through holes22a. The first through holes21aand the second through holes22aare different in position from each other as seen in the thickness direction. In other words, the first through holes21aand the second through holes22ado not overlap as seen in the thickness direction. The fourth through holes22bare identical in circumferential position to the third through holes21b. The third through holes21bare disposed radially outside the fourth through holes22b. The third through holes21band the fourth through holes22bare different in position from each other as seen in the thickness direction. In other words, the third through holes21band the fourth through holes22bdo not overlap as seen in the thickness direction. The second through holes22apenetrate the second plate22in the thickness direction. The second through holes22aopen to the second fluid chamber C2. The fourth through holes22bpenetrate the second plate22in the thickness direction. The fourth through holes22bopen to the fourth fluid chamber C4. The second plate22includes a second annular portion22c, a second tubular portion22d, and a third tubular portion22e. The second annular portion22c, the second tubular portion22d, and the third tubular portion22ecompose a single plate. The second through holes22aand the fourth through holes22bare provided in the second annular portion22c. The second tubular portion22daxially extends from the outer peripheral end of the second annular portion22c. When described in detail, the second tubular portion22dextends from the second annular portion22ctoward the turbine14. The third tubular portion22eaxially extends from the inner peripheral end of the second annular portion22c. When described in detail, the third tubular portion22eextends from the second annular portion22ctoward the turbine14. It should be noted that the second tubular portion22dand the third tubular portion22eare formed by axially bending the outer peripheral part and the inner peripheral part of the second plate22by stamping or so forth. The third plate23has an annular shape. The third plate23is disposed between the first plate21and the second plate22. The first plate21, the third plate23, and the second plate22are laminated in this order in the axial direction. The third plate23includes a plurality of first connecting through holes23aand a plurality of second connecting through holes23b. It should be noted that in the present preferred embodiment, the third plate23includes a pair of first connecting through holes23aand a pair of second connecting through holes23b. In the present preferred embodiment, the first connecting through holes23aare equal in number to the first through holes21a. Likewise, the second connecting through holes23bare equal in number to the third through holes21b. The pair of first connecting through holes23ais disposed on the opposite sides from each other about the rotational axis O. Likewise, the pair of second connecting through holes23bis disposed on the opposite sides from each other about the rotational axis O. The first connecting through holes23aand the second connecting through holes23bare disposed at a phase difference of 90 degrees in the circumferential direction. The first connecting through holes23aare approximately identical in radial position to the second connecting through holes23b. The first connecting through holes23apenetrate the third plate23in the thickness direction. Each first connecting through hole23ais larger in flow channel area than each first through hole21aand each second through hole22aEach first connecting through hole23acommunicates with each first through hole21aand each second through hole22a. In other words, each first through hole21aand each second through hole22aoverlap each first connecting through hole23aas seen in the thickness direction. Each first through hole21aand each second through hole22acommunicate with each other through each first connecting through hole23aIn other words, each first through hole21a, each first connecting through hole23a, and each second through hole22acompose the first flow channel for making the first and second fluid chambers C1and C2communicate with each other therethrough. The second connecting through holes23bpenetrate the third plate23in the thickness direction. Each second connecting through hole23bis larger in flow channel area than each third through hole21band each fourth through hole22b. Each second connecting through hole23bcommunicates with each third through hole21band each fourth through hole22b. In other words, each third through hole21band each fourth through hole22boverlap each second connecting through hole23bas seen in the thickness direction. Each third through hole21band each fourth through hole22bcommunicate with each other through each second connecting through hole23b. In other words, each third through hole21b, each second connecting through hole23b, and each fourth through hole22bcompose the second flow channel for making the third and fourth fluid chambers C3and C4communicate with each other therethrough. As shown inFIG.6, the flow channel structure2includes a plurality of first seal members24aand a plurality of second seal members24b. In the present preferred embodiment, the flow channel structure2includes a pair of first seal members24aand a pair of second seal members24b. Each first seal member24ais disposed along an inner wall surface defining each first connecting through hole23a. Each second seal member24bis disposed along an inner wall surface defining each second connecting through hole23b. The first and second seal members24aand24bare, for instance, O-rings. The first and second seal members24aand24bare axially interposed between the first and second plates21and22. As shown inFIGS.4and5, the flow channel structure2includes a third seal member24c. The third seal member24cextends along the outer peripheral surface of the second plate22in the circumferential direction. When described in detail, the second plate22is provided with a groove extending along the outer peripheral surface of the second tubular portion22din the circumferential direction; the third seal member24cis disposed in the groove. <Clutch Part> As shown inFIGS.1and2, the clutch part5is a multi-plate clutch. The clutch part5is disposed axially between the front cover11and the piston6. The clutch part5includes a plurality of clutch plates51aand51b. The plural clutch plates51aand51bare disposed axially between the front cover11and the piston6. The plural clutch plates51aand51bare composed of a plurality of first clutch plates51aand a plurality of second clutch plates51b. It should be noted that in the present preferred embodiment, the plural clutch plates51aand51bare composed of two first clutch plates51aand two second clutch plates51b. Each of the first and second clutch plates51aand51bhas an annular shape. The first clutch plates51aand the second clutch plates51bare alternately disposed in the axial direction. Each first clutch plate51ais provided with a plurality of teeth on the inner peripheral part thereof. The teeth of the first clutch plates51aare disposed in the grooves21eof the first plate21, respectively. Because of this, the first clutch plates51aare unitarily rotated with the flow channel structure2and the front cover11. Each of the first and second clutch plates51aand51bis provided with a friction facing fixed to either of the faces thereof. Each second clutch plate51bis provided with a plurality of teeth on the outer peripheral part thereof. <Piston> The piston6has an annular shape. The piston6is disposed to be axially movable on the outer peripheral surface of the flow channel structure2. When described in detail, the inner peripheral surface of the piston6is in contact with the outer peripheral surface of the second tubular portion22dof the second plate22. A gap between the inner peripheral surface of the piston6and the outer peripheral surface of the flow channel structure2is sealed by the third seal member24c. The piston6is disposed axially between the clutch part5and the chamber plate7. When the piston6is moved toward the clutch part5, the clutch part5is interposed between the piston6and the front cover11; accordingly, the clutch part5is turned to a torque transmission state. The piston6is provided with a groove extending on the outer peripheral surface thereof in the circumferential direction. Besides, a fifth seal member61, having an annular shape, is disposed in the groove of the piston6. <Chamber Plate> The chamber plate7is disposed axially between the turbine14and both the flow channel structure2and the piston6. The chamber plate7is axially opposed at the inner peripheral part thereof to the flow channel structure2, while being axially opposed at the outer peripheral part thereof to the piston6. The chamber plate7is fixed to the flow channel structure2. The chamber plate7is immovable in the axial direction. Besides, the chamber plate7is unitarily rotated with the flow channel structure2. The chamber plate7includes a body71, a fourth tubular portion72, and a fifth tubular portion73. The body71, the fourth tubular portion72, and the fifth tubular portion73compose a single plate. The body71has an annular shape. The fourth tubular portion72axially extends from the outer peripheral end of the body71. When described in detail, the fourth tubular portion72extends from the body71toward the front cover11. The fourth tubular portion72is disposed to cover the piston6from radially outside. In other words, the outer peripheral surface of the piston6is opposed to the inner peripheral surface of the fourth tubular portion72. A gap between the fourth tubular portion72and the piston6is sealed by the fifth seal member61. The fifth tubular portion73axially extends from the inner peripheral end of the body71. When described in detail, the fifth tubular portion73extends from the body71toward the turbine14. A sixth seal member74is disposed for sealing between the fifth tubular portion73and the turbine hub143. It should be noted that the fourth and fifth tubular portions72and73are formed by axially bending the outer peripheral part and the inner peripheral part of the chamber plate7by stamping or so forth. <Fluid Chambers> The first fluid chamber C1is defined by the flow channel structure2, the front cover11, and the turbine hub143. The first fluid chamber C1communicates with the first through holes21aof the flow channel structure2. The first fluid chamber C1communicates with a flow channel axially extending in the interior of the input shaft101. The hydraulic oil flows into the first fluid chamber C1through the flow channel in the input shaft10. The second fluid chamber C2is defined by the piston6, the chamber plate7, and the flow channel structure2. The second fluid chamber C2communicates with the second through holes22aof the flow channel structure2. The second fluid chamber C2does not overlap the first fluid chamber C1as seen in the thickness direction (axial direction). The second fluid chamber C2is sealed. Because of this, when the hydraulic oil is supplied to the interior of the second fluid chamber C2, the piston6is moved toward the clutch part5. The third fluid chamber C3is defined by the flow channel structure2, the front cover11, and the piston6. The third fluid chamber C3communicates with the third through holes21bof the flow channel structure2. The third fluid chamber C3accommodates the clutch part5in the interior thereof. The third fluid chamber C3communicates with a torus of the torque converter body12. The fourth fluid chamber C4is defined by the turbine hub143, the flow channel structure2, and the chamber plate7. The fourth fluid chamber C4communicates with the fourth through holes22bof the flow channel structure2. Besides, the fourth fluid chamber C4communicates with a flow channel produced between the stationary shaft105and the input shaft101through the sixth through holes143bprovided in the turbine hub143. When the lock-up device10is actuated, the hydraulic oil is supplied to the first fluid chamber C1through the flow channel in the input shaft101. The hydraulic oil, supplied to the first fluid chamber C1, flows to the second fluid chamber C2through the first flow channel in the flow channel structure2. When described in detail, the hydraulic oil flows from the first fluid chamber C1to the second fluid chamber C2through the first through holes21a, the first connecting through holes23a, and the second through holes22a. When the hydraulic oil is supplied to the second fluid chamber C2, the second fluid chamber C2is increased in hydraulic pressure, whereby the piston6is moved toward the clutch part5; consequently, the clutch part5is turned to the torque transmission state. On the other hand, the hydraulic oil, supplied to the fourth fluid chamber C4, flows to the third fluid chamber C3through the second flow channel in the flow channel structure2. When described in detail, the hydraulic oil flows from the fourth fluid chamber C4to the third fluid chamber C3through the fourth through holes22b, the second connecting through holes23b, and the third through holes21b. When the hydraulic oil is supplied to the third fluid chamber C3, the clutch part5inside the third fluid chamber C3can be cooled. It should be noted that the hydraulic oil flows from the third fluid chamber C3to the interior of the torus of the torque converter body12. When the torque transmission state of the clutch part5is released, the first fluid chamber C1is connected to a drain circuit. Accordingly, the hydraulic oil inside the second fluid chamber C2is discharged to the first fluid chamber C1through the first flow channel in the flow channel structure2, whereby the second fluid chamber C2is reduced in hydraulic pressure. As a result, the clutch part5is released from being pressed by the piston6, whereby the torque transmission state of the clutch part5is released. <Damper Part> FIG.7is a cross-sectional view of the damper part8. As shown inFIG.7, the damper part8attenuates vibration to be inputted thereto through the front cover11. The damper part8includes a first input plate81a, a second input plate81b, a plurality of inner torsion springs82, an intermediate plate83, a plurality of outer torsion springs84, and a driven plate85. The first input plate81ais fixed to the second input plate81bby at least one rivet or so forth, whereby the first and second input plates81aand81bare unitarily rotated with each other. The first input plate81ais disposed on the engine side of the second input plate81b. The first input plate81ais engaged with the second clutch plates51band is unitarily rotated therewith. When described in detail, the first input plate81aincludes a plurality of grooves extending in the axial direction. The grooves are disposed apart from each other at predetermined intervals in the circumferential direction. The teeth provided on the outer peripheral part of each second clutch plate51bare engaged with the grooves. Therefore, the second clutch plates51band the first and second input plates81aand81bare non-rotatable relative to each other but are axially movable relative to each other. The first input plate81aincludes a plurality of first window portions811adisposed apart from each other at intervals in the circumferential direction. The inner torsion springs82are disposed in the first window portions811a, respectively. Besides, a pair of walls of each first window portion811aof the first input plate81ais engaged with both ends of each inner torsion spring82. The second input plate81bincludes a plurality of second window portions811bdisposed apart from each other at intervals in the circumferential direction. The inner torsion springs82are disposed in the second window portions811b, respectively. Besides, a pair of walls of each second window portion811bis engaged with both ends of each inner torsion spring82. The plural inner torsion springs82are disposed in alignment in the circumferential direction. The inner torsion springs82are disposed in the first and second window portions811aand811bof the first and second input plates81aand81band third window portions83aof the intermediate plate83(to be described). The intermediate plate83is disposed axially between the first and second input plates81aand81b. The intermediate plate83is rotatable relative to the driven plate85and the first and second input plates81aand81b. The intermediate plate83is a member for making the inner torsion springs82and the outer torsion springs84act in series. The outer peripheral part of the intermediate plate83has a substantially tubular shape and is opened toward the turbine14. The outer peripheral part of the intermediate plate83holds the outer torsion springs84. Besides, the driven plate85extends through the opening of the outer peripheral part of the intermediate plate83. The intermediate plate83includes the plural third window portions83a. The plural third window portions83aare provided in the inner peripheral part of the intermediate plate83. The plural third window portions83aare disposed apart from each other at intervals in the circumferential direction. The third window portions83aare disposed in axial opposition to the first window portions811aand the second window portions811b, respectively. The inner torsion springs82are disposed in the third window portions83a, respectively. Besides, a pair of walls, circumferentially opposed to each other in each third window portion83a, is engaged with both ends of each inner torsion spring82. The intermediate plate83includes a plurality of first engaging portions83b. The first engaging portions83bare provided in the outer peripheral part of the intermediate plate83so as to be disposed apart from each other at intervals in the circumferential direction. The first engaging portions83bare engaged with the outer torsion springs84. When described in detail, each outer torsion spring84is disposed between adjacent two of the first engaging portions83b. The outer torsion springs84are disposed in alignment in the circumferential direction. Besides, the outer torsion springs84are disposed radially outside the clutch part5. The outer torsion springs84are held by the outer peripheral part of the intermediate plate83. The outer torsion springs84act in series with the inner torsion springs82through the intermediate plate83. The driven plate85is an annular disc member that is fixed to the turbine shell141. Besides, the driven plate85is rotatable relative to the intermediate plate83. The driven plate85includes at least one first stopper pawl85a, at least one second stopper pawl85b, and a plurality of second engaging portions85c. The at least one first stopper pawl85ais inserted into at least one cutout of the intermediate plate83. Accordingly, the intermediate plate83is restricted from rotating relative to the driven plate85at a predetermined angle or greater. The at least one second stopper pawl85bis inserted into at least one cutout of the second input plate81b. Accordingly, the first and second input plates81aand81bare restricted from rotating relative to the driven plate85at a predetermined angle or greater. The second engaging portions85care engaged with the outer torsion springs84. The plural second engaging portions85care disposed apart from each other at predetermined intervals in the circumferential direction. Each outer torsion spring84is disposed between each circumferentially adjacent pair of second engaging portions85c. The circumferentially adjacent pair of second engaging portions85cis engaged with both ends of each outer torsion spring84. [Action] First, an action of the torque converter body12will be explained. During rotation of the front cover11and the impeller13, the hydraulic oil flows from the impeller13to the turbine14and further flows to the impeller13through the stator15. Accordingly, a torque is transmitted from the impeller13to the turbine14through the hydraulic oil. The torque transmitted to the turbine14is then transmitted to the input shaft101of the transmission through the turbine hub143. It should be noted that during running of the engine, the hydraulic oil constantly flows into the fourth fluid chamber C4through the sixth through holes143bthe turbine hub143and further flows into the third fluid chamber C3through the second flow channel in the flow channel structure2so as to be supplied to the clutch part5and the impeller3. When the speed ratio of the torque converter100increases and the rotation of the input shaft101reaches a predetermined speed, the hydraulic oil is supplied to the first fluid chamber C1and is further supplied to the second fluid chamber C2through the first flow channel in the flow channel structure2. The hydraulic oil in the second fluid chamber C2becomes greater in pressure than that to be supplied to the third fluid chamber C3. Accordingly, the piston6is moved toward the front cover11. As a result, the piston6presses the first and second clutch plates51aand51btoward the front cover11, whereby a lock-up state is turned on (a clutch-on state is made). In the clutch-on state described above, a torque is transmitted from the front cover11to the turbine hub143through the lock-up device10. Specifically, the torque inputted to the front cover11is transmitted through a path of “the clutch part5→the first and second input plates81aand81b→the inner torsion springs82→the intermediate plate83→the outer torsion springs84→the driven plate85” and is then outputted to the turbine hub143. Here, the lock-up device10, for which the clutch-on state is made, transmits a torque as described above, and simultaneously, attenuates fluctuations of a torque inputted thereto through the front cover11. Specifically, when torsional vibrations occur in the lock-up device10, the inner torsion springs82and the outer torsion springs84are compressed in series between the first and second input plates81aand81band the driven plate85. Torque fluctuations, occurring with torsional vibrations, are thus attenuated by the actuation of the inner torsion springs82and the outer torsion springs84. It should be noted that when the lock-up state is turned off (i.e., a clutch-off state is made), the first fluid chamber C1is connected to the drain circuit. Accordingly, the hydraulic oil in the second fluid chamber C2is discharged through the first flow channel in the flow channel structure2and the first fluid chamber C1. Because of this, the second fluid chamber C2becomes lower in hydraulic pressure than the third fluid chamber C3, whereby the piston6is moved toward the turbine14. As a result, the piston6is released from pressing the clutch part5. Thus, the clutch-off state is made. Other Preferred Embodiments The present invention is not limited to the preferred embodiment described above, and as described below, a variety of changes or modifications can be made without departing from the scope of the present invention. It should be noted that modifications to be described are simultaneously applicable. (a) For example, in the preferred embodiment described above, the first plate21is provided as a single plate. However, the first plate21can be composed of a plurality of plates. In this case, the first and third through holes21aand21bpenetrate the plural plates. It should be noted that similarly to the first plate21, each of the second and third plates22and23can be composed of a plurality of plates. (b) In the preferred embodiment described above, the flow channel structure2includes the first and second flow channels. However, the configuration of the flow channel structure2is not limited to this. For example, the flow channel structure2can include only the first flow channel without including the second flow channel. In this case, the first plate21is not provided with any third through holes21b; the second plate22is not provided with any fourth through holes22b; the third plate23is not provided with any second connecting through holes23b. (c) The first and third through holes21aand21b, provided in the first plate21, are not limited in number to those in the preferred embodiment described above. For example, the number of the first through holes21aand that of the third through holes21bcan set to one, respectively. Likewise, the second and fourth through holes22aand22b, provided in the second plate22, are not limited in number to those in the preferred embodiment described above. Still likewise, the first and second connecting through holes23aand23b, provided in the third plate23, are not limited in number to those in the preferred embodiment described above. (d) In the preferred embodiment described above, the flow channel structure is applied to the lock-up device10of the torque converter100. However, the flow channel structure is similarly applicable to another type of device. For example, as shown inFIGS.8and9, a flow channel structure20is usable as a manifold block. The flow channel structure20includes a first plate201, a second plate202, and a third plate203. The first plate201includes a first through hole201a. The first through hole201aopens to the first fluid chamber C1. It should be noted that the first fluid chamber C1is, for instance, a plumbing pipe. The second plate202includes a second through hole202aand a fifth through hole202b. The second through hole202aopens to the second fluid chamber C2, whereas the fifth through hole202bopens to a fifth fluid chamber C5. In other words, the second and fifth through holes202aand202bopen to fluid chambers that are different from each other. It should be noted that the second and fifth fluid chambers C2and C5are, for instance, plumbing pipes. The third plate203includes a first connecting through hole203a. The first connecting through hole203acommunicates with the first, second, and fifth through holes201a,202a, and202b. A first seal member204ais disposed along the inner wall surface defining the first connecting through hole203a. The flow channel structure20includes a first flow channel branched into two. When described in detail, the fluid, flowing from the first fluid chamber C1, is supplied to the first connecting through hole203athrough the first through hole201a. Then, the fluid is supplied from the first connecting through hole203athrough the second through hole202ato the second fluid chamber C2and is simultaneously supplied from the first connecting through hole203athrough the fifth through hole202bto the fifth fluid chamber C5. It should be noted that the fluid can reversely flow through the first flow channel. Specifically, the fluid is supplied from the second and fifth fluid chambers C2and C5through the second and fifth through holes202aand202cto the first connecting through hole203a. Then, the fluid flowing from the second fluid chamber C2and that flowing from the fifth fluid chamber C5can be collectively discharged to the first fluid chamber C1through the first through hole201a. In this modification, the second plate202includes two through holes composed of the second and fifth through holes202aand202c, but alternatively, can include three or more through holes. The three or more through holes are herein opened to fluid chambers that are different from each other. With the configuration, the first flow channel in the flow channel structure20can be branched into three or more. (e) Gaskets can be used instead of the first and second seal members24aand24b. When described in detail, gasket seals can be inserted between the first and third plates21and23and between the second and third plates22and23, respectively. REFERENCE SIGNS LIST 2: Flow channel structure21: First plate21a: First through hole21b: Third through hole22: Second plate22a: Second through hole22b: Fourth through hole23: Third plate23a: First connecting through hole23b: Second connecting through hole24a: First seal member24b: Second seal member5: Clutch part6: Piston7: Chamber plate10: Lock-up device11: Front cover14: Turbine143: Turbine hubC1: First fluid chamberC2: Second fluid chamberC3: Third fluid chamberC4: Fourth fluid chamberC5: Fifth fluid chamber | 37,063 |
11859703 | MODE FOR CARRYING OUT THE INVENTION Hereinafter, a power transmission device for a vehicle according to each of embodiments in the present invention will be in detail explained with references to the accompanying drawings, by taking a case of being applied to a wheel loader as an example. Each step in flow charts shown inFIGS.5and6is indicated as notation “S” (for example, step1is indicated as “S1”). FIGS.1to7show a power transmission device for a vehicle according to embodiments of the present invention. InFIG.1, a wheel loader1is representative example of a vehicle (working vehicle). The wheel loader1is configured as an articulate-type working vehicle in which a front vehicle body3provided with left and right front wheels2is connected to a rear vehicle body5provided with left and right rear wheels4to be capable of bending in the left-and-right direction. That is, the front vehicle body3and the rear vehicle body5configures a vehicle body of the wheel loader1. A center hinge6and a steering cylinder (not shown) are arranged between the front vehicle body3and the rear vehicle body5. The front vehicle body3and the rear vehicle body5bend in the left-and-right direction, with the center hinge6positioned centrally by extending and contracting the steering cylinder. This allows to perform the steering of the wheel loader at the traveling. A working mechanism7called also a cargo handling machine is disposed in the front vehicle body3of the wheel loader1to be capable of tilting/lifting thereto. The working mechanism7comprises a loader bucket7A. On the other hand, a cab8that defines therein an operating room, an engine9, a hydraulic pump10, a transmission21as a speed-changing device and the like are arranged in the rear vehicle body5of the wheel loader1. As shown inFIG.7, an operator's seat8A, a steering wheel8B, an accelerator pedal8C, a brake pedal8D, an FNR lever8E, a switch for parking brake and the like are provided in the cab8. An operator operates the FNR lever8E to switch between forward and retreat of the wheel loader1and to switch a shift stage. The operator switches the FNR lever8E to a forward position (F) to advance the wheel loader1. The operator switches the FNR lever8E to a retreat position (R) to retreat the wheel loader1. The operator switches the FNR lever8E to a neutral position (N) to continue the stop of the wheel loader1without allowing it to travel. The operator rotates the FNR lever8E around a lever shaft when switching the shift stages. The engine9is a power source (prime mover) for the wheel loader1. The power source (prime mover) can be configured one unit of the engine9as an internal combustion engine, besides may be configured with, for example, an engine and an electric motor or an electric motor unit. The hydraulic pump10is connected to the engine9. The hydraulic pump10is a hydraulic power source for operating the working mechanism7. A front axle12extending in the left-and-right direction is disposed under the front vehicle body3. The left and right front wheels2are attached in both ends of the front axle12. On the other hand, a rear axle13extending in the left-and-right direction is disposed under the rear vehicle body5. The left and right rear wheels4are mounted on both ends of the rear axle13. The front axle12is connected to a transmission21via a front propeller shaft14. The rear axle13is connected to the transmission21via a rear propeller shaft15. The transmission21reduces the rotation of the engine9to be transmitted to the front propeller shaft14and the rear propeller shaft15. That is, the power from the engine9is transmitted to the transmission21connected to the engine9. The power from the engine9is transmitted from front and rear output shafts23A,23B of the transmission21to the front axle12and the rear axle13via the front propeller shaft14and the rear propeller shaft15after the transmission21controls the rotational speed and the rotating direction. That is, as shown inFIG.2, the transmission21comprises an input shaft22connected to the engine9, a front side output shaft23A connected to the front propeller shaft14, and a rear side output shaft23B connected to the rear propeller shaft15. The transmission21performs the switching of forward rotation and reverse rotation between the input shaft22and the output shafts23A,23B by switching a power transmission path in the transmission. Next, an explanation will be made of the transmission21according to an embodiment by referring toFIGS.3to6, in addition toFIGS.1and2.FIG.3schematically shows the output shaft23of the transmission21as a common output shaft23(=output shafts23A,23B) transmitting the power to both the front axle12and the rear axle13to avoid complexity of graphic configuration. That is, inFIG.3, a configuration of dividing the power between the front side output shaft23A and the rear side output shaft23B via a center differential mechanism and the like, for example, is omitted. The transmission21as a power transmitting device for a vehicle comprises an input shaft22, an output shaft23, a planetary continuously variable transmission mechanism31, and a controller43. Moreover, the transmission21comprises a transmission mechanism25as a stepped transmission mechanism, a direct connecting mechanism27, a transmission shaft28, and an idler gear29as an idler element. The input shaft22is rotated by the engine9, which is a prime mover mounted on a vehicle. That is, (a drive shaft of) the engine9is connected to the input shaft22. On the other hand, the output shaft23outputs the rotation to the front axle12and/or the rear axle13, which are traveling devices of the vehicle. That is, the power of the engine9is outputted from the output shaft23via the transmission21as a speed-changing device. The output shaft23outputs the rotation to the front wheel2and/or the rear wheel4via the front axle12and/or the rear axle13of the wheel loader1. That is, the power of the output shaft23is transmitted to the front axle12and/or the rear axle13, which are traveling devices. The input power from the input shaft22to the transmission21is transmitted to the idler gear29via the planetary continuously variable transmission mechanism31or the direct connecting mechanism27. The power transmitted to the idler gear29is outputted from the output shaft23through the transmission mechanism25. The planetary continuously variable transmission mechanism31is disposed between the input shaft22and the output shaft23. The planetary continuously variable transmission mechanism31changes the speed of a rotation on the input shaft22-side and transmits the power to the output shaft23-side. An input side of the planetary continuously variable transmission mechanism31is connected to the input shaft22provided with the input side gear27A of the direct connecting mechanism27. An output side of the planetary continuously variable transmission mechanism31is connected to the transmission shaft28provided with the idler gear29. The transmission mechanism25is disposed between the input shaft22and the output shaft23in series with the planetary continuously variable transmission mechanism31and the direct connecting mechanism27. The transmission mechanism25also changes the speed of a rotation on the input shaft22-side and transmits the power to the output shaft23-side. In this case, the transmission mechanism25is disposed between an intermediate gear26meshing with the idler gear29and the output shaft23. That is, an input side of the transmission mechanism25is connected to the intermediate gear26. An output side of the transmission mechanism25is connected to the output shaft23. The transmission mechanism25is configured as a step-shifting transmission mechanism, for example. The transmission mechanism25is configured to comprise a plurality of transmission shafts, a plurality of gears, and a plurality of clutches, for example. In this case, the transmission mechanism25can be configured as a transmission mechanism (DCT: Dual Clutch Transmission) including, for example, a forward clutch25A to be connected when the wheel loader1is advanced and a reverse clutch25B to be connected when the wheel loader1is retreated. For example, the forward clutch25A is connected to the output shaft23when the FNR lever8E of the cab8is at a forward position (F). The reverse clutch25B is connected to the output shaft23when the FNR lever8E of the cab8is at a retreat position (R). Such a transmission mechanism25may be omitted. That is, the intermediate gear26and the output shaft23may directly be connected not via the transmission mechanism25. The direct connecting mechanism27transmits a rotation on the input shaft22-side to the output shaft23-side by bypassing the planetary continuously variable transmission mechanism31. That is, the direct connecting mechanism27directly transmits the rotation of the input shaft22to the transmission mechanism25not via the planetary continuously variable transmission mechanism31. The direct connecting mechanism27comprises an input side gear27A connected to the input shaft22, an output side gear27B meshing with the input side gear27A, a rotational shaft27B1disposed coaxially with the transmission shaft28, and a direct connecting clutch30as a third clutch. The rotation of the output side gear27B is transmitted to the transmission shaft28via the direct connecting clutch30. In an embodiment, the input side gear27A is disposed on the input shaft22. The output side gear27B is disposed on the rotational shaft27B1disposed coaxially with the transmission shaft28. The direct connecting clutch30is disposed coaxially between the transmission shaft28and the rotational shaft27B1. The transmission shaft28corresponds to an output shaft of the direct connecting mechanism27and an output shaft of the planetary continuously variable transmission mechanism31. In this case, the transmission shaft28is disposed coaxially with the rotational shaft27B1of the direct connecting mechanism27and a motor shaft39of the planetary continuously variable transmission mechanism31. The transmission shaft28is connected to the rotational shaft27B1of the direct connecting mechanism27via the direct connecting clutch30. In a case where the direct connecting clutch30is connected, the rotation of the output side gear27B of the direct connecting mechanism is transmitted to the transmission shaft28. The transmission shaft28is connected to the hydraulic motor38of the planetary continuously variable transmission mechanism31via the motor side clutch40. In a case where the motor side clutch40is connected, the rotation of the hydraulic motor38of the planetary continuously variable transmission mechanism31is transmitted to the transmission shaft28. Moreover, the transmission shaft28is connected to the planetary output gear32B of the planetary continuously variable transmission mechanism31via the idler gear29. The idler gear29as an idler element is disposed on the transmission shaft28. The idler gear29mechanically connects the output side of the planetary continuously variable transmission mechanism31and the output side of the direct connecting mechanism27. The idler gear29meshes with the planetary output gear32B of the planetary gear mechanism32which configures the planetary continuously variable transmission mechanism31. The idler gear29meshes with the intermediate gear26. The rotation of the idler gear29is transmitted to the transmission mechanism25via the intermediate gear26. That is, the input power from the input shaft22of the transmission21is transmitted to the idler gear29via the planetary continuously variable transmission mechanism31or the direct connecting mechanism27. The power transmitted to the idler gear29is outputted from the output shaft23via the transmission mechanism25. The direct connecting clutch30is provided within the direct connecting mechanism27that is disposed between the input shaft22and the idler gear29. That is, the direct connecting clutch30is disposed between the rotational shaft27B1of the output side gear27B within the direct connecting mechanism27and the transmission shaft28provided with the idler gear29. The direct connecting clutch30is capable of switching between a “connecting state (fastening state)” where the transmission of a rotation (torque, rotational force, power) is performed between the direct connecting mechanism27(rotational shaft27B1) and the idler gear29(transmission shaft28) and a “blocking state (releasing state)” where the transmission of the rotation transmission is cut off. In a case where the direct connecting clutch30is in the connecting state, the rotation of the output side gear27B (rotational shaft27B1) of the direct connecting mechanism27is transmitted to the idler gear29via the transmission shaft28. In a case where the direct connecting clutch30is in the releasing state, the rotation of the output side gear27B (rotational shaft27B1) is not transmitted to the transmission shaft28. The connection and release of the direct connecting clutch30are controlled based upon a command from the controller43(command signal C1). Next, an explanation will be made of the planetary continuously variable transmission mechanism31. The planetary continuously variable transmission mechanism31comprises the planetary gear mechanism32, a pump side clutch33as a first clutch, a hydrostatic continuously variable transmission mechanism34, and the motor side clutch40as a second clutch, and a controller43. The hydrostatic continuously variable transmission mechanism34comprises a pump shaft35, a hydraulic pump36, a pair of main lines37A,37B, the hydraulic motor38, the motor shaft39, an electromagnetic on-off valve41, and a connecting line42. The planetary gear mechanism32is connected to the input shaft22-side. Specifically, the planetary gear mechanism32is connected to the input shaft22. The planetary gear mechanism32is configured by one unit or step-shifting planetary gear device (not shown), a planetary output shaft32A, and a planetary output gear32B. The planetary gear device comprises a sun gear, a ring gear, and a carrier supporting a planetary gear meshing with the sun gear and the ring gear, for example. For example, the input shaft22is connected to any member(s) of the sun gear, the ring gear and the carrier. The planetary output shaft32A is connected to any member(s) of the sun gear, the ring gear and the carrier to which the input shaft22is not connected. The planetary output gear32B is connected to the remaining member(s) of the Sun gear, the ring gear and the carrier. The planetary output shaft32A is connected to the pump shaft35of the hydrostatic continuously variable transmission mechanism34(hydraulic pump36) via the pump side clutch33. The rotation of the planetary output shaft32A is transmitted to the pump shaft35of the hydrostatic continuously variable transmission mechanism34(hydraulic pump36) via the pump side clutch33. The planetary output gear32B meshes with the idler gear29. The rotation of the planetary output gear32B is transmitted to the idler gear29. The pump side clutch33is disposed on the output side of the planetary gear mechanism32. That is, the pump side clutch33is disposed between the planetary output shaft32A of the planetary gear mechanism32and the pump shaft35(hydraulic pump36) of the hydrostatic continuously variable transmission mechanism34. The pump side clutch33is capable of switching between a “connecting state (fastening state)” where the transmission of a rotation is performed between the planetary gear mechanism32(planetary output shaft32A) and the hydraulic pump36(pump shaft35) of the hydrostatic continuously variable transmission mechanism34and a “blocking state (releasing state)” where the transmission of the rotation transmission is cut off. The rotation of the planetary output shaft32A of the planetary gear mechanism32is transmitted to the hydraulic pump36via the pump shaft35of the hydrostatic continuously variable transmission mechanism34when the pump side clutch33is in the connecting state. The rotation of the planetary output shaft32A is not transmitted to the pump shaft35when the pump side clutch33is in the releasing state. The connection and release of the pump side clutch33are controlled based upon a command from the controller43(command signal C2). The pump shaft35of the hydrostatic continuously variable transmission mechanism34corresponds to an input shaft of the hydrostatic continuously variable transmission mechanism34. The pump shaft35is connected to a rotational shaft (input shaft) of the hydraulic pump36. Alternatively, the pump shaft35corresponds to the rotational shaft (input shaft) of the hydraulic pump36. The hydraulic pump36is connected to the output side of the planetary gear mechanism32, or the planetary output shaft32A of the planetary gear mechanism32via the pump side clutch33. The hydraulic pump36circulates pressurized oil in the pair of main lines37A,37B by rotatively driving the pump shaft35. The hydraulic pump36is configured by a variable displacement swash plate type of a hydraulic pump, for example. The hydraulic pump36includes a regulator36A controlling the pump capacity. The regulator36A of the hydraulic pump36is variably controlled based upon a command from the controller43(command signal WP). The pair of main lines37A,37B connect a pair of supply and discharge ports of the hydraulic pump36and a pair of supply and discharge ports of the hydraulic motor38. The hydraulic motor38is connected to the hydraulic pump36via the pair of main lines37A,37B. The hydraulic motor38is rotated by pressurized oil fed from the hydraulic pump36. The hydraulic motor38is configured by a variable displacement swash plate type of a hydraulic motor, for example. The hydraulic motor38includes a regulator38A controlling the motor capacity. The regulator38A of the hydraulic motor38is variably controlled based upon a command from the controller43(command signal WM). The motor shaft39of the hydrostatic continuously variable transmission mechanism34corresponds to an output shaft of the hydrostatic continuously variable transmission mechanism34. The motor shaft39is connected to a rotational shaft (output shaft) of the hydraulic motor38. Alternatively, the motor shaft39corresponds to the rotational shaft (output shaft) of the hydraulic motor38. The motor side clutch40is disposed between the hydraulic motor38and the output shaft23-side. That is, the motor side clutch40is disposed between the hydraulic motor38and the idler gear29. As a result, the hydraulic motor38is connected to the idler gear29via the motor side clutch40. In this case, the motor side clutch40is disposed between the motor shaft39of the hydrostatic continuously variable transmission mechanism34and the transmission shaft28provided with the idler gear29. The motor side clutch40is capable of switching between a “connecting state (fastening state)” where transmission of a rotation is performed between the idler gear29(transmission shaft28) and the hydraulic motor38(motor shaft39) of the hydrostatic continuously variable transmission mechanism34and a “blocking state (releasing state)” where transmission of the rotation is cut off. The rotation of the motor shaft39of the hydrostatic continuously variable transmission mechanism34(=rotation of the hydraulic motor38) is transmitted to the idler gear29via the transmission shaft28when the motor side clutch40is in the connecting state. The rotation of the motor shaft39is not transmitted to the transmission shaft28when the motor side clutch40is in the releasing state. The connection and release of the motor side clutch40are controlled based upon a command from the controller43(command signal C3). In an embodiment, the input power from the input shaft22of the transmission21can optionally be transmitted to the transmission mechanism25via the planetary continuously variable transmission mechanism31, or transmitted to the transmission mechanism25via the direct connecting mechanism27. As a result, if a planetary continuously variable transmission mechanism31is suitably operated, such a planetary continuously variable transmission mechanism31can be used. On the other hand, in a case where the direct connecting mechanism27suitably changes the speed, the power can be transmitted via the direct connecting mechanism27. The direct connecting clutch30is released to connect the pump side clutch33and the motor side clutch40in a case where the power is transmitted to the transmission mechanism25via the planetary continuously variable transmission mechanism31. In this case, the power may be distributed to the transmission mechanism25-side via the planetary gear mechanism32and the hydrostatic continuously variable transmission mechanism34, or the power may be transmitted to the transmission mechanism25-side without transmitting the power to the hydrostatic continuously variable transmission mechanism34by setting the rotational speed of the hydraulic pump36at 0. The state of releasing the direct connecting clutch30, connecting the pump side clutch33and the motor side clutch40, transmitting no power to the hydrostatic continuously variable transmission mechanism34but transmitting the power to the transmission mechanism25-side is referred to as “internal direct connection”. On the other hand, the state of releasing the direct connecting clutch30, connecting the pump side clutch33and the motor side clutch40, transmitting the power to the hydrostatic continuously variable transmission mechanism34and transmitting the power to the transmission mechanism25-side is referred to as the state of continuously variable transmission. During internal direct connection, the tilting (discharged capacity) of the hydraulic pump36is increased above a predetermined value and the tilting of the hydraulic motor38is set in a neutral state to allow for braking in the hydrostatic continuously variable transmission mechanism34and setting the rotational speed of the hydraulic pump36at 0. As a result, the power from the engine9is transmitted to the transmission mechanism25. In fact, the rotational speed of the hydraulic pump36never reaches 0 because the hydraulic pump36and the hydraulic motor38are leaking oil, but most of the power from the engine9can be distributed to the transmission mechanism25. On the other hand, in a case where the power is transmitted to the transmission mechanism25via the direct connecting mechanism27, the direct connecting clutch30is connected to release the pump side clutch33and the motor side clutch40. Herein, the direct connecting clutch30, the pump side clutch33and the motor side clutch40may each be adopted to a wet multiple-disk clutch or a synchromesh mechanism clutch. The wet multiple-disk clutch presses friction plates to generate a transmission torque. The synchromesh mechanism clutch allows small gears on end surfaces of hubs fixed on the shaft to mesh with each other to transmit the torque. The synchromesh mechanism clutch is smaller in size and larger in transmission torque capacity than the friction plate clutch because small gears are allowed to mesh with each other to transmit the torque. Moreover, with a small drag torque in the synchromesh mechanism clutch upon release of meshing, heat generation by dragging is smaller than in the wet multiple-disk clutch. Therefore, in an embodiment, the pump side clutch33and the motor side clutch40are each an engagement clutch transmitting the rotation by meshing with a pawl portion, or a synchromesh mechanism clutch to reduce transmission torque loss. The direct connecting clutch30is a wet multiple-disk clutch. However, in a case where the pump side clutch33and the motor side clutch40are each a synchromesh mechanism clutch, it is difficult to connect and release the pump side clutch33and the motor side clutch40if the loads on the hydraulic pump36and the hydraulic motor38of the hydrostatic continuously variable transmission mechanism34are not reduced. Therefore, in an embodiment, the hydrostatic continuously variable transmission mechanism34comprises an electromagnetic on-off valve41as a communication valve. That is, the pair of main lines37A,37B of the hydrostatic continuously variable transmission mechanism34are connected by the connecting line42. Herein, the electromagnetic on-off valve41is provided on the way of the connecting line42. As a result, the electromagnetic on-off valve41capable of switching between a communicating state and a blocking state between the pair of main lines37A,37B is provided between the pair of main lines37A,37B. The electromagnetic on-off valve41is capable of switching between an open position (A) corresponding to the communicating state and a closed position (B) corresponding to the blocking state. Switching of the electromagnetic on-off valve41is controlled based upon a command (command signal W) from the controller43. The electromagnetic on-off valve41is at the closed position (B) cutting off the pair of main lines37A,37B in the state of power transmission through the planetary continuously variable transmission mechanism31. On the other hand, the electromagnetic on-off valve41is switched to the open position (A) communicating the pair of main lines37A,37B when performing the power transmission path switched between the planetary continuously variable transmission mechanism31and the direct connecting mechanism27. At this time, the pump side clutch33and the motor side clutch40are connected and released in a state of cutting off power transmission by hydraulic power in the hydraulic circuit of the planetary continuously variable transmission mechanism31in a short period of time by communicating the pair of main lines37A,37B. As a result, the power transmission is capable of switching from the planetary continuously variable transmission mechanism31to the direct connecting mechanism27and from the direct connecting mechanism27to the planetary continuously variable transmission mechanism31. Next, consideration will be made of a neutral state, that is, the neutral state of preventing transmission of the power from the engine9as a prime mover to the front axle12and/or the rear axle13as traveling devices via the output shaft23of the transmission21. The neutral state is required in a case where the wheel loader1is allowed to stop with the engine9being operated (rotated). Herein, the neutral state corresponds to a state of “cutting off” or “restricting” transmission of the power from the engine9to the front axle12and/or the rear axle13(hereafter also referred to as “traveling devices12,13”). The state of “cutting off” transmission of the power from the engine9to the traveling devices12,13corresponds to a state of switching the FNR lever8E, for example, to the neutral position (N) and releasing the forward clutch25A and the reverse clutch25B of the transmission mechanism25. The state of “restricting” transmission of the power from the engine9to the traveling devices12,13corresponds to a state of switching the FNR lever8E, for example, to the forward position (F) or the retreat position (R) and connecting the forward clutch25A or the reverse clutch25B of the transmission mechanism25, but no intention of an operator to drive the vehicle. The state of no intention of the operator to drive the vehicle corresponds to the state of, for example, a vehicle speed of V1 or less (V1: 0 to 1 km/h, substantially 0 km/h) and an acceleration instruction of 0 (depression of accelerator pedal8C is 0). More specifically, the state corresponds to the state of, for example, switching the FNR lever8E to the forward position (F) or the retreat position (R), but stopping the wheel loader1and the operator's depressing of the brake pedal8D. In such a neutral state, that is, in a state where both the pump side clutch33and the motor side clutch40are connected when the power form the engine9is in the state of preventing (cutting off or restricting) from being transmitted to the traveling devices12,13, for example, the hydraulic pump36may remain in rotation, resulting in a large energy loss. Therefore, in an embodiment, at least one clutch33(40) of the pump side clutch33and the motor side clutch40is released in the neutral state. More specifically, in the neutral state, both the pump side clutch33and the motor side clutch40are released. As a result, energy loss by rotation of the hydraulic pump36in the neutral state can be reduced. In addition to that, in an embodiment, in the neutral state, the electromagnetic on-off valve41is switched from the closed position (B) to the open position (A). That is, the electromagnetic on-off valve41is at the closed position (B) when the planetary continuously variable transmission mechanism31is on the power transmission path. In other words, the electromagnetic on-off valve41is at the closed position (B) in the traveling state capable of transmitting the power from the engine9to the traveling devices12,13via the planetary continuously variable transmission mechanism31and the output shaft23. On the other hand, in the neutral state, the electromagnetic on-off valve41is switched from the closed position (B) to the open position (A). That is, in the neutral state, the electromagnetic on-off valve41is at the open position (A). Therefore, the hydraulic power transmission in the hydraulic circuit of the planetary continuously variable transmission mechanism31can be cut off by communicating the pair of main lines37A,37B and from this aspect, the energy loss in the neutral state can be reduced. Moreover, in the state of cutting off power transmission, the pump side clutch33and the motor side clutch40can be released. As a result, this also allows stable release of the pump side clutch33and the motor side clutch40. Furthermore, in an embodiment, after the tilting of the hydraulic pump36is minimized, the pump side clutch33and the motor side clutch40are released when the controller43switches from the traveling state to the neutral state. As a result, this allows smooth release of the pump side clutch33and the motor side clutch40in the state of reducing the load on the hydraulic pump36. That is, in an embodiment, the pump side clutch33and the motor side clutch40are released when the controller43switches from the traveling state to the neutral state. In addition, the electromagnetic on-off valve41is switched from the closed position (B) to the open position (A) when the controller43switches from the traveling state to the neutral state. Next, an explanation will be made of the controller43of the transmission21with reference toFIGS.3and4. Herein,FIG.4is block diagram showing the controller43in detail. An input side of the controller43is connected to the first speed detector44, the second speed detector45, the first pressure detector46, the second pressure detector47, and the third pressure detector48. An output side of the controller43is connected to the electromagnetic on-off valve41, the direct connecting clutch30, the pump side clutch33, the motor side clutch40, the regulator36A of the hydraulic pump36of the planetary continuously variable transmission mechanism31, and the regulator38A of the hydraulic motor38of the planetary continuously variable transmission mechanism31. The controller43is configured to comprise a microcomputer including a central processing unit (CPU), a memory and the like and the memory stores a processing program for performing an after-mentioned processing flow shown inFIGS.5and6, that is, a processing program and the like used in processing a switching control of connection and release of the pump side clutch33and the motor side clutch40. The first speed detector44is disposed on the input shaft22of the transmission21. The first speed detector44is a rotation detection sensor detecting the rotational speed and the rotating direction of the input shaft22. The rotational speed of the input shaft22corresponds to the rotational speed of the engine9(hereafter referred to as “engine rotational speed Vin”). The first speed detector44outputs a detection signal corresponding to the engine rotational speed Vinto the controller43. The second speed detector45is disposed on the output shaft23of the transmission21. The second speed detector45is a rotation detection sensor detecting the rotational speed of the output shaft23(hereafter referred to as “output rotational speed Vout”) and the rotating direction. The output rotational speed Voutcorresponds to the vehicle speed. The second speed detector45outputs a detection signal corresponding to the output rotational speed Voutand the rotating direction to the controller43. The first pressure detector46is disposed in one main line37A. The first pressure detector46is a pressure sensor detecting the fluid pressure (pressure) of the one main line37A. The first pressure detector46outputs a detection signal corresponding to the fluid pressure PAof the one main line37A to the controller43. The second pressure detector47is provided in the other main line37B. The second pressure detector47is a pressure sensor detecting the fluid pressure (pressure) of the other main line37B. The second pressure detector47outputs a detection signal corresponding to the fluid pressure PBof the other main line37B to the controller43. The third pressure detector48is disposed on the direct connecting clutch30. The third pressure detector48is a pressure sensor detecting the clutching pressure (pressure) of the direct connecting clutch30. The third pressure detector48outputs a detection signal corresponding to the clutch pressure PCof the direct connecting clutch30to the controller43. The controller43controls connection and release of the direct connecting clutch30, the pump side clutch33and the motor side clutch40. In a case where the power is transmitted to the transmission mechanism25via the direct connecting mechanism27, the controller43connects the direct connecting clutch30to release the pump side clutch33and the motor side clutch40. In this case, for example, corresponds to a high-speed mode capable of allowing the wheel loader1to travel at a high speed. In a case where the power is transmitted to the transmission mechanism25via the planetary continuously variable transmission mechanism31, the controller43releases the direct connection clutch30to connect the pump side clutch33and the motor side clutch40. In this case, for example, corresponds to a low-speed mode capable of allowing the wheel loader1to start or travel at a low speed. The controller43releases the direct connecting clutch30and releases both the pump side clutch33and the motor side clutch40in a neutral state. The controller43controls communication and blockade of the electromagnetic on-off valve41, in addition to the direct connecting clutch30, the pump side clutch33and the motor side clutch40. Herein, the state of releasing the direct connecting clutch30and connecting both the pump side clutch33and the motor side clutch40, that is, the state capable of transmitting the power to the traveling devices12,13via the planetary continuously variable transmission mechanism31and the output shaft23is defined as a first state (traveling state). On the other hand, the state of releasing the direct connecting clutch30and releasing both the pump side clutch33and the motor side clutch40, that is, the state of cutting off or restricting transmission of the power to the traveling devices12,13via the output shaft23is defined as a second state (neutral state). In this case, when the controller43switches from the first state to the second state, the controller43releases the pump side clutch33and the motor side clutch40after the controller43switches the electromagnetic on-off valve41from the closed position (B) to the open position (A). On the other hand, when the controller43switches from the second state to the first state, the controller43switches the electromagnetic on-off valve41from the open position (A) to the closed position (B) after the controller43connects the pump side clutch33and the motor side clutch40. That is, the controller43releases the pump side clutch33and the motor side clutch40when the controller43switches from the first state to the second state. Moreover, the controller43switches the electromagnetic on-off valve41from the closed position (B) to the open position (A) when the controller43switches from the first state to the second state. In addition, the controller43switches the electromagnetic on-off valve41based upon the detection values of the first pressure detector46and the second pressure detector47. The first pressure detector46and the second pressure detector47correspond to pressure detectors detecting the pressure differences of the pair of main lines37A,37B. The controller43switches the electromagnetic on-off valve41from the closed position (B) to the open position (A) when the detection values of the first pressure detector46and the second pressure detector47are a threshold value or less. More specifically, the controller43switches the electromagnetic on-off valve41from the closed position (B) to the open position (A) when a difference in the detection value between the first pressure detector46and the second pressure detector47, that is, a pressure difference (differential pressure) between the pair of main lines37A,37B is a threshold value or less. The differential pressure may be detected using a differential pressure gauge (differential pressure detector) directly detecting the differential pressures. Moreover, the threshold value of the differential pressure can be determined such that the electromagnetic on-off valve41is switched from the closed position (B) to the open position (A) to restrict pressure variations, for example. The controller43controls the tilting of the hydraulic pump36and the hydraulic motor38of the hydrostatic continuously variable transmission mechanism34, in addition to the direct connecting clutch30, the pump side clutch33and the motor side clutch40(that is, adjusts the pump capacity and the motor capacity). That is, the controller43controls the regulator36A of the hydraulic pump36and the regulator38A of the hydraulic motor38. In this case, when the controller43switches from a traveling state to a neutral state, the controller43releases the pump side clutch33and the motor side clutch40after minimizing the tilting of the hydraulic pump36. As shown inFIG.4, the controller43comprises an engine rotational speed detecting part43A, a vehicle speed determining part43B, a pressure detecting part43C, a command calculating part43D, a communication valve command part43E, a clutch command part43F, and a tilting control command part43G. The engine rotational speed Vinis inputted to the engine rotational speed detecting part43A from the first speed detector44. The engine rotational speed detecting part43A outputs the engine rotational speed Vinto the command calculating part43D. The output rotational speed Voutis inputted from the second speed detector45to the vehicle speed determining part43B. The vehicle speed determining part43B outputs the output rotational speed Voutcorresponding to the vehicle speed to the command calculating part43D. The fluid pressures PA, PBand the clutch pressure PCare inputted from the first pressure detector46, the second pressure detector47and the third pressure detector48to the pressure detecting part43C. The pressure detecting part43C outputs the pressure difference between the fluid pressure PAand the fluid pressure PB(=differential pressures of the pair of main lines37A,37B) and the clutch pressure PCto the command calculating part43D. Moreover, the controller43comprises a timer43H measuring the time and an inclination detector43J detecting the inclination relative to its horizontal surface. The timer43H measures, for example, the duration time for the wheel loader1to stop (stop duration time). Specifically, when the output rotational speed Voutdetected by the second speed detector45is a vehicle speed threshold value V1 or less, the timer43H measures the duration time T for which the output rotational speed Voutremains in this state, for example. The vehicle speed threshold value V1 is a determination value for determining whether or not the wheel loader1is stopped, and for example, V1 can be set at 0 to 1 km/h (substantially 0 km/h). The timer43H outputs the measured time T to the command calculating part43D. The inclination detector43J is a tilt sensor (gradient sensor) detecting a tilting angle θ of the wheel loader1relative to the horizontal surface. The inclination detector43J outputs the tilting angle θ to the command calculating part43D. The command calculating part43D calculates a command for the electromagnetic on-off valve41(solenoid valve command), commands for the clutches30,33,40(clutch command), a command for the regulator36A of the hydraulic pump36(pump command) and a command for the regulator38A of the hydraulic motor38(motor command), based upon inputs from the engine rotational speed detecting part43A, the vehicle speed determining part43B, the pressure detecting part43C, the timer43H and the inclination detector43J. The command calculating part43D outputs the solenoid valve command to the communication valve command part43E, outputs the clutch command to the clutch command part43F, and outputs the pump command and the motor command to the tilting control command part43G. The solenoid valve command is inputted from the command calculating part43D to the communication valve command part43E. The communication valve command part43E outputs a control command regarding opening and closing operations of the electromagnetic on-off valve41to the electromagnetic on-off valve41according to a solenoid valve command from the command calculating part43D. That is, the communication valve command part43E outputs an ON (communication)/OFF (blockade) signal W to the electromagnetic on-off valve41. In this case, the ON (communication) corresponds to the open position (A) of the electromagnetic on-off valve41, while the OFF (blockade) corresponds to the closed position (B) of the electromagnetic on-off valve41. A clutch command is inputted from the command calculating part43D to the clutch command part43F. The clutch command part43F outputs a control command regarding connection and release operations of the clutches30,33,40to the clutches30,33,40, based upon clutch commands from the command calculating part43D. That is, the clutch command part43F outputs ON (connect)/OFF (release) signals C1, C2, C3to the clutches30,33,40. In this case, the signal C1is outputted to the direct connecting clutch30, the signal C2is outputted to the pump side clutch33, and the signal C3is outputted to the motor side clutch40. A pump command and a motor command are inputted from the command calculating part43D to the tilting control command part43G. The tilting control command part43G outputs a control command regarding tilting operations of the hydraulic pump36and the hydraulic motor38to the regulator36A of the hydraulic pump36and the regulator38A of the hydraulic motor38, based upon a pump command and a motor command from the command calculating part43D. That is, the tilting control command part43G outputs swash plate or inclined shaft tilting command signals WP, WMto the regulator36A of the hydraulic pump36and the regulator38A of the hydraulic motor38. In this case, the tilting command signal WPis outputted to the regulator36A of the hydraulic pump36, and the tilting command signal WMis outputted to the regulator38A of the hydraulic motor38. The hydraulic pump36and the hydraulic motor38in the hydrostatic continuously variable transmission mechanism34are of variable displacement type. The hydraulic pump36and the hydraulic motor38changes the discharged capacity by changing the swash plate or inclined shaft tilting angle. The hydraulic pump36and the hydraulic motor38may be single tilting or both tilting. Next, an explanation will be made of a specific control processing of connection and release of the pump side clutch33and the motor side clutch40by the controller43. The direct connecting clutch30is released. FIG.5shows a specific processing flow controlled by the controller43when the pump side clutch33and the motor side clutch40are connected, that is, a control processing (determination processing) when the pump side clutch33and the motor side clutch40are released from the connected state. The control processing inFIG.5is repeated in predetermined control cycles while, for example, the pump side clutch33and the motor side clutch40are connected, in other words, the planetary continuously variable transmission mechanism31can transmit the power. For example, if an after-mentioned S12processing inFIG.6connects the pump side clutch33and the motor side clutch40, a processing flow inFIG.5will start. S1in FIG. determines whether or not an acceleration instruction is OFF. For example, S1determines whether or not the accelerator pedal8C is OFF. S1may determine whether or not the acceleration instruction is OFF by determining whether or not the brake pedal8D is depressed. In a case where S1determines “YES”, that is, the acceleration instruction is OFF (the accelerator pedal8C is not depressed), the processing will proceed to S3. On the other hand, in a case where S1determines “NO”, that is, the acceleration instruction is ON (the accelerator pedal8C is depressed), the processing will proceed to S2. S2continues the connection of the pump side clutch33and the motor side clutch40and the processing will return. That is, the processing gets back to “Start” via “Return” to repeat the processing after S1. S3determines whether or not the vehicle speed V of the wheel loader1is a vehicle speed threshold value V1 or less. The vehicle speed V corresponds to the speed of the actual wheel loader1(actual speed) detected by the second speed detector45. The vehicle speed threshold value V1 is a threshold value for determining whether or not the wheel loader1is stopped, and for example, V1=0 to 1 km/h. If S3determines “NO”, that is, the vehicle speed V exceeds the threshold value V1, the processing will proceed to S2. If S3determines “YES”, that is, the vehicle speed V is a threshold value V1 or less, the processing will proceed to S4. S4determines whether or not a parking brake switch disposed in the cab8is OFF. In a case where S4determines “NO”, that is, the parking brake switch is ON (braking provision), the processing will proceed to S5. S5turns the service brake ON, and the parking brake ON. The service brake is, for example, a wet multiple disk brake, which is disposed in the traveling devices12,13. The service brake is provided with braking forces by supplying pressurized oil. The parking brake is, for example, a negative brake disposed between the transmission mechanism25and the traveling devices12,13, and provided with braking forces by releasing the supply of pressurized oil. The following S6switches the electromagnetic on-off valve41from the closed position (B) to the open position (A). At this time, the tilting of the hydraulic pump36is minimized. The following S7releases the pump side clutch33and the motor side clutch40. If S7releases the pump side clutch33and the motor side clutch40, the processing inFIG.6will start. On the other hand, in a case where S4determines “YES”, that is, the parking brake switch is OFF, the processing will proceed to S8. S8determines whether or not the tilting angle θ of the wheel loader1is an inclination threshold value θ1 or less. The tilting angle θ of the wheel loader1corresponds to the tilting angle of the actual wheel loader1detected by the inclination detector43J. The inclination threshold value θ1 is a reference (threshold value) of the tilting angle for determining whether or not the stop of the wheel loader1can be maintained, for example, even by releasing the pump side clutch33and motor side clutch40. The inclination threshold value θ1 can be calculated from the weight of the wheel loader1(vehicle weight), friction with the road surface and other factors when the wheel loader1is stopped on the inclined ground. In a case where S8determines “NO”, that is, the tilting angle θ of the wheel loader1is 01 or more, the processing will proceed to S2. On the other hand, in a case where S8determines “YES”, that is, the tilting angle θ of the wheel loader1is θ1 or less, the processing will proceed to S9. S9determines whether or not the FNR lever8E is at the neutral position (N). In a case where S9determines “YES”, that is, the FNR lever8E is at the neutral position (N), the processing will proceed to S5. On the other hand, in a case where S9determines “NO”, that is, the FNR lever8E is not at the neutral position (N), the processing will proceed to S10. S10determines whether or not the vehicle speed V remains V1 or less for the T1 hours. The elapsed time after the vehicle speed V is V1 or less is measured by the timer43H. The threshold value T1 as a determination time can be set as the time determining the state of the working mechanism7of the wheel loader1to stop loading or the state of the vehicle to temporarily stop while loading. For example, the service brake is operated to stop the vehicle for about 2 to 6 seconds in the state of the FNR lever8E at the forward position (F) while the working mechanism7loads burdens onto a dump truck. On the other hand, the vehicle stops for about 10 to 180 seconds while waiting for a dump truck in the state of the FNR lever8E at the forward position (F). Therefore, the threshold value T1 can, for example, be set between 3 to 60 seconds. As such, the controller43can determine from the time difference in vehicle stop to whether the loading operation is in the state of being stopped or the vehicle has temporarily stopped in the state of loading operation by using the timer43H. In a case where S10determines “YES”, that is, the vehicle speed V remains V1 or less for the T1 hours or more, the processing will proceed to S5. On the other hand, in a case where S10determines “NO”, that is, the vehicle speed V doesn't remain V1 or less for the T1 hours or more, the processing will proceed to S2. FIG.6shows a specific processing flow controlled by the controller43when the pump side clutch33and the motor side clutch40are released, that is, control processing (determination processing) when the pump side clutch33and the motor side clutch40are connected from the released state. The control processing inFIG.6is repeated in predetermined control cycles while, for example, the pump side clutch33and the motor side clutch40are released. For example, if the above-described S7processing inFIG.5releases the pump side clutch33and the motor side clutch40, a processing flow inFIG.6will start. S11inFIG.6determines whether or not the vehicle speed V of the wheel loader1is a vehicle speed threshold value V1 or less. In a case where S11determines “NO”, that is, the vehicle speed V exceeds the threshold value V1, the processing will proceed to S12. S12connects the pump side clutch33and the motor side clutch40. The following S13switches the electromagnetic on-off valve41from the open position (A) to the closed position (B). The following S14turns the service brake OFF, and turns the parking brake OFF. If S14turns the service brake and the parking brake OFF, the processing inFIG.5will start. On the other hand, in a case where S11determines “YES”, that is, the vehicle speed V is a threshold value V1 or less, the processing will proceed to S15. S15determines whether or not the parking brake switch is OFF. In a case where S15determines “NO”, that is, the parking brake switch is ON, the processing will proceed to S16. S16continues the release of the pump side clutch33and the motor side clutch and the processing will return. That is, the processing gets back to “Start” via “Return” to repeat the processing after S11. On the other hand, in a case where S15determines “YES”, that is, the parking brake switch is OFF, the processing will proceed to S17. S17determines whether or not the FNR lever8E is at the neutral position (N). If S17determines “YES”, that is, the FNR lever8E is at the neutral position (N), the processing will proceed to S16. On the other hand, in a case where S17determines “NO”, that is, the FNR lever8E is not at the neutral position (N), the processing will proceed to S18. S18determines whether or not the FNR lever8E is operated from the neutral position (N) to the forward position (F). In a case where S18determines “YES”, that is, the FNR lever8E is operated to the forward position (F), the processing will proceed to S12. On the other hand, in a case where S18determines “NO”, that is, the FNR lever8E is not operated to the forward position (F), the processing will proceed to S19. S19determines whether or not the FNR lever8E is operated from the neutral position (N) to the retreat position (R). In a case where S19determines “YES”, that is, the FNR lever8E is operated to the retreat position (R), the processing will proceed to S12. On the other hand, in a case where S19determines “NO”, that is, the FNR lever8E is not operated to the retreat position (R), the processing will proceed to S16. As described above, according to an embodiment, the pump side clutch33(first clutch) is provided on the output side of the planetary gear mechanism32(between the planetary gear mechanism32and the hydraulic pump36). Moreover, the motor side clutch40(second clutch) is provided on the output side of the hydraulic motor38(between the hydraulic motor38and the idler gear29). Then, the controller43releases both the pump side clutch33and the motor side clutch40in the neutral state of cutting off or restricting transmission of the power from the engine9to the traveling devices12,13. Therefore, energy loss in the neutral state can be reduced. For example, the controller43releases both the pump side clutch33and the motor side clutch40in the state of switching the FNR lever8E to the neutral position (N) and releasing the forward clutch25A and the reverse clutch25B of the transmission mechanism25(in the neutral state of cutting off power). Therefore, the power is not transmitted to the hydraulic pump36or the hydraulic motor38. As a result, energy loss by rotation (idling) of the hydraulic pump36or the hydraulic motor38can be reduced. In addition, for example, while the FNR lever8E is switched to the forward position (F) or the retreat position (R) and the forward clutch25A or the reverse clutch25B of the transmission mechanism25is connected, both the pump side clutch33and the motor side clutch40are released in the state of no intention of the operator to drive the vehicle (in the neutral state of restricting power). Therefore, the power is not transmitted to the hydraulic pump36or the hydraulic motor38. As a result, also in this case, energy loss can be reduced. Moreover, in this case, the wheel loader1can immediately start only by connecting both the pump side clutch33and the motor side clutch40when the intention of the operator to drive the vehicle is detected by depressing the accelerator pedal8C and the like. Therefore, this allows both reducing energy loss in the neutral state and improving responsiveness for the wheel loader1to start. According to an embodiment, after the tilting of the hydraulic pump36is minimized, both the pump side clutch33and the motor side clutch40are released when the controller43switches from the traveling state capable of transmitting the power from the engine9to the traveling devices12,13to the neutral state. In this way, the pump side clutch33and the motor side clutch40can smoothly be released in the state of reducing the load on the hydraulic pump36. Therefore, in an embodiment, the vehicle releases both the pump side clutch33and the motor side clutch40when the controller43switches from the traveling state to the neutral state. According to an embodiment, the electromagnetic on-off valve41is provided between the pair of main lines37A,37B connecting the hydraulic pump36and the hydraulic motor38as a communication valve. The electromagnetic on-off valve41is at the open position (A) as a communication position in the neutral state. That is, the controller43sets the electromagnetic on-off valve41at the open position (A) in the neutral state. Therefore, hydraulic power transmission in the hydraulic circuit of the planetary continuously variable transmission mechanism31(hydrostatic continuously variable transmission mechanism34) can be cut off in the neutral state to accordingly reduce energy loss. Moreover, the pump side clutch33and the motor side clutch40can be released in the state of cutting off power transmission in the hydraulic circuit by setting the electromagnetic on-off valve41at the open position (A). As a result, the pump side clutch33and the motor side clutch40can also stably be released. Particularly, in an embodiment, the pump side clutch33and the motor side clutch40are each a synchromesh mechanism clutch. Therefore, the synchromesh mechanism clutch can stably be connected and released in the state of cutting off the power by rotation of the hydraulic pump36and the hydraulic motor38in a short period of time by allowing the electromagnetic on-off valve41to communicate the hydraulic pump36and the hydraulic motor38. As a result, a synchromesh mechanism clutch with a low drag torque can be used when the pump side clutch33and the motor side clutch40are released, and a transmission21(transmission) having reduced power loss of the vehicle and a high transmission efficiency can be provided. According to an embodiment, when the controller43changes the state (traveling state) of connecting both the pump side clutch33and the motor side clutch40to release both the pump side clutch33and the motor side clutch40, the controller43releases both the pump side clutch33and the motor side clutch40after the controller43switches the electromagnetic on-off valve41from the closed position (B) as the blockade position to the open position (A) as the communication position. Therefore, the pump side clutch33and the motor side clutch40can smoothly be released in the state of cutting off hydraulic power transmission in the hydraulic circuit of the planetary continuously variable transmission mechanism31(hydrostatic continuously variable transmission mechanism34) in a short period of time. Accordingly, in an embodiment, when the controller43switches from the traveling state to the neutral state, the electromagnetic on-off valve41is switched from the closed position (B) as the blockade position to the open position (A) as the communication position. According to an embodiment, when the controller43changes the state (neutral state) of releasing both the pump side clutch33and the motor side clutch40to connect both the pump side clutch33and the motor side clutch40, the controller43switches the electromagnetic on-off valve41from the open position (A) to the closed position (B) after the controller43connects both the pump side clutch33and the motor side clutch40. Therefore, pressure variations can be reduced when the pump side clutch33and the motor side clutch40are connected, and the pump side clutch33and the motor side clutch40can smoothly be connected. According to an embodiment, when the pressure difference of a pair of main lines37A,37B detected by the pressure detectors46,47is a threshold value or less, the controller43switches the electromagnetic on-off valve41from the closed position (B) to the open position (A). Therefore, sharp pressure variations generated when the pair of main lines37A,37B are communicated by switching the electromagnetic on-off valve41from the closed position (B) to the open position (A) can be reduced. According to an embodiment, the controller43comprises a second speed detector45detecting the rotational speed of the output shaft23and a timer43H measuring the time. If the controller43determines from the second speed detector and the timer43H that the stop duration time T (duration time during which the vehicle speed V is V1 or less) of the wheel loader1elapses in a predetermined T1 hours or more, the controller43releases the pump side clutch33and the motor side clutch40. That is, the controller43determines that the loading operation is not temporarily stopped but disrupted, when the stop duration time T elapses in a predetermined time (T1 hours) or more to release the pump side clutch33and the motor side clutch40. As a result, the pump side clutch33and the motor side clutch40can be released with proper timing to accordingly reduce energy loss. According to an embodiment, the controller43comprises the FNR lever8E. Moreover, the controller43releases the pump side clutch33and the motor side clutch40when the FNR lever8E is at the neutral position (N). In addition, the controller43releases the pump side clutch33and the motor side clutch40if the vehicle speed V is V1 or less for a predetermined time (T1 hours) or more even when the FNR lever8E is switched to the forward position (F) or the retreat position (R). Moreover, the controller43releases the pump side clutch33and the motor side clutch40when the controller43is provided with braking forces. As a result, the pump side clutch33and the motor side clutch40can be released when the operator has no intention to drive the vehicle. According to an embodiment, the controller43connects the pump side clutch33and the motor side clutch40when the vehicle speed V of the wheel loader1exceeds V1. Therefore, the power from the engine9can be transmitted to the traveling devices12,13when the power from the engine9should be transmitted to the traveling devices12,13. Moreover, the controller43continues the connection of the pump side clutch33and the motor side clutch40when the tilting angle θ detected by the inclination detector43J exceeds the inclination threshold value θ1. Therefore, the state of stopping the vehicle can be maintained by continuing the connection of the pump side clutch33and the motor side clutch40when the wheel loader1stops on the inclined road surface. According to an embodiment, a communication valve communicating and cutting off a pair of main lines37A,37B is defined as an electromagnetic on-off valve41. Therefore, a section between the pair of main lines37A,37B can be switched from the blocking state to the communicating state by switching the electromagnetic on-off valve41from the closed position (B) as a blockade position to the open position (A) as a communication position. On the other hand, the section between the pair of main lines37A,37B can be switched from the communicating state to the blocking state by switching the electromagnetic on-off valve41from the open position (A) to the closed position (B). The embodiments are explained by taking the case where the pump side clutch33and the motor side clutch40are each a synchromesh mechanism clutch as an example. However, not limited thereto, and for example, the pump side clutch (first clutch) and the motor side clutch (second clutch) may be a dog clutch or a wet multiple-disk clutch. The embodiments are explained by taking the case where a communication valve communicating and cutting off a pair of main lines37A,37B is defined as an electromagnetic on-off valve41as an example. However, not limited thereto, and for example, like a first variant shown inFIG.8, communication valves capable of switching between a communicating state and a blocking state between the pair of main lines37A,37B may be electromagnetic relief valves51A,51B capable of changing a set value (relief set value, relief starting pressure). Herein, the connecting line42connecting the pair of main lines37A,37B is provided with check valves52,53. The one check valve52allows pressurized oil to circulate from the one main line37A-side to the other main line37B-side and prevents the pressurized oil from circulating in the opposite direction. The other check valve53allows pressurized oil to circulate from the other main line37B-side to the one main line37A-side and prevents the pressurized oil from circulating in the opposite direction. Bypass lines54,55bypassing the respective check valves52,53are connected to the connecting line42. The relief valves51A,51B are disposed on the way of the bypass lines54,55. The electromagnetic relief valves51A,51B are configured by an electrically-operated variable relief valve changing the valve opening pressure (relief pressure) based upon a command signal (command signal W) from the controller43. Changes in set values (relief set value, relief starting pressure) of the electromagnetic relief valves51A,51B are controlled based upon a command signal (command signal W) from the controller43. The electromagnetic relief valves51A,51B are in a blocking state cutting off a pair of main lines37A,37B by raising the set value and in a communicating state communicating a pair of main lines37A,37B by lowering the set value. Accordingly, the first variant uses electromagnetic relief valves51A,51B, which are each a variable relief valve, as a means of cutting off hydraulic power transmission in the hydrostatic continuously variable transmission mechanism34. In the electromagnetic relief valves51A,51B, the relief pressure is normally set at a predetermined value on the high pressure side (for example, from 35 MPa to 50 MPa). Then, the controller43changes relief pressures of the electromagnetic relief valves51A,51B to the low-pressure side prescribed value (for example, the minimum) in the neutral state. That is, the pressure is relieved between the pair of main lines37A,37B by the electromagnetic relief valve51A,51B. Moreover, when the controller43switches from the first state (traveling state) of connecting both the pump side clutch33and the motor side clutch40to the second state (neutral state) of releasing the pump side clutch33and the motor side clutch40, the controller43releases the pump side clutch33and the motor side clutch40after changing the relief pressures of the electromagnetic relief valves51A,51B to the low-pressure prescribed value (the minimum). On the other hand, when the controller43switches from the second state (neutral state) of releasing both the pump side clutch33and the motor side clutch40to the first state (traveling state) of connecting both the pump side clutch33and the motor side clutch40, the controller43changes the relief pressures of the electromagnetic relief valves51A,51B to the high-pressure side prescribed value after connecting the pump side clutch33and the motor side clutch40. Therefore, the pump side clutch33and the motor side clutch40can be connected and released in the state of cutting off power transmission by the hydraulic power in the hydrostatic continuously variable transmission mechanism34. As communication valves, it can be configured to provide both the electromagnetic on-off valve41and the electromagnetic relief valves51A,51B. That is, such a communication valve serves as the electromagnetic on-off valve41capable of switching from the open position (A) to the closed position (B) and the electromagnetic relief valves51A,51B capable of changing the set value. The electromagnetic on-off valve41and the electromagnetic relief valves51A,51B are disposed in parallel between the pair of main lines37A,37B.FIG.8shows an example of the electromagnetic on-off valve41with a two-dot chain line (virtual line). In this case, when the controller43switches from the first state (traveling state) of connecting both the pump side clutch33and the motor side clutch40to the second state (neutral state) of releasing the pump side clutch33and the motor side clutch40, the controller43switches the electromagnetic on-off valve41from the closed position (B) to the open position (A) and releases the pump side clutch33and the motor side clutch40after the controller43changes the relief pressures of the electromagnetic relief valves51A,51B to the low-pressure prescribed value (the minimum). On the other hand, when the controller43switches from the second state (neutral state) of releasing both the pump side clutch33and the motor side clutch40to the first state (traveling state) of connecting both the pump side clutch33and the motor side clutch40, the controller43switches the electromagnetic on-off valve41from the open position (A) to the closed position (B) and changes the relief pressures of the electromagnetic relief valves51A,51B to the high-pressure side prescribed value after the controller43connects the pump side clutch33and the motor side clutch40. The embodiments are described by taking the case where a motor side clutch40as a second clutch is provided between a hydraulic motor38of a planetary continuously variable transmission mechanism31and an idler gear29as an example. However, not limited thereto, and for example, like a second variant shown inFIG.9, a motor side clutch40may be provided between the hydraulic motor38of the planetary continuously variable transmission mechanism31and the output shaft23. That is, the output shaft23to be connected to the output side of the transmission mechanism25comprises an output shaft gear61. The output shaft side transmission shaft62comprises a transmission gear63directly meshing with the output shaft gear61of the output shaft23or via a plurality of gears (not shown). The motor side clutch40is disposed between the motor shaft39of the hydrostatic continuously variable transmission mechanism34and the output shaft side transmission shaft62. The motor side clutch40is capable of switching between a “connecting state (fastening state)” where the transmission of the rotation is performed between the output shaft23and the hydrostatic continuously variable transmission mechanism34(the motor shaft39of the hydraulic motor38) and a “blocking state (releasing state)” where the transmission of the rotation is disconnected. The rotation of the motor shaft39of the hydrostatic continuously variable transmission mechanism34(=rotation of the hydraulic motor38) is transmitted to the output shaft23via the output shaft side transmission shaft62, the transmission gear63, and the output shaft gear61when the motor side clutch40is in the connecting state. The rotation of the motor shaft39is not transmitted to the output shaft side transmission shaft62when the motor side clutch40is in the releasing state. According to this second variant, the transmission mechanism25can be configured in small size. The embodiments are explained by taking the case where an operating tool switching between a forward (F), a retreat (R) and a neutral (N) as operator's operation modes is an FNR lever8E, and S9inFIGS.5and S17inFIG.6determine “YES” when the FNR lever8E is at the neutral (N) position as an example. However, not limited thereto, and the operating tool may be an FNR switch, for example. Moreover, the operating tool may be an FR lever and an N switch, for example. Furthermore, the operating tool may be an FR switch and an N switch, for example. The embodiments are explained by taking the case where the transmission21comprises the direct connecting mechanism27, the transmission shaft28, the idler gear29, the direct connecting clutch30as a third clutch and the third pressure detector48as an example. However, not limited thereto, and for example, such a configuration, or the configuration of the direct connecting mechanism may be omitted. The embodiments are explained by taking the case where the configuration in which the electromagnetic on-off valve41is at the open position (A) in the neutral state as an example. However, not limited thereto, and the electromagnetic on-off valve41may remain at the closed position (B), not at the open position (A) in the neutral state. The embodiments are explained as an example of the case where the electromagnetic on-off valve41is switched before and after the connection and release of the pump side clutch33and the motor side clutch40as an example. However, not limited thereto the electromagnetic on-off valve41may not be switched before and after the connection and release of the pump side clutch33and the motor side clutch40. This is applied to the electromagnetic relief valves51A,51B as well. The embodiments are explained by taking the case where the controller43releases both the pump side clutch33and the motor side clutch40in the neutral state as an example. However, not limited thereto, and for example, the pump side clutch33may be released and the motor side clutch40may remain connected in the neutral state. Moreover, the motor side clutch40may be released and the pump side clutch33may remain connected in the neutral state. That is, the controller releases at least one clutch of the first clutch (pump side clutch) and the second clutch (motor side clutch) in the neutral state of cutting off or restricting the power from the prime mover to the traveling device. Preferably, at least the first clutch (pump side clutch) of the first clutch (pump side clutch) and the second clutch (motor side clutch) is released in the neutral state. In other words, the embodiments are explained by taking the case where the controller43releases both the pump side clutch33and the motor side clutch40when the controller switches from the traveling state to the neutral state as an example. However, not limited thereto, and for example, the pump side clutch33may be released and the motor side clutch40may remain connected when the controller switches from the traveling state to the neutral state. Moreover, the motor side clutch may be released and the pump side clutch33may remain connected in the neutral state when the controller switches from the traveling state to the neutral state. That is, the controller releases at least one clutch of the first clutch (pump side clutch) and the second clutch (motor side clutch) when the controller switches from the traveling state capable of transmitting the power from the prime mover to the traveling device to the neutral state. Preferably, at least the first clutch (pump side clutch) of the first clutch (pump side clutch) and the second clutch (motor side clutch) is released when the controller switches from the traveling state to the neutral state. The embodiments are explained by taking the case where a transmission21as a power transmitting device for a vehicle is mounted on a wheel loader1as a working vehicle for example. However, not limited thereto, and for example, can widely be used as power transmission devices for various types of vehicles, for example, construction vehicles such as wheel-type excavators, transport vehicles such as lift trucks, farm vehicles such as tractors and the like. DESCRIPTION OF REFERENCE NUMERALS 1: Wheel loader (Vehicle)9: Engine (Prime mover)12: Front axle (Traveling device)13: Rear axle (Traveling device)21: Transmission (Power transmission device for a vehicle)22: Input shaft23,23A,23B: Output shaft31: Planetary continuously variable transmission mechanism32: Planetary gear mechanism33: Pump side clutch (First clutch)36: Hydraulic pump37A,37B: Main line38: Hydraulic motor40: Motor side clutch (Second clutch)41: Electromagnetic on-off valve (Communication valve)43: Controller51A,51B: Electromagnetic relief valve (Communication valve) | 75,433 |
11859704 | DETAILED DESCRIPTION OF EMBODIMENTS The present disclosure will be further described below with reference to the embodiments and accompanying drawings to enable those skilled in the art to implement the technical solutions disclosed herein. An embodiment illustrated inFIGS.1-3provides a four-mode dual-motor coupling electric drive axle, which includes a primary drive motor1000, an auxiliary drive motor2000, a reducer3000, a torque vectoring (TV) coupler4000, a power coupling differential5000, a housing assembly, and a power output mechanism. The primary drive motor1000is a hollow-shaft inner-rotor permanent magnet synchronous motor, which includes an outer stator and an inner rotor output shaft. The outer stator is fixedly connected to the housing assembly, and the inner rotor output shaft is configured to output a drive torque. The primary drive motor1000is arranged on a left side of the electric drive axle and is configured to output power via an output shaft1001of the primary drive motor. The auxiliary drive motor2000is a hollow-shaft outer-rotor permanent magnet synchronous motor, which includes an inner stator and an outer housing rotor. The inner stator is fixedly connected to the housing assembly, and the outer housing rotor is configured to output a torque. The auxiliary drive motor2000is arranged on a right side of the electric drive axle and is configured to output power via the outer housing rotor2001of the auxiliary drive motor. An end of the output shaft1001of the primary drive motor is machined with an external spline, and an inner side of an end of the outer housing rotor2001of the auxiliary drive motor is machined with an inner gear. As shown inFIGS.1and3-4, a main body of the reducer3000is a single-row single-planetary-gear planetary gear mechanism, including a first sun gear3001, a first planet gear3002, a first planet gear shaft3003, a first ring gear3004, and a first planet carrier3005. An inner hole of the first sun gear3001is machined with an internal spline and is connected to the external spline of the output shaft1001of the primary drive motor. The first planet gear3002is engaged with the first sun gear3001. The first planet gear3002is rotatably supported on the first planet gear shaft3003. The first planet gear shaft3003is rotatably supported on the first planet carrier3005. The first ring gear3004is fixedly connected to the housing and engaged with the first planet gear3002. It should be noted that the reducer3000can be composed of a variety of reducers, and different reducers can achieve the same function. Therefore, the replacement of the reducer3000is not considered as an innovation to the present disclosure. As shown inFIGS.1,3, and5, the main body of the TV coupler4000is a dual-row planetary gear mechanism consisting of two planetary gear sets having the same characteristic parameter. Each planetary gear set includes a second planet gear4001, a second planet gear shaft4002, a second planet carrier4003, a second sun gear4004, a third sun gear4005, a third planet gear4006, a third planet gear shaft4007, a third planet carrier4008, a second ring gear4009, a first clutch4100, and a second clutch4200. The second planet gear4001is internally engaged with the outer housing rotor2001of the auxiliary drive motor. The second planet gear4001is rotatably supported on the second planet gear shaft4002. The second planet gear shaft4002is rotatably supported on the second planet carrier4003. The second sun gear4004is externally engaged with the second planet gear4001. An outer side of an end of the second sun gear4004is machined with an outer spline. The third sun gear4005is machined with an inner spline on an inner hole and an outer spline on an outer side at an end of the third sun gear4005. The third sun gear4005is splined to the second sun gear4004. The third planet gear4006is externally engaged with the third sun gear4005. The third planet gear4006is rotatably supported on the third planet gear shaft4007. The third planet gear shaft4007is rotatably supported on the third planet carrier4008. The inner hole on one side of the third planet carrier4008is machined with an internal spline. The second ring gear4009is internally engaged with the third planet gear4006. The first clutch4100is a wet multi-plate friction electromagnetic clutch with an outer ring splined to the second planet carrier4003. The second clutch4200is a wet multi-plate friction electromagnetic clutch with an inner ring splined to the third sun gear4005and an outer ring splined to the third planet carrier4008. It should be noted that any change in the type or engagement of the first clutch4100and the second clutch4200is not considered as an innovation to the present invention. As shown inFIGS.1,3, and6, the main body of the power coupling differential5000is a dual-row planetary gear mechanism, a first planetary row of the dual-row planetary gear mechanism is a single planetary gear set, and a second planetary row of the dual-row planetary gear mechanism is a double planetary gear set having a characteristic parameter of 2. The power coupling differential5000includes a differential end cover5001, a differential housing5002, a fourth sun gear5003, a fourth planet gear5004, a fourth planet gear shaft5005, a third ring gear5006, a fifth planet gear5007, a fifth planet gear shaft5008, a sixth planet gear5009, a sixth planet gear shaft5010, a fifth sun gear5011, a fourth planet carrier5012, and a third clutch5100. The differential end cover5001is fixedly connected to the differential housing5002through differential housing screws5013. An outer side of one end of the fourth sun gear5003is provided with two outer splines. The fourth sun gear5003is in splined connection with the third planet carrier4008. The fourth planet gear5004is externally engaged with the fourth sun gear5003. The fourth planet gear5004is rotatably supported on the fourth planet gear shaft5005. The fourth planet gear shaft5005is rotatably supported on the differential housing5002. The third ring gear5006is rotatably supported on the differential housing5002, and is internally engaged with the fourth planet gear5004. The fifth planet gear5007is internally engaged with the third ring gear5006. The fifth planet gear5007is rotatably supported on the fifth planet gear shaft5008. The sixth planet gear5009is externally engaged with the fifth planet gear5007. The sixth planet gear5009is rotatably supported on the sixth planet gear shaft5010. The fifth planet gear shaft5008and the sixth planet gear shaft5010are rotatably supported on the fourth planet carrier5012. The inner hole on one side of the fourth planet carrier5012is provided with an internal spline. The fifth sun gear5011is externally engaged with the sixth planet gear5009, and the inner hole of the fifth sun gear5011is machined with an internal spline. The third clutch5100is a wet multi-plate friction electromagnetic clutch with an inner ring splined to the third sun gear5003and an outer ring splined to the differential housing5002. It is to be noted that any change in the type or engagement of the third clutch5100is not considered an innovation to the present disclosure. As shown inFIGS.1and3, the housing assembly includes a first housing6001, a second housing6002, a first end cover6003, and a second end cover6004. The first end cover6003is fixedly connected to the first housing6001through a first housing screw6005. The first housing6001is fixedly connected to the second housing6002through a second housing screw6006. The second end cover6004is fixedly connected to the second housing6002through a third housing screw6007. One end of the power coupling differential5000is rotatably supported on the first housing6001through a tapered roller bearing5200, and the other end of the power coupling differential5000is rotatably supported on the second housing6002through a tapered roller bearing5300. The first ring gear3004is in interference connection with the first housing6001. The second ring gear4009is in interference connection with the second housing6002. As shown inFIGS.1and3, the power output mechanism includes a first half shaft7001, a second half shaft7002, a first flange7003, and a second flange7004. Two ends of both the first half shaft7001and the second half shaft7002are machined with external splines. The inner holes of both the first flange7003and the second flange7004are machined with internal splines. One end of the first half shaft7001is splined to the fifth sun gear5011, and the other end of the first half shaft7001is splined to the first flange7003. The first flange7003is axially fixed through a first flange nut7005. One end of the second half shaft7002is splined to the fourth planet carrier5012, and the other end of the second half shaft7002is splined to the second flange7004. The second flange7004is axially fixed through a second flange nut7006. The first half shaft7001is rotatably supported on the output shaft1001of the primary drive motor through a needle roller bearing7100and a needle roller bearing7200. One end of the second half shaft7002is rotatably supported on the fourth sun gear5003by a needle roller bearing7300, and the other end of the second half shaft7002is rotatably supported on the second end cover6004by a needle roller bearing7400. A first rubber seal7007is provided between the first flange7003and the first end cover6003for sealing. A second rubber seal7008is provided between the second flange7004and the second end cover6004for sealing. The inner ring of the first clutch4100is fixedly connected to the second half shaft7002. The first sun gear4004is rotatably supported on the first half shaft7001. The second sun gear4005is rotatably supported on the first half shaft7001. As shown inFIG.7, a control signal cable and power cable of the first clutch4100successively pass through an axial gap between the first clutch4100and the auxiliary drive motor2000and a wiring hole of the second end cover6004to access the outside. A control signal cable and power cable of the second clutch4200successively pass through a radial gap between the second clutch4200and the second housing6002and a wiring hole of the second housing6002to access the outside. A control signal cable and power cable of the third clutch5100successively pass through a radial gap between the third clutch5100and the second housing6002and a wiring hole of the second housing6002to access the outside. The operating modes of a four-mode dual-motor coupling electric drive axle provided herein will be further described in detail with reference to the accompanying drawings. As shown in Table 1, the four-mode dual-motor coupling electric drive axle provided herein has four drive modes, namely, a single-motor drive mode, a TV drive mode, a dual-motor torque coupling drive mode, and a dual-motor speed coupling drive mode. The electric drive axle is switchable among the four operating modes by controlling operating modes of the TV coupler4000and the power coupling differential5000. The TV coupler4000has three operating modes, namely, a disconnected mode, a TV mode, and a reducer mode, and is switchable among the three operating modes by controlling operating states of the first clutch4100and the second clutch4200. The power coupling differential5000has two operating modes, namely, a torque coupling mode and a speed coupling mode, and is switchable between the two operating modes by controlling operating states of the third clutch5100. When the electric drive axle operates in the single-motor drive mode, the TV coupler4000is in the disconnected mode, and the first clutch4100and the second clutch4200are disconnected; and the power coupling differential is in the torque coupling mode, and the third clutch5100is engaged. When the electric drive axle operates in the TV drive mode, the TV coupler4000is in the TV mode, the first clutch4100is engaged, and the second clutch4200is disconnected; and the power coupling differential5000is in torque coupling mode, and the third clutch5100is engaged. When the electric drive axle operates in the dual-motor torque coupling drive mode, the TV coupler4000is in the reducer mode, the first clutch4100is disengaged, and the second clutch4200is engaged; and the power coupling differential5000is in the torque coupling mode, and the third clutch5100is engaged. When the electric drive axle operates in the dual-motor speed coupling drive mode, the TV coupler4000is in the reducer mode, the first clutch4100is disconnected, and the second clutch4200is engaged; and the power coupling differential5000is in the speed coupling mode, and the third clutch5100is disconnected. TABLE 1Correspondence table between the four operating modes of the four-mode dual-motor coupling electric drive axle, the operating state of the threeclutches and the operating mode of the relevant assemblyPower couplingTV coupler 4000differential 5000OperatingFirstSecondThirdmodes of theOperatingclutchclutchOperatingclutchelectric drive axlestates41004200modes5100Single-motorDisconnectedDisconnectedDisconnectedTorqueEngageddrive modemodecouplingTV drive modeTV modeEngagedDisconnectedmodeDual-motor torqueReducerDisconnectedEngagedcoupling drive modemodeDual-motor speedSpeedDisconnectedcoupling drive modecouplingmode As shown inFIG.8, when the four-mode dual-motor coupling electric drive axle provided herein operates in the single-motor drive mode, the power output of the primary drive motor1000is directly transmitted to the first half shaft7001and the second half shaft7002through the power coupling differential5000, where the auxiliary drive motor2000is not involved in the transmission. At this time, a torque output from the first half shaft7001and the second half shaft7002is expressed as To1=To2=½Ti1i, where To1represents a torque output from the first half shaft7001, To2represents a torque output from the second half shaft7002, Ti1represents a torque output from the primary drive motor1000, i represents a transmission ratio of the reducer3000, and i=k1+1, where k1represents a characteristic constant of the planetary row of the reducer3000. The relationship of rotation speeds of the output shaft1001of the primary drive motor, the first half shaft7001and the second half shaft7002is expressed as 1ini1=12(no1+no2), where ni1represents a rotation speed of the output shaft1001of the primary drive motor, no1represents a rotation speed of the first half shaft7001, and no2represents a rotation speed of the second half shaft7002. Under the single-motor drive mode, the primary drive motor1000, as the only power source, has a higher load rate under the driving conditions of low power demand of the vehicle, and thus can work in the high efficiency range as much as possible. At this time, the whole vehicle is driven more efficiently and thus has good economic efficiency. As shown inFIG.9, when the four-mode dual-motor coupling electric drive axle provided herein operates in the TV drive mode, the power output from the primary drive motor1000is transmitted directly to the first half shaft7001and the second half shaft7002via the power coupling differential5000, and the power output from the auxiliary drive motor2000reduces the torque output from the first half shaft7001and increases the torque output from the second half shaft7002. At this time, the torque output from the first half shaft7001is expressed as To1=12Ti1i-k2+12k2Ti2, and the torque output from the second half shaft7002is expressed as To2=12Ti1i+k2+12k2Ti2, where Ti2represents a torque output from the auxiliary drive motor2000, and k2represents a characteristic constant of the planetary row of the TV coupler4000. The relationship of rotation speeds among the output shaft1001of the primary drive motor, the outer housing rotor2001of the auxiliary drive motor, the first half shaft7001, and the second half shaft7002is expressed as 1ini1=12(no1+no2)andni2=k2+12k2(no2-no1), where ni2represents a rotation speed of the outer housing rotor2001of the auxiliary drive motor. The effects of the torque vectoring under the TV drive mode are further explained below with reference toFIG.10. Embodiment 1 When the vehicle turns left, the rotation speed of the first half shaft7001is less than that of the second half shaft7002, and the auxiliary drive motor2000rotates positively. At this time, if the auxiliary drive motor2000outputs a positive torque, the torque output from the first half shaft7001will be smaller than the torque output from the second half shaft7002, making the driving force of the left wheel of the vehicle smaller than the driving force of the right wheel of the vehicle, thus generating an additional transverse torque whose direction is the same as the direction of the angular velocity of the yaw of the vehicle, thereby increasing the yaw of the vehicle. If the auxiliary drive motor2000outputs a negative torque, the torque output from the first half shaft7001will be greater than the torque output from the second half shaft7002, making the driving force of the left wheel of the vehicle greater than the driving force of the right wheel of the vehicle, thus generating an additional transverse torque whose direction is opposite to the direction of the angular velocity of the yaw of the vehicle, thereby reducing the yaw of the vehicle. When the vehicle turns right, the rotation speed of the first half shaft7001is greater than that of the second half shaft7002, and the auxiliary drive motor2000rotates reversely. At this time, if the auxiliary drive motor2000outputs a positive torque, the torque output from the first half shaft7001will be greater than the torque output from the second half shaft7002, making the driving force of the left wheel of the vehicle greater than the driving force of the right wheel of the vehicle, thus generating an additional transverse torque whose direction is the same as the direction of the transverse angular velocity of the vehicle, thereby increasing the yaw of the vehicle. If the auxiliary drive motor2000outputs a negative torque, the torque output from the first half shaft7001will be less than the torque output from the second half shaft7002, making the driving force of the left wheel of the vehicle less than the driving force of the right wheel of the vehicle, thus generating an additional transverse moment whose direction is opposite to the direction of the transverse angular velocity of the vehicle, thereby reducing the transverse moment of the car. In this scenario, when the yaw of the vehicle is increased by the torque output from the auxiliary drive motor2000, the cornering maneuverability and steering maneuverability of the vehicle can be enhanced. When the yaw of the vehicle is reduced by the torque outputted from the auxiliary drive motor2000, the steering stability can be ensured, thereby improving the active safety of the vehicle. Embodiment 2 When a left wheel of a vehicle is stuck in a mud puddle or the wheels skid when driving on a low adhesion road surface, such as ice or snow, the rotation speed of the first half shaft7001is greater than that of the second half shaft7002, and the auxiliary drive motor2000rotates positively. At this time, if the auxiliary drive motor2000outputs a positive torque, the torque output from the second half shaft7002is increased and the torque output from the first half shaft7001is reduced, which will increase the drive force of the right wheel of the vehicle while reduce the drive force of the left wheel of the vehicle, and thus restoring the drive force of the vehicle to extricate. When the right wheel of the vehicle is stuck in a mud puddle or when the wheels skid when driving on low adhesion roads, such as snow and ice, the rotation speed of the second half shaft7002is greater than that of the first half shaft7001, and the auxiliary drive motor2000rotates reversely. At this time, if the auxiliary drive motor2000outputs a positive torque, the torque output from the first half shaft7001is increased and the torque output from the second half shaft7002is reduced, which will increase the driving force of the left wheel and reduce the driving force of the right wheel of the vehicle, thus restoring the driving force of the vehicle to extricate. In this scenario, the torque vectoring can significantly improve the trafficability of the vehicle. As shown inFIG.11, when the four-mode dual-motor coupling electric drive axle provided herein operates in the dual-motor torque coupling drive mode, the power output from the primary drive motor1000and the auxiliary drive motor2000is output to the first half shaft7001and the second half shaft7002after torque coupling by the power coupling differential5000. At this time, the torque output from the first half shaft7001and the second half shaft7002is expressed as To1=To2=½(Ti1i+Ti2(k2+1)). The relationship among rotation speeds of the output shaft1001of the primary drive motor, the outer housing rotor2001of the auxiliary drive motor, the first half shaft7001, and the second half shaft7002is expressed as 1ini1=1k2+1ni2=12(no1+no2). In the dual-motor torque coupling drive mode, the power output from the primary drive motor1000is coupled with the power torque output from the auxiliary drive motor2000to drive the vehicle. In this case, the vehicle has better acceleration and hill climbing ability, better dynamics, and can meet the driving conditions requiring high power. In addition, through the reasonable matching of the primary drive motor1000and the auxiliary drive motor2000, the power output from the auxiliary drive motor2000can cut the peaks and fill the valleys of the power outputted from the primary drive motor1000, that is, replenish the insufficient power and absorb the excess power output from the primary drive motor1000, which can reduce the fluctuation of the power output from the primary drive motor1000and enable the primary drive motor1000to operate in the high-efficiency range as much as possible, and thus maximizing the drive efficiency of the vehicle and improving its economy. As shown inFIG.12, when the four-mode dual-motor coupled electric drive axle provided herein operates in the dual-motor speed-coupled drive mode, the power output from the primary drive motor1000and the auxiliary drive motor2000is output to the first half shaft7001and the second half shaft7002after speed coupling by the power-coupled differential5000. At this time, the torque output from the first half shaft7001and the second half shaft7002is expressed as To1=To2=12Ti1ik3k3+1=-12Ti2(k2+1)k3. The relationship among rotation speeds of the output shaft1001of the primary drive motor, the outer housing rotor2001of the auxiliary drive motor, the first half shaft7001, and the second half shaft7002is expressed as k3+1ini1-1k2+1ni2=12(no1+no2)k3. In the dual-motor speed coupling drive mode, the power output from the main drive motor1000is coupled to the power outputted from the auxiliary drive motor2000. In this case, the auxiliary drive motor2000works mainly in the power generation mode, acting as a speed control motor, which enables the primary drive motor to work in the high-efficiency range as much as possible and prevents it from entering the weak magnetic inefficiency range, maintaining a high drive efficiency of the vehicle. In addition, the auxiliary drive motor2000can also act as a stepless speed regulator, realizing electronic stepless speed change, so as to realize continuous change of vehicle speed while the operating point of the primary drive motor1000remains in the high-efficiency range, so that the vehicle has high economy when driving at high speeds. The embodiments disclosed above are merely illustrative of the disclosure, and are not intended to limit the present disclosure. It should be understood that any modifications, changes and replacements made by those skilled in the art without departing from the spirit of the disclosure shall fall within the scope of the disclosure defined by the appended claims. | 24,152 |
11859705 | DETAILED DESCRIPTION OF THE INVENTION Turning now to the drawings, cup-type flexsplines for metal strain wave gears, and systems and methods for their design and manufacture, are described. In many embodiments, the cup-type flexspline has a base and a vertical wall, where the vertical wall transitions through a curvature to the base. An input shaft locates at the base of the flexspline and has a diameter. The vertical wall is in a circular shape with an outer wall diameter, and the flexspline maintains circularity along the rotational axis of the vertical wall. Many embodiments of the invention describe a flexspline that the cup of the flexspline is free from sharp edges and with a rounded bottom with curvature maximized based on the geometry of the flexspline. Many embodiments describe the maximum radius of curvature at the base of the cup is at least 10% of the diameter of the flexspline. Many other embodiments highlight that the radius of curvature is between about 15% to about 20% of the diameter of the flexspline. Flexsplines according to such embodiments demonstrate improved fatigue life of at least about 10% over designs with sharp angles between the base and the wall when run at the same torque. In many embodiments, the flexspline has a hemispherical base curvature. In some other embodiments, the flexspline has an elliptical base curvature. In some embodiments, the flexspline has a flush input base. In some other embodiments, the flexspline has two different spherical radii of curvature. Many embodiments describe that the flexspline is made of bulk metallic glass-based material. Many embodiments reveal that the bulk metallic glass-based material can be made from near or net-shaped processes, such as injection molding, die casting, 3D printing, thermoplastic forming, blow molding, discharge forming, metal injection molding, pressing with powder, suction casting, forming from sheet metal or a variety of other processes whereby feedstock is formed into the flexspline in a single step without significant machining. In many embodiments, the flexspline is made from a brittle material with a fracture toughness of less than about 50 MPa m1/2. In some other embodiments, the flexspline is made from a metal alloy with less than about 10% ductility in a tension test. In some other embodiments, the flexspline is made from tool steel, nanocrystalline metals, nanograined metals, ceramics, or metal matrix composites. Harmonic drives are one of the driving factors in the early formulation of spacecraft design because they limit the size of the spacecraft. Harmonic drives are also used very heavily on Jet Propulsion Lab rovers, including many that were integrated into the Mars Exploration Rovers (MER). Developing low cost harmonic drives or high performance drives is game-changing for future NASA missions and for terrestrial robotics. Harmonic drives were developed to take advantage of the elastic dynamics of metals, particularly the expansion of a metal ring to engage gear teeth without exceeding the elastic limit of the ring, which would cause permanent (i.e. plastic) deformation. The harmonic drive is made of three components: a wave generator, a flexspline (a.k.a. an inner race), and a circular spline (a.k.a. an outer race). FIG.1illustrates an exploded view of a typical strain wave gear that can be fabricated from BMG-based materials in accordance with embodiments of the invention. In particular, the strain wave gear100includes a wave generator102, a flexspline108, and a circular spline112. The illustrated wave generator102includes a wave generator plug104and a ball bearing106. Importantly, the wave generator plug104is elliptical in shape, and is disposed within the ball bearing106so that the ball bearing106conforms to the elliptical shape. In this arrangement, the outer race of the ball bearing106can rotate relative to the wave generator plug104. In the illustrated embodiment, the flexspline108is depicted as being in the shape of a cup; notably, the outer rim of the cup includes a set of gear teeth110. In the illustration, the flexspline is fitted over the ball bearing, such that the outer rim of the flexspline conforms to the aforementioned elliptical shape. Note that in this arrangement, the ball bearing allows the flexspline to rotate relative to the wave generator plug. The circular spline,112is in the shape of a ring; importantly, the inner perimeter of the ring includes a set of gear teeth. Normally, there are more gear teeth on the circular spline114than on the flexspline110. In many instances there are two more gear teeth on the circular spline112than on the flexspline108. Typically, the flexspline108is fitted within the circular spline112such that the gear teeth of the flexspline110engage the gear teeth of the circular spline114. Notably, because the gear teeth of the flexspline110conform to an elliptical shape, only the gear teeth proximate the major axis of the elliptical shape engage the gear teeth of the circular spline114in the usual case. Conversely, the gear teeth of the flex spline110that are proximate the minor axis of the elliptical shape are disengaged from the gear teeth of the circular spline114. In many instances, 30% of the gear teeth of the flexspline110are engaged with the gear teeth of the circular spline114. With this arrangement, the wave generator plug104can rotate in a first direction about the central axis of the elliptical shape, and thereby cause the flexspline108to rotate in a second opposite direction and at a different rate of rotation (generally slower) about the central axis of the elliptical shape. This can be achieved as the flexspline108is made of a flexible material that can accommodate the deflections that may result from the rotation of the wave generator plug104. The primary method by which strain wave gear flexsplines are manufactured is through the machining of steel.FIGS.3A-3Billustrate methods where flexsplines are manufactured from solid billets or castings using conventional machining processes, such as lathing, milling, or grinding. A lathe301rotates a flexspline about an axis of rotation to perform cutting by the cutting tool302. A straight edge303of the flexspline is shown inFIG.3B. In this method, machining a large radius of curvature is challenging compared to a straight edge. The vast majority of current commercial flexsplines are made of steel, which is known for its combination of high toughness and wear resistance. Typical cup-type flexsplines are made with a vertical wall that transitions through a 90 degree angle to a base where an input shaft is located.FIG.4depicts three common sizes of strain wave gear flexspline:401is CSF-32 flexspline,402is the CSF-20 flexspline, and403is CSF-8 flexspline. Each flexspline is made from machined steel, and has a radius of curvature404between the base of the cup405and the wall406of about 1% to about 2% of the diameter of the wall. The flexspline has a flat input that interfaces with a component to transmit torque. The base405is preferably to be flat to make a mating interface. Due to the high toughness of steel, the small radius of curvature404is sufficient to prevent fracture. The torque that the flexspline can support is a function of the size of the flexspline cup, its length and the number of teeth on the flexspline outer wall. Due to the very high toughness of steel and the limitations of conventional machining, a very small radius of curvature is added to the bottom of the flexspline cup, typically about 1% to about 2% of the diameter of the flexspline.FIG.5shows the cross-section of a typical machined steel size CSF-20 flexspline with a radius of curvature501of about 1 millimeter, which is about 1% to 2% of the diameter of the flexspline. Machining larger radii of curvature is more difficult due to the necessity of keeping the flexspline perfectly symmetric along its rotational axes. Due to the high toughness of steel, the small radius of curvature is not a normal location of failure of the flexspline, which normally fails due to buckling of the flexspline wall or the degradation of the flexspline teeth. In operation, a steel flexspline is rarely expected to crack or fail due to a stress concentration. Despite the high performance of steel in the flexspline, it is expensive to manufacture due to the difficulty with machining steel, the high-tolerance features, and the very thin wall. Bulk metallic glasses (BMGs) have been demonstrated to be ideal candidates for flexsplines because they can be manufactured using near or net-shaped processes, such as injection molding, die casting, thermoplastic forming, metal injection molding or a variety of other processes whereby feedstock is formed into the flexspline in a single step without significant machining. (See e.g., U.S. Pat. No. 9,328,813 B2 to Hofmann et al., U.S. Pat. No. 10,151,377 B2 to Hofmann et al., U.S. patent application Ser. No. 15/918,831 to Hofmann et al., U.S. patent application Ser. No. 62/811,765 to Hofmann et al.; the disclosures of which are hereby incorporated by reference.) BMG-based material flexsplines have been manufactured to mimic the shape of the steel flexsplines, which contain several locations of stress concentrations. As an example,FIGS.6A-6Dillustrate an injection molding technique that can be implemented to form a flexspline of a strain wave gear in accordance with embodiments of the invention. In particular,FIG.6Adepicts that a molten BMG-based material601that has been heated to a molten state and is thereby ready to be inserted into a mold602. The mold602helps define the shape of the flexspline to be formed.FIG.6Bdepicts that the molten BMG-based material601is pressed into the mold602.FIG.6Cdepicts that the mold602is released after the BMG-based material has cooled.FIG.6Ddepicts that any excess flash603is removed. Thus, it is depicted that a strain wave gear component is fabricated using direct casting techniques in conjunction with a BMG-based material in accordance with embodiments of the invention. Note that the straight edge of the flexspline604from replicating the steel flexspline models creates stress concentration.FIG.7shows the BMG-based material flexsplines made with injection molding technique. The flexsplines have been cast to replicate the shape of the machined steel versions, which are designed to maximize torque due to the straight walls. FIGS.8A-8Cillustrate the forming of a flexspline using blow molding techniques. In particular,FIG.8Adepicts that a BMG-based material801is placed within a mold802.FIG.8Bdepicts that the BMG-based material801is exposed to pressurized gas or liquid that forces the BMG-based material to conform to the shape of the mold802. Typically, a pressurized inert gas is used. The BMG-based material801is usually heated so that it is sufficiently pliable and can be influenced by the pressurized gas or liquid. Again, any suitable heating technique can be implemented in accordance with embodiments of the invention.FIG.8Cdepicts that due to the force of the pressurized gas or liquid, the BMG-based material conforms to the shape of the mold802. Replicating the steel flexspline creates sharp edges803in the BMG-based flexspline. However, unlike steel, BMG-based materials are known for having much lower fracture toughness and fatigue life. In fact, BMG flexsplines tend to fail via cracking or shearing at much lower number of cycles than their steel counterparts. BMG-based materials are typically associated with fracture toughness less than about 50 MPa m1/2whereas steel is normally greater than about 100 MPa m1/2. Fatigue strengths of steel are typically greater than about 20% of their yield strength whereas BMG-based materials normally fail at less than about 10% of their yield strengths at about 107 cycles. As an example,FIGS.9A-9Billustrate schematically a BMG flexspline fatigue failure due to the low toughness of the BMG-based material.FIG.9Adepicts the outer spline901rotates counter clockwise along the axis of rotation of the flexspline, while the input shaft903rotates clockwise along the axis of rotation. The brittle BMG-based material flexspline902is loaded. The straight edge of the flexspline creates the stress concentration904.FIG.9Bdepicts the low cycle fatigue failure905due to the low toughness of the BMG-based material. For brittle materials, like BMG, stress concentration creates premature failure under loading. FIG.10illustrates the stress concentration in a BMG-based material flexspline. A BMG flexspline1001is connected to an input shaft1003, and then to an outer spline1004to drive torque. Due to the brittle nature of the BMG, sharp corners1002are locations of failure.FIG.11shows a fatigue crack in a CSF-20-50 BMG flexspline. The low cycle fatigue crack1101appears in the flexspline after approximately 20,000 cycles at 30 Nm of torque. The crack originates from the stress concentration at the small radius of curvature1102.FIG.12shows a BMG flexspline that has been sheared off under load at the location of a stress concentration. These types of failure do not occur in steel flexsplines. Although BMGs can be cast for potentially much lower cost than steel, their brittle nature makes them perform worse, despite their higher strength (about 2000 MPa compared to about 500 MPa for steel), higher wear resistance, lower elastic modulus (about 90 GPa compared to about 215 GPa for steel), higher elasticity (about 2% compared to about 0.1% for steel), and corrosion resistance. Improving the design of the flexspline could simultaneously improve performance and reduce the difficulty with net-shaped casting. Embodiments Implementing Rounded Bulk Metallic Glass-Based Materials Flexsplines Many embodiments of the invention describe a strain wave gear flexspline where the cup of the flexspline is free from sharp edges and with a rounded bottom with curvature maximized based on the geometry of the flexspline (FIG.2). Compared to a steel flexspline, the new design will have the same outer diameter, the same number of teeth and profile, the length of the flexspline, the same size and shape of the input shaft/base, the same wall thickness near the teeth, but will have a rounded bottom where the input shaft/base transitions to the straight wall of the flexspline. Embodiments demonstrate that the large radius of curvature of the flexspline improves the performance of a BMG-based material flexspline by reducing low cycle fatigue failures due to stress concentrations. Many embodiments of the invention refer to bulk metallic glass (BMG) as an alloy which can be quenched into a vitreous state at a relatively large casting thickness (generally over 1 mm). BMGs can also be referred to as amorphous metals (AMs) and their composites as amorphous metal composites (AMCs). Many other embodiments of the invention refer to in-situ composite or bulk metallic glass matrix composite (BMGMC) as an alloy which, upon rapid cooling (cooling rate from about 1K/s to about 1000 K/s), chemically partitions into two or more phases, one being an amorphous matrix and the other(s) being crystalline inclusions. The term “bulk metallic glass-based materials” (BMG-based materials) includes both BMGs and BMGMCs. Given that shearing and cracking is not a normal mode of failure for steel, changing the radius of curvature of the flexspline cup as described in many of the embodiments is not a conventional approach. Moreover, almost all flexsplines are machined from steel and small radii of curvatures are far easier to machine than large ones, especially when circularity must be maintained to high tolerances. In addition, flexspline cups having small radii of curvature maximize the operating torque of the strain wave gear. Nevertheless, embodiments implementing rounded edges are shown to improve the fatigue life of a BMG flexspline as compared to a straight wall cup. Moreover, the rounded shape reduces the net shaped manufacturing, as inserts normally used for casting around release much easier from the mold when they are round, as opposed to sharp. Accordingly, embodiments implementing brittle materials, like BMGs and others, simultaneously improve castability and fatigue life by increasing the curvature of the flexspline cup. Rounded flexsplines according to embodiments decrease the performance of the strain wave gears, because rounded corners do not take as much load as straight walls. The performance of rounded flexsplines is compensated by the use of brittle materials in the flexsplines, which would otherwise crack in straight wall structures. In some embodiments, the brittle materials provide better performance in rounded flexsplines. In some other embodiments, the brittle materials are easier to manufacture. BMGs, according to such embodiments, can be cast into the flexsplines, which lowers the manufacturing cost of flexsplines. Many embodiments of the invention remove stress concentrations at the base of the flexspline by adding a large radius of curvature to the base of the cup. Many embodiments increase the radius of curvature at the base of the flexspline cup from about 1% to about 2% of the flexspline diameter to at least 10% of the diameter of a standard flexspline while maintaining circularity along the rotational axis. Many other embodiments implement configurations that reduce other sharp edges in the apparatus. In various embodiments, cup-type flexsplines have a maximum radius of curvature of about 15% to about 20% based on the ratio of the input base diameter to the flexspline diameter. In many such embodiments, the maximum radius of curvature can be calculated with Equation 1: Maximumradiusofcurvature=(Diameterofouterwallofflexspline)-(Diameterofinputshaft)2 FIG.13illustrates a cup-type flexspline with a rounded edge according to many embodiments. Based on the fixed diameter of the flexspline wall and the input base, the maximum possible radius of curvature1301at the edge of the cup is 8 millimeter for a size CFS-20 flexspline. Without changing the diameter of the flexspline1302or the diameter of the input base1303, the BMG flexspline can support a radius of curvature between about 15% to about 20% of the diameter of the flexspline. As a comparison, a conventional steel cup-type CFS-20 flexspline as depicted inFIG.5has a radius of curvature501of about 1 millimeter, which is about 1% to about 2% of the flexspline diameter. Table 1 lists measurements of the diameter of the flexspline, the diameter of the input shaft/base, the approximate radius of curvature of the machined steel, the maximum radius of curvature possible and the maximum radius of curvature as a percentage of the diameter for three standard sizes of flexsplines. Overall, the radius of curvature of the machined steel is about 1% to about 2% of the diameter of the flexspline. By contrast, embodiments implement radius of curvature between about 15% to about 20% of the flexspline diameter, based on standard sizes. Embodiments demonstrate that the larger curvatures decrease the possible torque on the strain wave gear but reduces the stress concentrations of the BMG, resulting in longer life. Moreover, the rounded shape is easier to cast through near or net-shaped processes, such an injection molding, die casting, blow molding or metal injection molding. TABLE 1MaximumDiameterDiameterMachinedMaximumRadius ofofofRadius ofRadius ofCurvatureGearinput shaftflexsplineCurvatureCurvatureas % ofsize(mm)(mm)(mm)(mm)DiameterCSF-812.25200.253.87519%CSF-2048321817%CSF-328152214.518% In various embodiments, rounded edge BMG-based material flexsplines are manufactured with direct casting techniques in accordance with embodiments of the invention. Rounded edges are easier to cast than sharp edges. As an example,FIGS.14A-14Dillustrate a modified injection molding process that can be implemented to form a round edge flexspline in accordance with embodiments of the invention. In particular,FIG.14Adepicts a molten BMG-based material1402that has been heated to a molten state and is thereby ready to be inserted into a mold1403. The mold1403helps define the shape of the flexspline to be formed to have rounded edges1401.FIG.14Bdepicts that the molten BMG-based material1402is pressed into the rounded edge1401mold1403.FIG.14Cdepicts that the mold1403is released after the BMG-based material has cooled.FIG.14Ddepicts that any excess flash1404is removed. Note that the rounded edge of the cup of the flexspline1401reduces the stress concentration while simultaneously reduces the difficulty with manufacturing. FIGS.15A-15Dillustrate the forming a rounded flexspline using blow molding techniques. In particular,FIG.15Adepicts that a BMG-based material1501is placed within a mold1502with rounded edges1503.FIG.15Bdepicts that the BMG-based material1501is exposed to pressurized gas or liquid that forces the BMG-based material to conform to the shape of the mold1502. Typically, a pressurized inert gas is used. The BMG-based material1501is usually heated so that it is sufficiently pliable and can be influenced by the pressurized gas or liquid. Again, any suitable heating technique can be implemented in accordance with embodiments of the invention.FIG.15Cdepicts that due to the force of the pressurized gas or liquid, the BMG-based material conforms to the shape of the mold1502with rounded edges1503. The modified blow molding process allows a curve1503to form at the edges of the flexspline.FIG.15Dshows a prototype blow molded flexspline showing the natural tendency to form a hemisphere when expanding. This shape has the largest radius of curvature possible for the given diameter and thus the lowest stress concentration. Many embodiments describe the flexspline is made at least in part of a bulk metallic glass-based material that has been manufactured into a near or net-shaped flexspline. The fatigue life of the flexspline is improved by at least 10% when run at the same torque as a flexspline made from the same material but with a standard flexspline design created for steel. Many embodiments describe that the BMG can be injection molded, die cast, 3D printed, thermoplastically formed, blow molded, discharge formed, metal injection molded, pressed with powder, suction cast, or formed from sheet metal. In other embodiments, the flexspline has an elliptical base curvature. Many other embodiments describe that the cracking during operation of the flexspline can be suppressed compared to a similar cup with a radius of curvature of about 1% to about 2% of the flexspline diameter. Many other embodiments describe a flexspline of a cup-type strain wave gear that the radius of curvature at the base of the cup is at least 10% of the diameter of the flexspline. In some embodiments, the flexspline is made from a brittle material with a fracture toughness of less than 50 MPa m1/2. In some other embodiments, the flexspline is made from a metal alloy with less than 10% ductility in a tension test. In some other embodiments, the flexspline is made from tool steel, nanocrystalline or nanograined metals, ceramics, metal matrix composites. Embodiments Implementing BMG-Based Material Flexsplines With A Spherical Radius Of Curvature To accommodate BMG properties and manufacturing, many embodiments implement flexspline cups with features having reduced sharp edges.FIG.16illustrates embodiments where the BMG-based material flexspline has a hemispherical base with a protruding flat input base. In such embodiments, the flexspline has a wall1605with a diameter, an input base1602with a diameter, and a hemispherical base1604. More particularly, the flexspline has a flat input base1602to connect to the input shaft. The radius of curvature of the hemisphere, according to such embodiments, depends on the diameter of the flexspline and the diameter of the input shaft. Many embodiments describe a radius of curvature of at least 10% of the diameter of the flexspline. Many other embodiments include the flexspline has a spherical radius of curvature. In some embodiments, the rounded base of the flexspline has axial symmetry around the rotational axis of the flexspline. Many other embodiments describe increasing the wall thickness to decrease stress concentrators. In many such embodiments, the diameter at the teeth1601of the flexspline and the thickness of the wall near the teeth do not change from the standard flexspline such that the flexspline will fit into a standard outer spline and wave generator. In many embodiments, the BMG flexspline can be used with a standard outer spline and wave generator based on the required size. However, the fatigue life and the manufacturing will be greatly enhanced through the rounding of the base. Embodiments Implementing BMG-Based Material Flexsplines With An Elliptical Radius Of Curvature Many other embodiments describe another design of the flexspline cup base that does not maintain the standard input base sizes and shapes.FIG.17illustrates a BMG-based material flexspline, according to embodiments, having a hemispherical base with a protruding flat input base. In such embodiments, the flexspline has a wall1705with a diameter, an input base1702with a diameter, and a hemispherical base1704. The flexspline has a flat input base1702to connect to the input shaft. The radius of curvature of the rounded edge depends on the diameter of the flexspline and the diameter of the input shaft. Many embodiments describe the radius of curvature is at least 10% of the diameter of the flexspline. Many other embodiments include the flexspline has an elliptical radius of curvature. In some embodiments, the rounded base of the flexspline has axial symmetry around the rotational axis of the flexspline. In many such embodiments, the diameter at the teeth1701of the flexspline and the thickness of the wall near the teeth do not change from the standard flexspline such that the flexspline fits into a standard outer spline and wave generator. In many embodiments, the BMG flexspline can be used with a standard outer spline and wave generator based on the required size. However, the fatigue life and the manufacturing will be greatly enhanced through the rounding of the base. Embodiments Implementing BMG-Based Material Flexsplines With A Flush Input Base Many other embodiments describe embodiments including a flush input base such that when the flexspline is cast from BMG, it has an improved fatigue life of at least 10% over a BMG with a steel design when run at the same torque.FIG.18illustrates embodiments of a BMG-based material flexspline with a flush input base. The flexspline has a wall1805with a diameter, an input base1802with a diameter, and a hemispherical base1804. The input shaft or base1802of the flexspline cup where connections are made is flush with the flexspline, to eliminate sharp stress concentration. The flush input base1802connects to the input shaft. The radius of curvature depends on the diameter of the flexspline and the diameter of the input shaft. Many embodiments describe the radius of curvature is at least 10% of the diameter of the flexspline. In some embodiments, the hemispherical base of the flexspline has axial symmetry around the rotational axis of the flexspline. In many such embodiments the diameter at the teeth1801of the flexspline and the thickness of the wall near the teeth do not change from the standard flexspline such that the flexspline will fit into a standard outer spline and wave generator. In many embodiments, the BMG flexspline can be used with a standard outer spline and wave generator based on the required size. However, the fatigue life and the manufacturing will be greatly enhanced through the rounding of the base. Embodiments Implementing BMG-Based Material Flexsplines With Two Different Spherical Radii Of Curvature In some other embodiments, the flexspline has two different spherical radii of curvature that make up the rounded corners of the flexspline.FIG.19illustrates the BMG-based material flexspline has a rounded base with a flush input base. The flexspline has a wall1905with a diameter, an input base1902with a diameter, and a rounded base1904. The input base1902flushes to the flexspline and connects to the input shaft. The radius of curvature depends on the diameter of the flexspline and the diameter of the input shaft. Many embodiments describe two different spherical radii of curvature1903and1903′ that comprise the rounded corners of the flexspline. Many embodiments describe the radius of curvature is at least 10% of the diameter of the flexspline. In many such embodiments the diameter at the teeth1901of the flexspline and the thickness of the wall near the teeth do not change from the standard flexspline such that the flexspline will fit into a standard outer spline and wave generator. In many embodiments, the BMG flexspline can still be used with a standard outer spline and wave generator based on the required size. However, the fatigue life and the manufacturing will be greatly enhanced through the rounding of the base. Doctrine of Equivalents As can be inferred from the above discussion, the above-mentioned concepts can be implemented in a variety of arrangements in accordance with embodiments of the invention. Accordingly, although the present invention has been described in certain specific aspects, many additional modifications and variations would be apparent to those skilled in the art. It is therefore to be understood that the present invention may be practiced otherwise than specifically described. Thus, embodiments of the present invention should be considered in all respects as illustrative and not restrictive. | 29,777 |
11859706 | DETAILED DESCRIPTION Before describing various embodiments of the present disclosure in detail, it is to be understood that this disclosure is not limited to the parameters of the particularly exemplified systems, methods, apparatus, products, processes, and/or kits, which may, of course, vary. Thus, while certain embodiments of the present disclosure will be described in detail, with reference to specific configurations, parameters, components, elements, etc., the descriptions are illustrative and are not to be construed as limiting the scope of the claimed embodiments. In addition, the terminology used herein is for the purpose of describing the embodiments and is not necessarily intended to limit the scope of the claimed embodiments. The present disclosure includes embodiments for an integrated gearbox lockout device that improves upon the prior art and solves the problems associated with prior approaches. Certain embodiments can utilize keyless locking technology to keep a gearbox from rotating when the lockout device is engaged. Furthermore, embodiments of the lockout device can remain installed on the gearbox and perform its functions while maintaining a seal between the environment and the internals of the gearbox. Benefits of embodiments under the present disclosure include, but are not limited to:A locking device that is integral to the gearbox, is externally accessible, and maintains a sealed gearbox environment throughout all modes of operation;A keyless design that allows the locking system to slip torsionally above a specified torque threshold without the creation of foreign object damage (FOD) or damaging components (prevents damage to other components if inadvertently left engaged);A sliding shaft that can be engaged or disengaged through external input; by allowing disengagement, no direct lubrication is required, and components do not wear during aircraft operation;A fail-safe feature that manually prevents the sliding shaft from engaging while the aircraft is in operation;A compact, self-contained design that can be retrofitted onto fielded gearboxes and replaced in the field without impacting other gearbox internals; andSpecific packaging that prevents FOD from getting into the gearbox even in the event of component failure. One embodiment of a gearbox and drive shaft for a tilt rotor aircraft is shown inFIG.1. Gearbox10contains multiple gears that can provide power to drive train20. Second drive train30can couple gearbox10to a central drive system of an aircraft. At certain times, such as during maintenance procedures, or shipping to another location, it may be desirable to lock gearbox10and/or drive train20such that drive train20is not capable of rotating by itself or of being moved by the gears within gearbox10. One embodiment of a lockout device under the present disclosure is shown inFIG.2.FIG.2shows a cut-away view of a lockout device20coupled to a gearbox10, similar to the gearbox10ofFIG.1. Lockout device20comprises shaft25, outer collar30, inner collar35, housing40, and cover45. Screws48couple cover45to housing40. While the aircraft is in use (or is otherwise not in a lockout operation) cover45will preferably be kept in place to protect housing40and shaft25from wear and tear. When a user wishes to perform a lockout operation, cover45can be removed by removing screws48. When not in a lockout operation, shaft25with teeth27will sit to the left (in the view ofFIG.2) of teeth58of drive train59. When a user performs a lockout operation, cover45is removed and then shaft25can be pushed to engage teeth58. Socket head or receiving slot28in shaft25can receive a socket wrench operated by a user. The user can use the socket wrench to push in shaft25to engage teeth58with teeth27, and then to rotate the shaft25(and by extension the gearbox10) so as to torque up gearbox10and then restrain further movement during the lockout operation. Further description of the movement of shaft25and the lockout device20can be provided with respect toFIGS.2,3and4. Reference numbers are kept consistent betweenFIGS.2to4so as to assist in illustrating the movement of the described components.FIG.2shows a view of lockout device20unengaged from teeth58of gearbox10.FIG.3shows a view of lockout device20engaged in teeth58.FIG.4shows a view of lockout device20from outside of gearbox10. Screws48(shown in ghost form inFIGS.3and4because they would be removed with the cover45) are used to couple housing40to cover45and can be removed when a lockout operation is desired. Bolts42couple housing to gearbox10. Hex screws36couple inner collar35to outer collar30. Ring21along shaft25prevents the leftward movement (in this view) of inner collar35along the exterior of shaft25. Additionally, ring21can prevent shaft25from being pressed too far into gearbox10. Once a user has removed cover45, the user may push rightward (in this view) shaft25to engage teeth58. The user can then rotate hex screws36(e.g., in a clockwise direction)—this will pull inner collar35and outer collar30toward each other. In the view shown, inner collar35will move right with regard to outer collar30and vice versa. This motion will force inner collar35against the surface of shaft25and lock the rotation of shaft25, and by extension gearbox10and drive train59because shaft25is engaged with teeth58via teeth27. The inner collar35and outer collar30engage each other along line33, forcing each other in the movements described and thereby causing the locking functionality. Hex screws36pass through unthreaded holes in inner collar35and engage threaded holes in outer collar30. The rotation of hex screws36pulls outer collar30and inner collar35together and forces inner collar35downward against the shaft25. Holes37in inner collar35, visible inFIG.4, can be threaded. Screws or bolts placed here can be screwed in and can engage a flat face of outer collar30. Rotating the screws/bolts sufficiently can push against the outer collar and move inner collar35leftward (from the view ofFIG.3) and create additional freedom for the rotation of shaft25. The screws or bolts used in holes37can be hex screws36. Hex screws36can be removed from the threaded holes in outer collar30and threaded into holes37. Removing hex screws36from outer collar30and threading them into holes37can be part of ending a lockout operation and preparing the gearbox for use. O-ring18provides sealing protection to keep any fluids or other material from entering gearbox10through the lockout device20. Rims43of housing40can be shaped to abut the right edge (in this view) of outer collar30and to restrain rightward movement of outer collar30and inner collar35along shaft25. Cover45, or a portion thereof, can be clear or transparent and allow a user to visually inspect a status of lockout device20. Alternatively, an indicator, such as a toggle or flipped switch due to placement of the lockout device20components, can provide a user an indication of the status of lockout device20and/or gearbox10. As seen inFIG.2, cover45has a ridge70that engages slot72on shaft25. While the aircraft is in use and apart from times during lockout operations, ridge70and slot72hold shaft25in place with respect to cover45and prevent the engagement of teeth27with teeth58. Housing40can comprise a slot or ridge for an o-ring82for engaging a portion of gearbox10to hold housing40stationary with respect to gearbox10. The o-ring can provide an interference fit, sealing, and/or friction, between the housing and the gearbox. A portion of the interior of housing40can be hollow so as to save weight. Socket head28can be hex-shaped for use with a socket wrench when torquing shaft25and gearbox10. Shaft25can also comprise threaded hole or receiving slot29at the bottom of socket head28. Threaded hole29can be used with a threaded device to pull out shaft25if it gets pressed in too far. Socket head28can comprise other shapes besides a hexagonal shape. In some embodiments socket head28could comprise spline teeth that engage a tool for pulling out shaft25. Socket head28could be square-shaped in other embodiments. Other shapes are possible as well if they allow for torquing the system. Reference has been made to hex-shaped receiving components, or screws, bolts, screw-driver compatible components, Phillips head compatible components, etc. While the Figures show certain embodiments, other shaped components can be used. For example, a hex-shaped socket head28is shown. But other embodiments could comprise a pentagonal-shaped head, Phillips screwdriver head, proprietary-shaped head, spline teeth that can be engaged, and other styles. The current disclosure is not limited to a specific set up regarding the use of hex or other shaped or compatible components. FIG.5shows a method embodiment500under the present disclosure. Step510is unscrewing a cover from its coupling to a housing, the housing comprising a hole therethrough and configured to be fixedly coupled to the gearbox. Step520is uncoupling the cover from a shaft, the shaft configured to pass through the hole and comprising a first plurality of teeth at one end and a socket head on a distal end, the shaft configured to be translatable along its axis, wherein coupling the shaft to the cover prevents the shaft from engaging the drive train. Step530is manipulating the shaft so as to engage a second plurality of teeth on the drive train with the first plurality of teeth so as to transmit rotation from the shaft to the drive train. Step540is applying a torque to the drive train by rotating the socket head. Step550is rotating a plurality of threaded bolts coupled to a plurality of threadless holes in an inner collar and a plurality of threaded holes in an outer collar, the inner collar configured to sit around the shaft and at least partially between the shaft and the housing, the outer collar configured to sit around the shaft and at least partially between the inner collar and the housing, wherein rotating the plurality of threaded bolts can adjust the relative position of the inner collar and the outer collar, wherein as the inner collar and the outer collar are pulled closer together the inner collar is pushed against the shaft and restricts a displacement of the shaft within the hole. FIGS.6to12can help illustrate additional views of a lockout device embodiment and the performance of a lockout procedure and ending the lockout for use of the aircraft. FIG.6displays lockout device600, comprising a housing630and cover640, coupled to gearbox650. Bolts641couple cover640to housing630. Bolts631couple housing630to gearbox650. Bolts641can be removed to begin a lockout procedure. As seen inFIG.7, cover640has been removed. Holes642on housing630are now empty after the removal of bolts641. Shaft620can now be seen. Socket head622, ring623, and threaded hole624are also seen. Inner collar660is seen with threaded bolts665that couple inner collar660to outer collar670(not shown inFIG.7). Threaded holes667are shown, empty right now but available to receive threaded bolts665to assist in pushing inner collar660away from outer collar670. Referring toFIGS.8A-8B, threaded bolts665can be loosened, which will loosen the grip of inner collar660and outer collar670on shaft620. Referring toFIG.8B, shaft620can now be pushed axially into gearbox650so as to engage gear655. Shaft620can comprise teeth629that engage gear655. Gear655can comprise a portion of a drive train657. Ring623on shaft620prevents the shaft620from being pressed too far into gearbox650. Moving toFIGS.9A-9B, after shaft620has been moved to engage gear655, threaded bolts665can be tightened, drawing outer collar670and inner collar660closer together and pushing inner collar660more tightly around shaft620. After sufficient tightening (FIG.9B) the shaft620will be “locked” in gear655. Cover640can be reattached and the vehicle and/or gearbox can be shipped, undergo maintenance or storage, or as otherwise desired. When the user desires to end the lockout procedure, the cover640can be removed again. As seen inFIG.10, threaded bolts665can be removed from outer collar670and be threaded into threaded holes667. Using the threaded bolts665in threaded holes667will cause the tip of the threaded bolts665to press against a flat surface of outer collar670and thereby press inner collar660and outer collar670apart from each other and reduce grip on the shaft620. Shaft620can now be pulled away from gear655, allowing the gearbox650and drive train657to be operable for flight or other vehicle usage. Threaded bolts665can be retrieved from threaded holes667and reinserted into the inner collar660and outer collar670and tightened to “lock” the shaft in the unengaged position. Collar640(FIG.12) can then be reattached to housing630. Coupling649between collar640and shaft620can help hold shaft620in its locked and unengaged position so that it does not touch or engage gear655or drive train657during operation. Abbreviations and Defined Terms To assist in understanding the scope and content of this written description and the appended claims, a select few terms are defined directly below. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present disclosure pertains. The terms “approximately,” “about,” and “substantially,” as used herein, represent an amount or condition close to the specific stated amount or condition that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount or condition that deviates by less than 10%, or by less than 5%, or by less than 1%, or by less than 0.1%, or by less than 0.01% from a specifically stated amount or condition. Various aspects of the present disclosure, including devices, systems, and methods may be illustrated with reference to one or more embodiments or implementations, which are exemplary in nature. As used herein, the term “exemplary” means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments disclosed herein. In addition, reference to an “implementation” of the present disclosure or embodiments includes a specific reference to one or more embodiments thereof, and vice versa, and is intended to provide illustrative examples without limiting the scope of the present disclosure, which is indicated by the appended claims rather than by the present description. As used in the specification, a word appearing in the singular encompasses its plural counterpart, and a word appearing in the plural encompasses its singular counterpart, unless implicitly or explicitly understood or stated otherwise. Thus, it will be noted that, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. For example, reference to a singular referent (e.g., “a widget”) includes one, two, or more referents unless implicitly or explicitly understood or stated otherwise. Similarly, reference to a plurality of referents should be interpreted as comprising a single referent and/or a plurality of referents unless the content and/or context clearly dictate otherwise. For example, reference to referents in the plural form (e.g., “widgets”) does not necessarily require a plurality of such referents. Instead, it will be appreciated that independent of the inferred number of referents, one or more referents are contemplated herein unless stated otherwise. References in the specification to “one embodiment,” “an embodiment,” “an example embodiment,” and the like indicate that the embodiment described may include a particular feature, structure, or characteristic, but it is not necessary that every embodiment includes the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. It shall be understood that although the terms “first” and “second” etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and similarly, a second element could be termed a first element, without departing from the scope of example embodiments. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed terms. It will be further understood that the terms “comprises”, “comprising”, “has”, “having”, “includes” and/or “including”, when used herein, specify the presence of stated features, elements, and/or components etc., but do not preclude the presence or addition of one or more other features, elements, components and/or combinations thereof. Conclusion The present disclosure includes any novel feature or combination of features disclosed herein either explicitly or any generalization thereof. Various modifications and adaptations to the foregoing exemplary embodiments of this disclosure may become apparent to those skilled in the relevant arts in view of the foregoing description, when read in conjunction with the accompanying drawings. However, any and all modifications will still fall within the scope of the non-limiting and exemplary embodiments of this disclosure. It is understood that for any given component or embodiment described herein, any of the possible candidates or alternatives listed for that component may generally be used individually or in combination with one another, unless implicitly or explicitly understood or stated otherwise. Additionally, it will be understood that any list of such candidates or alternatives is merely illustrative, not limiting, unless implicitly or explicitly understood or stated otherwise. In addition, unless otherwise indicated, numbers expressing quantities, constituents, distances, or other measurements used in the specification and claims are to be understood as being modified by the term “about,” as that term is defined herein. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the subject matter presented herein. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the subject matter presented herein are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Any headings and subheadings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. The terms and expressions which have been employed herein are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the present disclosure. Thus, it should be understood that although the present disclosure has been specifically disclosed in part by preferred embodiments, exemplary embodiments, and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and such modifications and variations are considered to be within the scope of this present description. It will also be appreciated that systems, devices, products, kits, methods, and/or processes, according to certain embodiments of the present disclosure may include, incorporate, or otherwise comprise properties or features (e.g., components, members, elements, parts, and/or portions) described in other embodiments disclosed and/or described herein. Accordingly, the various features of certain embodiments can be compatible with, combined with, included in, and/or incorporated into other embodiments of the present disclosure. Thus, disclosure of certain features relative to a specific embodiment of the present disclosure should not be construed as limiting application or inclusion of said features to the specific embodiment. Rather, it will be appreciated that other embodiments can also include said features, members, elements, parts, and/or portions without necessarily departing from the scope of the present disclosure. Moreover, unless a feature is described as requiring another feature in combination therewith, any feature herein may be combined with any other feature of a same or different embodiment disclosed herein. Furthermore, various well-known aspects of illustrative systems, methods, apparatus, and the like are not described herein in particular detail in order to avoid obscuring aspects of the example embodiments. Such aspects are, however, also contemplated herein. All references cited in this application are hereby incorporated in their entireties by reference to the extent that they are not inconsistent with the disclosure in this application. It will be apparent to one of ordinary skill in the art that methods, devices, device elements, materials, procedures, and techniques other than those specifically described herein can be applied to the practice of the described embodiments as broadly disclosed herein without resort to undue experimentation. All art-known functional equivalents of methods, devices, device elements, materials, procedures, and techniques specifically described herein are intended to be encompassed by this present disclosure. When a group of materials, compositions, components, or compounds is disclosed herein, it is understood that all individual members of those groups and all subgroups thereof are disclosed separately. When a Markush group or other grouping is used herein, all individual members of the group and all combinations and sub-combinations possible of the group are intended to be individually included in the disclosure. The above-described embodiments are examples only. Alterations, modifications, and variations may be effected to the particular embodiments by those of skill in the art without departing from the scope of the description, which is defined solely by the appended claims. | 23,170 |
11859707 | DETAILED DESCRIPTION OF EMBODIMENTS Following, an embodiment of the present invention is explained. FIG.1is a skeleton diagram for explaining a power transmission device1according to the present embodiment. FIG.2is a cross section schematic diagram for explaining the power transmission device1of the present embodiment. FIG.3is an enlarged view around a planetary reduction gear4of the power transmission device1. FIG.4is an enlarged view around a differential mechanism5of the power transmission device1. As shown inFIG.1, the power transmission device1has a motor2, and the planetary reduction gear4that reduces the output rotation of the motor2and inputs it to the differential mechanism5. The power transmission device1also has drive shafts9(9A,9B) as the drive shaft, and a park lock mechanism3. In the power transmission device1, the park lock mechanism3, the planetary reduction gear4, the differential mechanism5, and the drive shafts9(9A,9B) are provided along the transmission route of the output rotation of the motor2around the rotation axis X. In the power transmission device1, after being reduced by the planetary reduction gear4and inputted to the differential mechanism5, the output rotation of the motor2is transmitted via the drive shafts9(9A,9B) to left and right drive wheels W, W of a vehicle in which the power transmission device1is mounted. Here, the planetary reduction gear4is a gear mechanism constituted from a plurality of gears. The rotation axis of the planetary reduction gear4is coaxial with the rotation axis X of the motor2. The planetary reduction gear4is connected downstream of the motor2. The differential mechanism5is connected downstream of the planetary reduction gear4. The drive shafts9(9A,9B) are connected downstream of the differential mechanism5. As shown inFIG.2, a body box10of the power transmission1has a first box11that houses the motor2, and a second box12that is externally fitted on the first box11. The body box10has a third box13assembled on the first box11, and a fourth box14assembled on the second box12. The first box11has a cylindrical support wall part111, and a flange shaped junction part112provided on one end111aof the support wall part111. In the first box11, the support wall part111is provided facing along the rotation axis X of the motor2. The motor2is housed inside the support wall part111. The junction part112is provided facing orthogonal to the rotation axis X. The junction part112is formed with a larger outer diameter than the support wall part111. The second box12has a cylindrical peripheral wall part121, a flange shaped junction part122provided on one end121aof the peripheral wall part121, and a flange shaped junction part123provided on another end121bof the peripheral wall part121. The peripheral wall part121is formed with an inner diameter that can be externally fitted on the support wall part111of the first box11. The first box11and the second box12are assembled to each other by the peripheral wall part121of the second box12being externally fitted on the support wall part111of the first box11. The junction part122of the one end121aside of the peripheral wall part121abuts the junction part112of the first box11from the rotation axis X direction. These junction parts122,112are linked to each other by bolts (not illustrated). In the first box11, a plurality of recessed grooves111bare provided on the outer circumference of the support wall part111. The plurality of recessed grooves111bare provided with a gap open in the rotation axis X direction. Each of the recessed grooves111bis provided along the entire circumference in the circumferential direction around the rotation axis X. The peripheral wall part121of the second box12is externally fitted on the support wall part111of the first box11. The openings of the recessed grooves111bare closed by the peripheral wall part121. A plurality of cooling paths CP through which cooling water is circulated are formed between the support wall part111and the peripheral wall part121. At the outer circumference of the support wall part111of the first box11, ring grooves111c,111care formed at both sides of the region in which the recessed grooves111bare provided. Seal rings113,113are externally engaged and attached to the ring grooves111c,111c. These seal rings113are press fitted on the inner circumference of the peripheral wall part121that is externally fitted on the support wall part111, and seal the gap between the outer circumference of the support wall part111and the inner circumference of the peripheral wall part121. On the other end121bof the second box12, a wall part120extending to the inner diameter side is provided. The wall part120is provided facing orthogonal to the rotation axis X. An opening120ain which the drive shaft9A is inserted is opened in the region intersecting the rotation axis X of the wall part120. In the wall part120, a cylindrical motor support unit125that surrounds the opening120ais provided on the motor2side (right side in the drawing) surface. The motor support unit125is inserted inside a coil end253bdescribed later. The motor support unit125faces an end part21bof a rotor core21with a gap open in the rotation axis X direction. In the peripheral wall part121of the second box12, in the vertical line direction with the mounted state of the power transmission device1in the vehicle as reference, the thickness in the radial direction of the lower region is thicker than the upper region. In this region that is thick in the radial direction, an oil reservoir128is provided penetrating in the rotation axis X direction. The oil reservoir128is connected via a communication hole112ato an axial oil passage138provided in a junction part132of the third box13. The communication hole112ais provided in the junction part112of the first box11. The third box13has a wall part130that is orthogonal to the rotation axis X. A junction part132that forms a ring shape seen from the rotation axis X direction is provided on the outer circumference part of the wall part130. Seen from the first box11, the third box13is positioned on the opposite side (right side in the drawing) from the differential mechanism5. The junction part132of the third box13is joined to the junction part112of the first box11from the rotation axis X direction. The third box13and the first box11are linked to each other by bolts (not illustrated). In this state, in the first box11, the opening on the junction part122side (right side in the drawing) of the support wall part111is blocked by the third box13. In the third box13, an insertion hole130aof the drive shaft9A is provided in the center of the wall part130. A lip seal RS is provided on the inner circumference of the insertion hole130a. In the lip seal RS, a lip section (not illustrated) is in elastic contact with the outer circumference of the drive shaft9A. The gap between the inner circumference of the insertion hole130aand the outer circumference of the drive shaft9A is sealed by the lip seal RS. A peripheral wall part131that surrounds the insertion hole130ais provided on the surface of the first box11side (left side in the drawing) in the wall part130. The drive shaft9A is supported with a bearing B4interposed on the inner circumference of the peripheral wall part131. Seen from the peripheral wall part131, a motor support unit135is provided on the motor2side (left side in the drawing). The motor support unit135forms a tube shape that surrounds the outer circumference of the rotation axis X with a gap open. A cylindrical connecting wall136is connected to the outer circumference of the motor support unit135. The connecting wall136is formed with a larger outer diameter than the peripheral wall part131of the wall part130side (right side in the drawing). The connecting wall136is provided facing along the rotation axis X, and extends in the direction separating from the motor2. The connecting wall136connects the motor support unit135and the wall part130of the third box13. The motor support unit135is supported by the third box13with the connecting wall136interposed. One end20aside of a motor shaft20penetrates the inside of the motor support unit135from the motor2side to the peripheral wall part131side. A bearing B1is supported on the inner circumference of the motor support unit135. The outer circumference of the motor shaft20is supported by the motor support unit135with the bearing B1interposed. The lip seal RS is provided on the position adjacent to the bearing B1. In the third box13, an oil hole136adescribed later is open at the inner circumference of the connecting wall136. Oil OL from the oil hole136ais made to flow into a space (internal space Sc) surrounded by the connecting wall136. The lip seal RS is provided to prevent the inflow of oil OL inside the connecting wall136to the motor2side. The fourth box14has a peripheral wall part141that surrounds the outer circumference of the planetary reduction gear4and the differential mechanism5, and a flange shaped junction part142provided on the end part of the second box12side in the peripheral wall part141. The fourth box14is positioned at the differential mechanism5side (left side in the drawing) seen from the second box12. The junction part142of the fourth box14is joined from the rotation axis X direction to the junction part123of the second box12. The fourth box14and the second box12are linked to each other by bolts (not illustrated). Inside the body box10of the power transmission device1, a motor chamber Sa that houses the motor2and a gear chamber Sb that houses the planetary reduction gear4and the differential mechanism5are formed. The motor chamber Sa is formed between the wall part120of the second box12and the wall part130of the third box13on the inside of the first box11. The gear chamber Sb is formed between the wall part120of the second box12and the peripheral wall part141of the fourth box14on the inner diameter side of the fourth box14. A plate member8is provided on the inside of the gear chamber Sb. The plate member8is fixed by the bolt B to the fourth box14. In the plate member8, the gear chamber Sb is partitioned into a first gear chamber Sb1that houses the planetary reduction gear4and the differential mechanism5, and a second gear chamber Sb2that houses the park lock mechanism3. The second gear chamber Sb2is positioned between the first gear chamber Sb1and the motor chamber Sa in the rotation axis X direction. The motor2has the cylindrical motor shaft20, the cylindrical rotor core21externally fitted on the motor shaft20, and a stator core25that surrounds the outer circumference of the rotor core21with a gap open. In the motor shaft20, bearings B1, B1are externally fitted and fixed at both sides of the rotor core21. The bearing B1positioned at one end20aside (right side in the drawing) of the motor shaft20seen from the rotor core21is supported on the inner circumference of the motor support unit135of the third box13. The bearing B1positioned at the other end20bside is supported on the inner circumference of the cylindrical motor support unit125of the second box12. The motor support units135,125are arranged facing with a gap open in the rotation axis X direction on the one end part21aand the other end part21bof the rotor core21on the inner diameter side of coil ends253a,253bdescribed later. The rotor core21is formed by laminating a plurality of silicon steel sheets, and each of the silicon steel sheets is externally fitted on the motor shaft20in a state where relative rotation with the motor shaft20is regulated. Seen from the rotation axis X direction of the motor shaft20, the silicon steel sheet has a ring shape. At the outer circumference side of the silicon steel sheet, N pole and S pole magnets (not illustrated) are provided alternately in the circumferential direction around the rotation axis X. The stator core25surrounding the outer circumference of the rotor core21is formed by laminating a plurality of electromagnetic steel sheets. The stator core25is fixed to the inner circumference of the cylindrical support wall part111of the first box11. Each of the electromagnetic steel sheets has a ring-shaped yoke part251fixed to the inner circumference of the support wall part111, and a teeth part252projecting to the rotor core21side from the inner circumference of the yoke part251. With the present embodiment, the stator core25having a configuration in which a winding253is distributed and wound across a plurality of teeth parts252is adopted. The stator core25has a longer length in the rotation axis X direction than the rotor core21by the amount of the coil ends253a,253bprojecting in the rotation axis X direction. It is also possible to adopt the stator core of a configuration in which the windings are concentrically wound on each of the plurality of teeth parts252projecting to the rotor core21side. The opening120ais provided in the wall part120(motor support unit125) of the second box12. The other end20bside of the motor shaft20is positioned inside the fourth box14, penetrating the opening120aat the differential mechanism5side (left side in the drawing). The other end20bof the motor shaft20faces a side gear54A described later with a gap open in the rotation axis X direction on the inside of the fourth box14. As shown inFIG.3, in the motor shaft20, a step201is provided in a region positioned inside the fourth box14. The step201is positioned in the vicinity of the motor support unit125. The lip seal RS supported on the inner circumference of the motor support unit125is abutting the outer circumference of the region between the step201and the bearing B1. The lip seal RS is partitioned into the motor chamber Sa that houses the motor2and the gear chamber Sb inside the fourth box14. The oil OL for lubricating the planetary reduction gear4and the differential mechanism5is sealed at the inner diameter side of the fourth box14(seeFIG.2). The lip seal RS is provided to prevent inflow of the oil OL to the motor chamber Sa. As shown inFIG.3, in the motor shaft20, the region from the step201to the vicinity of the other end20bis a fitted part202with a spline provided on the outer circumference. The parking gear30and a sun gear41are spline fitted on the outer circumference of the fitted part202. In the parking gear30, one side surface of the parking gear30in the rotation axis X direction abuts the step201(right side in the drawing). One end410aof a cylindrical base410of the sun gear41abuts the other side surface of the parking gear30(left side in the drawing). A nut N screwed onto the other end20bof the motor shaft20is press fitted from the rotation axis X direction on the other end410bof the base410. The sun gear41and the parking gear30are provided in a state sandwiched between the nut N and the step201, without being able to rotate relatively to the motor shaft20. The sun gear41is provided in a positional relationship overlapping the motor2noted above when seen from the rotation axis X direction. The sun gear41has teeth411on the outer circumference of the other end20bside of the motor shaft20. A large pinion gear431of a stepped pinion gear43engages with the outer circumference of the teeth411. The stepped pinion gear43has the large pinion gear431that engages with the sun gear41, and a small pinion gear432with a smaller diameter than the large pinion gear431. The stepped pinion gear43is a gear component in which the large pinion gear431and the small pinion gear432are provided integrally aligned in an axis line X1direction parallel to the rotation axis X. The large pinion gear431is formed with an outer diameter R1greater than an outer diameter R2of the small pinion gear432. The stepped pinion gear43is provided facing along the axis line X1. In this state, the large pinion gear431is positioned at the motor2side (right side in the drawing). The outer circumference of the small pinion gear432is engaged with the inner circumference of a ring gear42. The ring gear42forms a ring shape that surrounds the rotation axis X with a gap open. A plurality of engagement teeth421projecting radially outward are provided on the outer circumference of the ring gear42. The plurality of engagement teeth421are provided at intervals in the circumferential direction around the rotation axis X. In the ring gear42, the engagement teeth421provided on the outer circumference are spline fitted to teeth146aprovided on a support wall part146of the fourth box14. In the ring gear42, rotation around the rotation axis X is regulated. The stepped pinion gear43has a through hole430penetrating the inner diameter side of the large pinion gear431and the small pinion gear432in the axis line X1direction. The stepped pinion gear43is supported to be able to rotate on the outer circumference of a pinion shaft44penetrating the through hole430with needle bearings NB, NB interposed. On the outer circumference of the pinion shaft44, a middle spacer MS is interposed between the needle bearing NB that supports the inner circumference of the large pinion gear431and the needle bearing NB that supports the inner circumference of the small pinion gear432. As shown inFIG.4, a shaft-internal oil passage440is provided on the inside of the pinion shaft44. The shaft-internal oil passage440penetrates from one end44aof the pinion shaft44to another end44balong the axis line X1. Oil holes442,443that communicate between the shaft-internal oil passage440and the outer circumference of the pinion shaft44are provided on the pinion shaft44. The oil hole443opens in the region in which the needle bearing NB that supports the inner circumference of the large pinion gear431is provided. The oil hole442opens in the region in which the needle bearing NB that supports the inner circumference of the small pinion gear432is provided. In the pinion shaft44, the oil holes443,442open inside the region in which the stepped pinion gear43is externally fitted. Furthermore, an introduction path441for introducing the oil OL into the shaft-internal oil passage440is provided in the pinion shaft44. In the outer circumference of the pinion shaft44, the introduction path441opens in the region positioned inside a support hole71aof a second case unit7described later. The introduction path441communicates between the shaft-internal oil passage440and the outer circumference of the pinion shaft44. A case-internal oil passage781is opened on the inner circumference of the support hole71a. The case-internal oil passage781communicates between the outer circumference of a guide unit78projecting from a base71of the second case unit7and the support hole71a. In the cross section view along the axis line X1, the case-internal oil passage781is inclined with respect to the axis line X1. The case-internal oil passage781is inclined facing toward a slit710provided in the base71as it faces the rotation axis X side. The oil OL scooped up by a differential case50described later flows into the case-internal oil passage781. The oil OL that moves to the outer diameter side by centrifugal force due to rotation of the differential case50also flows into the case-internal oil passage781. The oil OL that flows into the introduction path441from the case-internal oil passage781flows into the shaft-internal oil passage440of the pinion shaft44. The oil OL that flows into the shaft-internal oil passage440is discharged radially outward from the oil holes442,443. The oil OL discharged from the oil holes442,443lubricates the needle bearing NB externally fitted on the pinion shaft44. In the pinion shaft44, a through hole444is provided more to the other end44bside than the region in which the introduction path441is provided. The through hole444penetrates the pinion shaft44in the diameter line direction. The pinion shaft44is provided so that the through hole444and an insertion hole782of the second case unit7described later are in phase around the axis line X1. A positioning pin P inserted in the insertion hole782penetrates the through hole444of the pinion shaft44. As a result, the pinion shaft44is supported on the second case unit7side in a state with rotation around the axis line X1regulated. As shown inFIG.4, on the one end44aside in the lengthwise direction of the pinion shaft44, a region projecting from the stepped pinion gear43is a first shaft part445. The first shaft part445is supported by a support hole61aprovided in a first case unit6of the differential case50. At the other end44bside in the lengthwise direction of the pinion shaft44, the region projecting from the stepped pinion gear43is a second shaft part446. The second shaft part446is supported by the support hole71aprovided in the second case unit7of the differential case50. Here, the first shaft part445means a region of the one end44aside in which the stepped pinion gear43is not externally fitted in the pinion shaft44. The second shaft part446means a region of the other end44bside in which the stepped pinion gear43is not externally fitted in the pinion shaft44. In the pinion shaft44, the length of the axis line X1direction is longer for the second shaft part446than the first shaft part445. Following, the main configuration of the differential mechanism5is explained. FIG.5is a perspective view around the differential case50of the differential mechanism5. FIG.6is an exploded perspective view around the differential case50of the differential mechanism5. As shown inFIG.4toFIG.6, the differential case50as a case houses the differential mechanism5. The differential case50is formed by assembling the first case unit6and the second case unit7in the rotation axis X direction. In the differential case50of the present embodiment, the first case unit6and the second case unit7have a function as carriers that support the pinion shaft44of the planetary reduction gear4. As shown inFIG.6, three pinion mate gears52and three pinion mate shafts51are provided between the first case unit6and the second case unit7of the differential case50. The pinion mate shafts51are provided at equal intervals in the circumferential direction around the rotation axis X (seeFIG.6). The end part of the inner diameter side of each pinion mate shaft51is linked to a common linking part510. One pinion mate gear52each is externally fitted on the pinion mate shafts51. Each pinion mate gear52is in contact with the linking part510from the radial outward side of the rotation axis X. Each of the pinion mate gears52in this state is supported to be rotatable on the pinion mate shaft51. As shown inFIG.4, a spherical washer53is externally fitted on the pinion mate shaft51. The spherical washer53is in contact with the spherical outer circumference of the pinion mate gear52. In the differential case50, the side gear54A is positioned at one side of the linking part510in the rotation axis X direction, and a side gear54B is positioned at the other side. The side gear54A is supported to be rotatable on the first case unit6. The side gear54B is supported to be rotatable on the second case unit7. The side gear54A is engaged to the three pinion mate gears52from one side in the rotation axis X direction. The side gear54B engages with the three pinion mate gears52from the other side in the rotation axis X direction. FromFIG.7toFIG.10are drawings for explaining the first case unit6. FIG.7is a perspective view of the first case unit6seen from the second case unit7side. FIG.8is a plan view of the first case unit6seen from the second case unit7side. FIG.9is a schematic diagram of the A-A cross section inFIG.8.FIG.9shows the arrangement of the pinion mate shaft51and the pinion mate gear52using virtual lines. FIG.10is a schematic diagram of the A-A cross section inFIG.8.FIG.10shows the arrangement of the side gear54A, the stepped pinion gear43, and the drive shaft9A using virtual lines while omitting an illustration of a linking beam62of the paper surface back side. As shown inFIG.7andFIG.8, the first case unit6has a ring-shaped base61. The base61is a plate-shaped member having a thickness W61in the rotation axis X direction. As shown inFIG.9andFIG.10, an opening60is provided in the center of the base61. A cylinder wall part611that surrounds the opening60is provided on the surface on the side opposite to the second case unit7(right side in the drawing) in the base61. The outer circumference of the cylinder wall part611is supported by the plate member8with a bearing B3interposed (seeFIG.2). Three linking beams62extending to the second case unit7side are provided on the surface of the second case unit7side (left side in the drawing) in the base61. The linking beams62are provided at equal intervals in the circumferential direction around the rotation axis X (seeFIG.7andFIG.8). The linking beams62have a base63orthogonal to the base61and a linking part64that is wider than the base63. As shown inFIG.9, a tip surface64aof the linking part64is a flat surface orthogonal to the rotation axis X, and a support groove65for supporting the pinion mate shaft51is provided on the tip surface64a. As shown inFIG.8, the support groove65seen from the rotation axis X direction is formed in a straight line along a radius line L of the ring-shaped base61. The support groove65crosses the center of the linking part64from the inner diameter side to the outer diameter side in the circumferential direction around the rotation axis X. As shown inFIG.9andFIG.10, the support groove65forms a semicircle shape along the outer diameter of the pinion mate shaft51. The support groove65is formed at a depth that can house half of the cylindrical pinion mate shaft51. Specifically, the support groove65is formed at a depth corresponding to half the diameter Da of the pinion mate shaft51(=Da/2). An arc part641is formed in a shape along the outer circumference of the pinion mate gear52on the inner diameter side (rotation axis X side) of the linking part64. In the arc part641, the outer circumference of the pinion mate gear52is supported with the spherical washer53interposed. In the arc part641, an oil groove642is provided facing along the radius line L noted above. The oil groove642is provided in a range from the support groove65of the pinion mate shaft51to a gear support part66fixed to the inner circumference of the linking part64. The gear support part66is connected to the boundary of the base63and the linking part64. The gear support part66is provided facing orthogonal to the rotation axis X. The gear support part66has a through hole660at the center. As shown inFIG.8, the outer circumference of the gear support part66is connected to the inner circumference of the three linking parts64. In this state, the center of the through hole660is positioned on the rotation axis X. As shown inFIG.9andFIG.10, in the gear support part66, a recess661surrounding the through hole660is provided on the surface of the side opposite to the base61(left side in the drawing). In the recess661, a ring-shaped washer55that supports the back surface of the side gear54A is housed. A cylindrical cylinder wall part541is provided on the back surface of the side gear54A. The washer55is externally fitted on the cylinder wall part541. Seen from the rotation axis X direction, three oil grooves662are provided on the surface of the recess661side in the gear support part66. The oil grooves662are provided at intervals in the circumferential direction around the rotation axis X. The oil groove662extends from the inner circumference of the gear support part66to the outer circumference along the radius line L noted above. The oil groove662is in contact with the oil groove642on the arc part641side noted above. As shown inFIG.7andFIG.8, the support holes61aof the pinion shaft44are open on the base61. The support holes61aare open at the region between the linking beams62,62arranged at prescribed intervals in the circumferential direction around the rotation axis X. A boss part616surrounding the support hole61ais provided on the base61. A washer We (seeFIG.10) externally fitted on the pinion shaft44is in contact with the boss part616from the rotation axis X direction. In the base61, an oil groove617is provided in the range from the center opening60to the boss part616. As shown inFIG.8, the oil groove617is formed in a tapered shape in which the circumferential direction width around the rotation axis X becomes narrower as it approaches the boss part616. The oil groove617is connected to an oil groove618provided on the boss part616. In the linking part64, bolt holes67,67are provided at both sides of the support groove65. A linking part74of the second case unit7side is joined from the rotation axis X direction to the linking part64of the first case unit6. The first case unit6and the second case unit7are joined to each other by the bolts B that penetrate the linking part of the second case unit7side being screwed into bolt holes67,67. FIG.11toFIG.16are drawings for explaining the second case unit7. FIG.11is a perspective view of the second case unit7seen from the first case unit6side. FIG.12is a plan view of the second case unit7seen from the first case unit6side. FIG.13is a schematic diagram of the A-A cross section inFIG.12.FIG.13shows the arrangement of the pinion mate shaft51and the pinion mate gear52using virtual lines. FIG.14is a schematic diagram of the A-A cross section inFIG.12.FIG.14shows the arrangement of the side gear54B, the stepped pinion gear43, and the drive shaft9B using virtual lines while omitting an illustration of the linking part74at the paper surface back side. FIG.15is a perspective view of the second case unit7seen from the side opposite to the first case unit6. FIG.16is a plan view of the second case unit7seen from the side opposite to the first case unit6. As shown inFIG.13andFIG.14, the second case unit7has the ring-shaped base71. The base71is a plate-shaped member having a thickness W71in the rotation axis X direction. A through hole70that penetrates the base71in the thickness direction is provided at the center of the base71. A cylinder wall part72that surrounds the through hole70and a peripheral wall part73that surrounds the cylinder wall part72with a gap open are provided at the surface on the side opposite to the first case unit6(left side in the drawing) in the base71. A projection73athat projects to the rotation axis X side is provided at the tip of the peripheral wall part73. The projection73ais provided across the entire circumference in the circumferential direction around the rotation axis X. As shown inFIG.16, three support holes71aof the pinion shaft44are open at the outer diameter side of the peripheral wall part73. The support holes71aare provided at intervals in the circumferential direction around the rotation axis X. Three slits710penetrating the base71in the thickness direction are provided on the inner diameter side of peripheral wall part73. Seen from the rotation axis X direction, the slits710form an arc shape along the inner circumference of the peripheral wall part73. The slits710are formed in a prescribed angle range in the circumferential direction around the rotation axis X. The slits710in the second case unit7are provided at intervals in the circumferential direction around the rotation axis X. Each of the slits710is provided crossing the inner diameter side of the support hole71ain the circumferential direction around the rotation axis X. Three projecting walls711projecting to the paper surface front side are provided between adjacent slits710,710in the circumferential direction around the rotation axis X. The projecting walls711extend in a straight line in the radial direction of the rotation axis X. The projecting walls711are provided connecting the peripheral wall part73of the outer diameter side and the cylinder wall part72of the inner diameter side. Three projecting walls711are provided at intervals in the circumferential direction around the rotation axis X. The projecting walls711are provided with a phase shift of approximately 45 degrees in the circumferential direction around the rotation axis X with respect to the slits710. Bolt housing parts76,76recessed at the paper surface back side are provided between support holes71a,71aadjacent in the circumferential direction around the rotation axis X at the outer diameter side of peripheral wall part73. These bolt housing parts76,76are provided in a positional relationship that is symmetrical with the radius line L sandwiched between. The bolt housing parts76open at an outer circumference71cof the base71. Bolt insertion holes77open at the inside of the bolt housing parts76. The insertion holes77penetrate the base71in the thickness direction (rotation axis X direction). As shown inFIG.11andFIG.12, the three linking parts74projecting to the first case unit6side are provided on the surface of the first case unit6side (right side in the drawing) in the base71. The linking parts74are provided at equal intervals in the circumferential direction around the rotation axis X. The linking parts74are formed at a width W7in the same circumferential direction as the linking parts64of the first case unit6side. As shown inFIG.13, a tip surface74aof the linking part74is a flat surface orthogonal to the rotation axis X. A support groove75for supporting the pinion mate shaft51is provided on the tip surface74a. As shown inFIG.12, the support groove75seen from the rotation axis X direction is formed in a straight line along the radius line L of the base71. The support groove75is formed crossing the linking part74from the inner diameter side to the outer diameter side. As shown inFIG.5, the support groove75forms a semicircle shape along the outer diameter of the pinion mate shaft51. As shown inFIG.13, the support groove75is formed at a depth capable of housing half of the cylindrical pinion mate shaft51. Specifically, the support groove75is formed at a depth corresponding to half the diameter Da (=Da/2) of the pinion mate shaft51. An arc part741is provided along the outer circumference of the pinion mate gear52on the inner diameter side (rotation axis X side) of the linking part74. In the arc part741, the outer circumference of the pinion mate gear52is supported with the spherical washer53interposed (seeFIG.13andFIG.14). An oil groove742facing along the radius line L noted above is provided in the arc part741. The oil groove742is provided in a range from the support groove75of the pinion mate shaft51to the base71positioned at the inner circumference of the linking part74. The oil groove742connects with an oil groove712provided in a front surface71bof the base71. The oil groove712seen from the rotation axis X direction is provided along the radius line L, and is formed to the through hole70provided in the base71. The ring-shaped washer55that supports the back surface of the side gear54B is placed on the front surface71bof the base71. A cylindrical cylinder wall part540is provided on the back surface of the side gear54B. The washer55is externally fitted on the cylinder wall part540. An oil groove721is formed at the position intersecting the oil groove712on the inner circumference of the cylinder wall part72surrounding the though hole70. The oil groove721is provided facing along the rotation axis X across the entire length of the rotation axis X direction of the cylinder wall part72on the inner circumference of the cylinder wall part72. As shown inFIG.11andFIG.12, the guide unit78is provided between linking parts74,74adjacent in the circumferential direction around the rotation axis X at the base71of the second case unit7. The guide unit78projects to the first case unit6side (paper surface front side). The guide unit78forms a cylinder seen from the rotation axis X direction. The guide unit78surrounds the support hole71aprovided in the base71. The outer circumference part of the guide unit78is cut along the outer circumference71cof the base71. As shown inFIG.13andFIG.14, in the cross section view along the axis line X1, the pinion shaft44is inserted from the first case unit6side in the support hole71aof the guide unit78. The pinion shaft44is positioned by the positioning pin P in a state with the rotation around the axis line X1regulated. In this state, the small pinion gear432of the stepped pinion gear43externally fitted on the pinion shaft44abuts the guide unit78from the axis line X1direction with the washer Wc sandwiched between. As shown inFIG.4, in the differential case50, a bearing B2is externally fitted on the cylinder wall part72of the second case unit7. The bearing B2that is externally fitted on the cylinder wall part72is held by a support unit145of the fourth box14. The cylinder wall part72of the differential case50is supported to be rotatable with the fourth box14with the bearing B2interposed. The drive shaft9B that penetrates an opening145aof the fourth box14is inserted from the rotation axis X direction in the support unit145. The drive shaft9B is supported to be rotatable with the support unit145. The lip seal RS is fixed to the inner circumference of the opening145a. The lip section (not illustrated) of the lip seal RS is elastically in contact with the outer circumference of the cylinder wall part540of the side gear54B externally fitted on the drive shaft9B. As a result, the gap between the outer circumference of the cylinder wall part540of the side gear54B and the inner circumference of the opening145ais sealed. The first case unit6of the differential case50is supported by the plate member8with the bearing B3that is externally fitted on the cylinder wall part611interposed (seeFIG.2). The drive shaft9A that penetrates the insertion hole130aof the third box13is inserted from the rotation axis direction inside the first case unit6. The drive shaft9A is provided crossing the motor shaft20of the motor2and the inner diameter side of the sun gear41of the planetary reduction gear4in the rotation axis X direction. As shown inFIG.4, in the interior of the differential case50, side gears54A,54B are spline fitted at the outer circumference of the tip end part of the drive shafts9(9A,9B). The side gears54A,54B and drive shafts9(9A,9B) are linked to be able to rotate integrally around the rotation axis X. In this state, the side gears54A,54B are arranged facing with a gap open in the rotation axis X direction, and the linking part510of the pinion mate shaft51is positioned between the side gears54A,54B. In the present embodiment, the total of three pinion mate shafts51extend radially outside from the linking part510. A pinion mate gear52is supported on each of the pinion mate shafts51. The pinion mate gears52are assembled in a state with the teeth mutually engaged on the side gear54A positioned at one side in the rotation axis X direction and the side gear54B positioned at the other side. As shown inFIG.2, the oil OL for lubrication is retained inside the fourth box14. The bottom side of the differential case50is positioned within the retained oil OL. In the present embodiment, when the linking beam62is positioned at the bottommost part, the oil OL is retained up to the height at which the linking beam62is positioned within the oil OL. When the output rotation of the motor2is transmitted, the retained oil OL is scooped up by the differential case50that rotates around the rotation axis X. FIG.17toFIG.22are drawings for explaining the oil catch unit15. FIG.17is a plan view of the fourth box14seen from the third box13side. FIG.18is a perspective view of the oil catch unit15shown inFIG.17seen from diagonally above. FIG.19is a plan view of the fourth box14seen from the third box13side.FIG.19is a drawing showing the state with the differential case50arranged. FIG.20is a perspective view of the oil catch unit15shown inFIG.19seen from diagonally above. FIG.21is a schematic diagram of the A-A cross section inFIG.19. FIG.22is a schematic diagram for explaining the positional relationship between the oil catch unit15and the differential case50(first case unit6, second case unit7) when the power transmission device1is seen from above. InFIG.17andFIG.19, to make the position of the junction part142of the fourth box14and the support wall part146clear, these are shown marked by cross hatching. As shown inFIG.17, the support wall part146surrounding the center opening145awith a gap open is provided in the fourth box14seen from the rotation axis X direction. The inside (rotation axis X) side of the support wall part146is a housing unit140of the differential case50(seeFIG.19). A space of the oil catch unit15and a space of a breather chamber16are formed on the top part inside the fourth box14. In the support wall part146of the fourth box14, a communication port147that communicates between the oil catch unit15and the housing unit140of the differential case50is provided in the region intersecting a vertical line VL. As shown inFIG.17, the oil catch unit15and the breather chamber16are respectively positioned at one side (left side in the drawing) and the other side (right side in the drawing) sandwiching the vertical line VL that is orthogonal to the rotation axis X. The oil catch unit15is arranged at a position offset from the vertical line VL passing through the rotation center of the differential case50(rotation axis X). As shown inFIG.22, when viewing the oil catch unit15from above, the oil catch unit15is arranged at a position offset from directly above the differential case50. Here, the vertical line VL is a vertical line VL with the installation state of the power transmission device1in the vehicle as reference. Seen from the rotation axis X direction, the vertical line VL is orthogonal to the rotation axis X. In the explanation hereafter, the horizontal line HL is the horizontal line HL with the installation state of the power transmission device1in the vehicle as reference. Seen from the rotation axis X direction, the horizontal line HL is orthogonal to the rotation axis X (seeFIG.17). As shown inFIG.18, the oil catch unit15is formed extending to the paper surface back side from the support wall part146. A support stand151projecting to the paper surface front side is provided on the bottom edge of the oil catch unit15. The support stand151is provided in a range on the paper surface front side from the support wall part146, to the paper surface back side from the junction part142of the fourth box14. As shown inFIG.17, seen from the rotation axis X direction, the communication port147that communicates between the oil catch unit15and the housing unit140of the differential case50is formed on the vertical line VL side (right side in the drawing) of the oil catch unit15. The communication port147is formed with a portion of the support wall part146cut out. Seen from the rotation axis X direction, the communication port147is provided in a range crossing the vertical line VL from the breather chamber16side (right side in the drawing) to the oil catch unit15side (left side in the drawing). As shown inFIG.19, in the present embodiment, during forward travel of the vehicle in which the power transmission device1is mounted, seen from the third box13side, the differential case50rotates in the counterclockwise direction CCW around the rotation axis X. For that reason, the oil catch unit15is positioned at the downstream side in the rotation direction of the differential case50. For the width in the circumferential direction of the communication port147, the left side sandwiching the vertical line VL is wider than the right side. The left side sandwiching the vertical line VL is at the downstream side in the rotation direction of the differential case50, and the right side is the upstream side. As a result, much of the oil OL scooped up by the differential case50rotating around the rotation axis X can flow into the oil catch unit15. Furthermore, as shown inFIG.22, the outer circumference position of the rotational orbit of a second shaft part446of the pinion shaft44noted above and the outer circumference position of the rotational orbit of the large pinion gear431are offset in the radial direction of the rotation axis X. The outer circumference position of the rotational orbit of the second shaft part446is positioned more to the inner diameter side than the outer circumference position of the rotational orbit of the large pinion gear431. For that reason, there is a spatial margin at the outer diameter side of the second shaft part446. By providing the oil catch unit15using this space, it is possible to effectively use the space inside the body box10. Also, the second shaft part446projects to the back side of the small pinion gear432seen from the motor2. The peripheral member of the second shaft part446(e.g. the guide unit78of the differential case50that supports the second shaft part446) is at a position near the oil catch unit15. Thus, it is possible to smoothly perform supplying of the oil OL (lubricating oil) from that peripheral member to the oil catch unit15. As shown inFIG.18, the end part of the outer diameter side of the oil hole151ais open at the back side of the support stand151. The oil hole151aextends to the inner diameter side inside the fourth box14. The end part of the inner diameter side of the oil hole151ais open on the inner circumference of the support unit145. As shown inFIG.2, the end part of the inner diameter side of the oil hole151ain the support unit145is open between the lip seal RS and the bearing B2. As shown inFIG.20andFIG.22, an oil guide152is placed on the support stand151. The oil guide152has a catch unit153, and a guide unit154extending from the catch unit153to the first box11side (paper surface front side inFIG.20). As shown inFIG.22, seen from above, the support stand151is provided radially outside the rotation axis X, at a position partially overlapping the differential case50(first case unit6, second case unit7), and to avoid interference with the stepped pinion gear43(large pinion gear431). Seen from the radial direction of the rotation axis X, the catch unit153is provided at a position overlapping the second shaft part446of the pinion shaft44. Furthermore, the guide unit154is provided at a position where the first shaft part445of the pinion shaft44and the large pinion gear431overlap. For that reason, when the differential case50rotates around the rotation axis X, the oil OL scooped up by the differential case50moves toward the catch unit153and the guide unit154side. As shown inFIG.20, a wall part153ais provided extending in the direction separating (upward) from the support stand151on the outer circumference edge of the catch unit153. A portion of the oil OL scooped up by the differential case50rotating around the rotation axis X is retained in the oil guide152. A notch part155is provided in the wall part153aat the back side of the catch unit153(paper surface back side inFIG.20). As shown inFIG.22, the notch part155is provided in a region facing the oil hole151a. A portion of the oil retained in the catch unit153is discharged from the notch part155portion toward the oil hole151a. As shown inFIG.21, the guide unit154is inclined downward as it separates from the catch unit153. As shown inFIG.20, wall parts154a,154aare provided at both sides in the width direction of the guide unit154. The wall parts154a,154aare provided across the entire length in the lengthwise direction of the guide unit154. The wall parts154a,154aare connected to the wall part153athat surrounds the outer circumference of the catch unit153. A portion of the oil retained in the catch unit153is also discharged to the guide unit154side. As shown inFIG.21, in the guide unit154, the position that avoids interference with the differential case50extends to the second box12side. A tip154bof the guide unit154faces an oil hole126aprovided on the wall part120of the second box12with a gap open in the rotation axis X direction. A boss part126that surrounds the oil hole126ais provided on the outer circumference of the wall part120. One end of a pipe127is fitted into the boss part126from the rotation axis X direction. The pipe127passes through the outside of the second box12to the third box13. The other end of the pipe127communicates with the oil hole136aprovided in the cylindrical connecting wall136of the third box (seeFIG.2). As shown inFIG.19, a portion of the oil OL scooped up by the differential case50rotating around the rotation axis X reaches the oil catch unit15. As shown inFIG.21, the oil OL passes through the guide unit154and the pipe127, and is supplied to the internal space Sc of the connecting wall136(seeFIG.2). As shown inFIG.2, a radial oil passage137that communicates with the internal space Sc is provided in the third box13. The radial oil passage137extends radially downward from the internal space Sc. The radial oil passage137communicates with the axial oil passage138provided inside the junction part132. The axial oil passage138connects with the oil reservoir128provided at the bottom of the second box12via the communication hole112aprovided in the junction part112of the first box11. The oil reservoir128penetrates inside the peripheral wall part121in the rotation axis X direction. The oil reservoir128connects with the gear chamber Sb provided in the fourth box14. In the gear chamber Sb, the disc-shaped plate member8is provided facing orthogonal to the rotation axis X. As described above, in the plate member8, the gear chamber Sb inside the fourth box14is partitioned into a first gear chamber Sb1on the differential case50side, and a second gear chamber Sb2on the motor2side. FIG.23toFIG.26are drawings that explain the plate member8. FIG.23is a plan view of the plate member8seen from the motor2side. FIG.24is a schematic drawing of the A-A cross section inFIG.23. FIG.25is a plan view of the plate member8seen from the differential case50side (planetary reduction gear4side). FIG.26is a schematic diagram of the A-A cross section inFIG.25. InFIG.25, to clarify the position of hook parts81c,82c,83c,84c,85c, these are shown marked by cross hatching. As shown inFIG.23, seen from the motor2side, the plate member8has a ring-shaped base80. At the center of the base80, a ring-shaped support part801is provided surrounding a through hole800. As shown inFIG.3, at the inner circumference of the support part801, the cylinder wall part611of the differential case50is supported with the bearing B3interposed. As shown inFIG.23, connecting pieces81,82,83,84are provided on an outer circumference edge80cof the base80. Each of the connecting pieces81,82,83,84extends radially outward from the outer circumference edge80cof the base80. Bolts81a,82a,83a,84aare provided respectively in the connecting pieces81,82,83,84. The connecting piece81is provided at a position intersecting the vertical line VL on the top part of the plate member8. The connecting piece81extends in the direction separating from the base80along the vertical line VL. At one side of the vertical line VL (left side inFIG.23), one each of the connecting pieces82,83is provided respectively on the upper side and the lower side sandwiching the horizontal line HL. These connecting pieces82,83also extend in the direction separating from the base80. At the other side of the vertical line VL (right side in theFIG.23), the connecting piece84is provided below the horizontal line HL. This connecting piece84passes through the lower edge of the connecting piece83noted above at the lower side of the horizontal line HL. The connecting piece84projects downward from the position intersecting a straight line HLa parallel to the horizontal line HL. At the other side of the vertical line VL (right side inFIG.23), the connecting piece85is provided above the horizontal line HL. The connecting piece85has a prescribed width in the circumferential direction around the rotation axis X. A bolt85ais provided at a position near the vertical line VL in the connecting piece85. A support pin85bis provided at a position near the horizontal line HL. As shown inFIG.25, the hook parts81c,82c,83c,84c,85care provided on a surface80bon the differential case50side in the base80. These hook parts81c,82c,83c,84c,85care positioned at the boundary between each of the connecting pieces81,82,83,84,85and the outer circumference edge80cof the base80(seeFIG.26).FIG.26illustrates only the hook part83c, but the other hook parts81c,82c,84c,85care the same. The hook parts81c,82c,83c,84c,85cproject to the differential case50side (paper surface front side inFIG.25). Seen from the rotation axis X direction, each of the hook parts81c,82c,83c,84c,85cforms an arc shape along the outer circumference edge80cof the base80. FIG.27toFIG.32are drawings for explaining peripheral wall parts148,149provided in the fourth box14. FIG.27is a drawing of the fourth box14seen from the motor2side. FIG.28is a cross section schematic diagram cutting the peripheral wall part148along line A-A inFIG.27. FIG.29is a cross section schematic diagram cutting the peripheral wall part148along line B-B inFIG.27. FIG.30is an enlarged view of region C inFIG.27. FIG.31is a cross section schematic diagram cutting the peripheral wall part148along line A-A inFIG.30. FIG.32is a cross section schematic diagram cutting the peripheral wall part148along line B-B inFIG.30. InFIG.27toFIG.32, to clarify the position of the peripheral wall parts148,149, and the arc-shaped wall part17, and the position of the steps148d,149d,17d, these are shown marked by cross hatching. FIG.33andFIG.34are drawings for explaining the arrangement of the plate member8in the fourth box14. FIG.33is a drawing of the fourth box14seen from the motor2side, and is a drawing for explaining the state with the plate member8attached to the fourth box14. FIG.34is cross section schematic diagram around the plate member8cutting along line A-A inFIG.33. As shown inFIG.27, peripheral wall parts148,149are provided on the fourth box14seen from the rotation axis X direction, at the outer diameter side of a region in which teeth146aare provided in the support wall part146. The peripheral wall parts148,149are formed in an arc shape with the rotation axis X as the center. The peripheral wall part148is positioned below the oil catch unit15noted above in the vertical line VL direction. Seen from the rotation axis X direction, the peripheral wall part148is provided in a range crossing the horizontal line HL that passes through the rotation axis X from the upper side to the lower side. An end part148aon the upper side of the peripheral wall part148is positioned in the vicinity of the support stand151. An end part148bon the lower side of the peripheral wall part148is positioned in the vicinity of the straight line HLa. As shown inFIG.28andFIG.29, the step148dis provided on the inner circumference of the tip end side of the peripheral wall part148. As shown inFIG.27, the step148dhas an arc-shaped inner circumference part148esurrounding the rotation axis X with a gap open, and a bottom part148forthogonal to the rotation axis X. The region with the step148dof the tip end side of the peripheral wall part148removed serves as a rib part148c. The rib part148cseen from the rotation axis X direction forms an arc shape along the outer circumference of the plate member8(base80) noted above. The inner diameter of the rib part148cof the peripheral wall part148with the rotation axis X as a reference is slightly larger than the outer diameter of the plate member8with the rotation axis X as a reference. As shown inFIG.27, the bottom part148fseen from the rotation axis X direction is positioned at the paper surface back side from the rib part148c. When the plate member8is attached to the fourth box14, hook parts82c,83cof the plate member8(base80) side abut the bottom part148ffrom the rotation axis X direction (seeFIG.28). Two boss parts18having a bolt hole18aare provided on the outside of the peripheral wall part148. The boss parts18,18are formed integrally with the peripheral wall part148. The boss parts18,18are respectively provided at the end part148aside of the upper side of the peripheral wall part148and in the vicinity of the end part148bof the lower side. InFIG.27, the boss parts18,18project to the paper surface front side from the peripheral wall part148. The peripheral wall part149is positioned below the abovementioned breather chamber16. The peripheral wall part149is positioned at the paper surface back side from the wall part160that partitions and forms the breather chamber16. The peripheral wall part149serves as a roof part projecting in the rotation axis X direction between the breather chamber16and the large pinion gear431revolution orbit. The end part149aon the upper side of the peripheral wall part149seen from the rotation axis X direction is connected to the boss part18on the vertical line VL. A side wall part159extending to the oil catch unit15side is further connected to the boss part18. The end part149bof the lower side of the peripheral wall part149is connected to the peripheral wall part141of the fourth box14below the breather chamber16(seeFIG.27). As shown inFIG.31andFIG.32, the step149dis provided on the inner circumference on the tip end side of the peripheral wall part149. As shown inFIG.30, the step149dhas an arc-shaped inner circumference part149esurrounding the rotation axis X with a gap open, and a bottom part149forthogonal to the rotation axis X. The region with the step149dremoved at the tip end side of the peripheral wall part149serves as a rib part149c. The rib part149cseen from the rotation axis X direction forms an arc shape along the outer circumference of the plate member8(base80) noted above. The inner diameter of the rib part149cwith the rotation axis X as the reference is slightly larger than the outer diameter of the plate member8with the rotation axis X as the reference. As shown inFIG.30, the bottom part149fseen from the rotation axis X direction is positioned to the paper surface back side from the rib part149c. When the plate member8is attached to the fourth box14, the hook parts81c,85cof the plate member8(base80) side abut the bottom part149ffrom the rotation axis X direction (seeFIG.32).FIG.32illustrates only the hook part85c. Though the illustration is omitted, the hook part81cis the same. Two boss parts18having a bolt hole18aare provided on the outside of the peripheral wall part149. The boss parts18,18are formed integrally with the peripheral wall part149. The boss parts18,18are provided with a gap open in the circumferential direction around the rotation axis X. The boss parts18,18are respectively provided at the outer circumference of the end part148aon the upper side of the peripheral wall part149and the outer circumference of the region positioned below the breather chamber16. The boss parts18,18project to the paper surface front side from the peripheral wall part149. As shown inFIG.27, in the fourth box14, the arc-shaped wall part17is provided in a region which is below the breather chamber16and below the horizontal line HL. The arc-shaped wall part17is provided in a positional relationship with a phase shift of approximately 180 degrees with respect to the peripheral wall part148in the circumferential direction around the rotation axis X. Seen from the rotation axis X direction, an inner circumference17cof the arc-shaped wall part17forms an arc shape along the outer circumference of the plate member8(base80) noted above. The inner diameter of the inner circumference17cof the arc-shaped wall part17with the rotation axis X as a reference is slightly larger than the outer diameter of the plate member8with the rotation axis X as a reference. In the arc-shaped wall part17, the boss part18having the bolt hole18ais formed at the position intersecting the straight line HLa noted above. The boss part18projects to the paper surface front side from the arc-shaped wall part17. As shown inFIG.27, a notch part18cis provided at the inner circumference of the rotation axis X side of the boss part18. This notch part18cis formed with a portion of the boss part18cut out. The notch part18cis an item for preventing interference by the outer circumference edge80c(seeFIG.25) of the base80of the plate member8with the boss part18when the plate member8is assembled with the fourth box14. Seen from the rotation axis X direction, the step17dprojecting in the rotation axis X direction is provided on the inner circumference of the notch part18c. When the plate member8is attached to the fourth box14, the outer circumference edge of the plate member8(base80) abuts the step17dfrom the rotation axis X direction. Here, for attachment of the plate member8to the fourth box14, first, the outer circumference edge of the plate member8(base80) is made to be inserted inside the peripheral wall parts148,149, and the plate member8is assembled with the fourth box14. At this time, the hook parts81c,82c,83c,84c,85cprovided at the root of the connecting pieces81,82,83,84,85of the plate member8abut the steps148d,149d(bottom parts148f,149f) and the step17dof the arc-shaped wall part17from the rotation axis X direction. Subsequently, the bolts B penetrating the bolt holes81ato85aof the connecting pieces81to85are screwed into the bolt holes18aof the corresponding boss parts18. As a result, the plate member8is fixed to the fourth box14(seeFIGS.30to32). In this state, the hook parts81c,82c,83c,84c,85cextending from the inner diameter side of the connecting pieces81,82,83,84,85are internally fitted in the corresponding peripheral wall parts148,149, or the boss part18. For example, as shown inFIG.28, the hook part82cprojecting from the root of the connecting piece82is internally fitted on the inner circumference part148eof the rib part148cof the peripheral wall part148. As shown inFIG.32, the hook part85cprojecting from the root of the connecting piece85is internally fitted in the inner circumference part149eof the rib part149cof the peripheral wall part149. Furthermore, as shown inFIG.34, the hook part85cprojecting from the root of the connecting piece85is internally fitted in the inner circumference of the rib part149cof the peripheral wall part149. For that reason, with the plate member8in the fourth box14, the hook parts81c,82c,83c,84c,85care also made to function as guides for positioning. As shown inFIG.34, when the plate member8is fixed to the fourth box14using the bolts B, the interior of the fourth box14is partitioned by the plate member8into the first gear chamber Sb1(first chamber) in which the planetary reduction gear4is arranged, and the second gear chamber Sb2(second chamber) that uses the wall part120as a portion of the wall. For that reason, at the top part of the fourth box14, when the planetary reduction gear4rotates around the rotation axis X, the oil OL inside the first gear chamber Sb1scooped up by the stepped pinion gear43does not flow easily to the second gear chamber Sb2side. In the fourth box14, the breather chamber16is provided above the peripheral wall part149to which the plate member8is fixed. The breather chamber16is formed between the peripheral wall part141and the wall part160of the fourth box14side and the wall part120of the second box12. In the fourth box14, the wall part160extending the inner circumference of the peripheral wall part141to the second box12side is provided. As shown inFIG.30, seen from the second box12side, the wall part160is formed in an arc shape surrounding the outer circumference of the peripheral wall part149with a gap open. One end and the other end of the wall part160are respectively connected to the peripheral wall part141. The space formed between the peripheral wall part141and the wall part160is open at the second box12side. Two notch parts161,161are provided on the wall part160with a gap open in the lengthwise direction of the wall part160. The notch parts161,161are open at the second box12side (seeFIG.34). The end surface of the second box12side (right side inFIG.34) of the wall part160and the peripheral wall part141are flush. When the fourth box14and the second box12are joined in the rotation axis X direction, the breather chamber16is formed surrounded by the peripheral wall part141, the wall part160, and the wall part120. As shown inFIG.34, in this state, the notch parts161,161provided in the wall part160form between themselves and the wall part120breather holes165,165that communicate between the breather chamber16and the second gear chamber Sb2. The breather holes165,165open to the wall part120side from the plate member8in the rotation axis X direction. For that reason, when the planetary reduction gear4rotates around the rotation axis X, the oil OL scooped up by the stepped pinion gear43is made to not easily reach as far as the breather chamber16even if it flows into the second gear chamber Sb2side from the first gear chamber Sb1. The operation of the power transmission device1of this configuration is explained. As shown inFIG.1, in the power transmission device1, the planetary reduction gear4, the differential device5, and the drive shafts9(9A,9B) are provided along the transmission route of the output rotation of the motor2. Also, the parking gear30of the park lock mechanism3(seeFIG.2) is provided between the motor2and the planetary reduction gear4in the power transmission route. As shown inFIG.2, in this state, when the motor2is driven and the rotor core21rotates around the rotation axis X, the rotation is inputted to the sun gear41of the planetary reduction gear4via the motor shaft20that rotates integrally with the rotor core21. As shown inFIG.3, with the planetary reduction gear4, the sun gear41serves as the input unit of the output rotation of the motor2. The differential case50that supports the stepped pinion gear43(seeFIG.3) serves as the output unit of the inputted rotation. When the sun gear41rotates around the rotation axis X by the inputted rotation, the stepped pinion gear43(large pinion gear431, small pinion gear432) rotates around the axis line X1by the rotation inputted from the sun gear41side. Here, the small pinion gear432of the stepped pinion gear43is engaged with the ring gear42fixed to the inner circumference of the fourth box14. For that reason, the stepped pinion gear43revolves around the rotation axis X while auto-rotating around the axis line X1. Here, with the stepped pinion gear43, the outer diameter R2of the small pinion gear432is smaller than the outer diameter R1of the large pinion gear431(seeFIG.3). As a result, the differential case50(first case unit6, second case unit7) that supports the stepped pinion gear43rotates around the rotation axis X at a rotation speed lower than the rotation inputted from the motor2side. For that reason, the rotation inputted to the sun gear41of the planetary reduction gear4is significantly reduced by the stepped pinion gear43. The reduced rotation is outputted to the differential case50(differential mechanism5). By the differential case50rotating around the rotation axis X by the inputted rotation, inside the differential case50, the drive shafts9(9A,9B) that engage with the pinion mate gear52rotate around the rotation axis X. As a result, drive wheels W, W (seeFIG.1) at the left and right of the vehicle in which the power transmission device1is mounted rotate by the transmitted rotational drive power. As shown inFIG.2, the oil OL for lubrication is retained inside the fourth box14. For that reason, the retained oil OL is scooped up by the differential case50rotating around the rotation axis X during transmission of the output rotation of the motor2. The engagement part between the sun gear41and the large pinion gear431, the engagement part between the small pinion gear432and the ring gear42, and the engagement part between the pinion mate gear52and the side gears54A,54B are lubricated by the scooped-up oil OL. As shown inFIG.19, the differential case50seen from the third box13side rotates in the counterclockwise direction CCW around the rotation axis X. The oil catch unit15is provided on the top part of the fourth box14. The oil catch unit15is positioned at the downstream side in the rotation direction of the differential case50. Much of the oil OL scooped up by the differential case50flows into the oil catch unit15. As shown inFIG.22, the oil guide152mounted on the support stand151is provided in the oil catch unit15. The guide unit154and the catch unit153of the oil guide152are positioned at the radial outside of the first case unit6of the differential case50and the radial outside of the second case unit7of the differential case50. For that reason, much of the oil that is scooped up by the differential case50and flows into the oil catch unit15is captured by the oil guide152. A portion of the oil OL captured by the oil guide152is discharged from the notch part155provided in the wall part153a, and flows into the oil hole151afor which one end is opened on the top surface of the support stand151. The end part of the inner diameter side of the oil hole151ais open at the inner circumference of the support unit145(seeFIG.2). For that reason, the oil OL that flows into the oil hole151ais discharged to a gap Rx between the inner circumference of the support unit145of the fourth box14and the cylinder wall part540of the side gear54B. A portion of the oil OL discharged to the gap Rx lubricates the bearing B2supported by the support unit145. The oil OL that lubricates the bearing B2moves to the outer diameter side by the centrifugal force by rotation of the differential case50. On the outer diameter side of the differential case50, the slit710is provided along the inner circumference of the peripheral wall part73(seeFIG.4). Further movement of the oil OL to the outer diameter side is obstructed by the peripheral wall part73. The oil OL passes through the slit710to the first case unit6side. At the first case unit6side of the slit710, the case-internal oil passage781is open in the inner circumference of the guide unit78. A portion of the oil OL that passes through the slit710flows inside the case-internal oil passage781by the centrifugal force by the rotation of the differential case. The oil OL that flows into the case-internal oil passage781passes through the introduction path441and flows into the shaft-internal oil passage440of the pinion shaft44. The oil OL that flows into the shaft-internal oil passage440is discharged radially outside from the oil holes442,443. The discharged oil OL lubricates the needle bearing NB externally fitted on the pinion shaft44. Furthermore, a portion of the oil OL discharged to the gap Rx passes through the oil groove721provided on the inner circumference of the cylinder wall part72of the second case unit7as shown inFIG.14. The oil OL that passes through the oil groove721is supplied to the washer55that supports the back surface of the side gear54B and lubricates the washer55. It also passes through the oil groove712provided in the base71of the second case unit7and the oil groove742provided in the arc part741. The oil OL that passes through the oil groove742is supplied to the spherical washer53that supports the back surface of the pinion mate gear52and lubricates the spherical washer53. Also, a portion of the oil OL captured by the oil guide152of the oil catch unit15is discharged to the guide unit154side (seeFIG.20). The tip154bof the guide unit154faces the oil hole126aprovided in the wall part120of the second box12with a gap open in the rotation axis X direction (seeFIG.21). For that reason, much of the oil OL discharged to the guide unit154side flows into the oil hole126aof the second box12. The oil OL that did not flow into the oil hole126agoes along the wall part120of the second box12and moves toward the bottom of the fourth box14. As shown inFIG.2, in the fourth box14, between the wall part120and the plate member8is the second gear chamber Sb2. The parking gear30of the park lock mechanism3is positioned in the second gear chamber Sb2. For that reason, the oil OL that did not flow into the oil hole126alubricates the parking gear30when it moves toward the bottom inside the second chamber Sb2. As shown inFIG.21, the boss part126surrounding the oil hole126ais provided on the outer circumference of the wall part120. One end of the pipe127is fitted into the boss part126from the rotation axis X direction. For that reason, the oil OL that flows into the oil hole126aof the second box12flows inside the pipe127. The pipe127passes through the outside of the second box12and extends to the third box13. The other end of the pipe127communicates with the oil hole136aprovided in the cylindrical connecting wall136of the third box13(seeFIG.2). For that reason, in the present embodiment, a portion of the oil OL that reaches the oil catch unit15passes through the guide unit154and the pipe127and is supplied to the internal space Sc of the connecting wall136. The oil OL discharged from the oil hole136ato the internal space Sc is retained in the internal space Sc. The oil OL lubricates the bearing B4supported by the peripheral wall part131of the third box13. A portion of the oil OL discharged to the internal space Sc passes through the gap between the outer circumference of the drive shaft9A and the inner circumference of the motor shaft20, and moves to the other end20bside of the motor shaft20. As shown inFIG.10, the other end20bof the motor shaft20is inserted inside the cylinder wall part541of the side gear54A. A connection path542that communicates with the back surface of the side gear54A is provided on the inner circumference of the cylinder wall part541. For that reason, a portion of the oil OL that moves to the other end20bside of the motor shaft20and is discharged to inside the cylinder wall part541passes through the connection path542. The oil OL that passes through the connection path542is supplied to the washer55of the back surface of the side gear54A and lubricates the washer55. Furthermore, the oil OL that lubricates the washer55of the back surface of the side gear54A passes through the oil groove662provided on the gear support part66of the first case unit6and the oil groove642provided on the arc part641. The oil OL that passes through the oil groove642is supplied to the spherical washer53that supports the back surface of the pinion mate gear52and lubricates the spherical washer53. Also, as shown inFIG.2, the internal space Sc of the third box13connects with the second gear chamber Sb2provided in the fourth box14via the radial oil passage137, the axial oil passage138, the communication hole112a, and the oil reservoir128provided at the bottom of the second box12. For that reason, the oil OL inside the internal space Sc is held at a position at the same height at which the oil OL is retained inside the fourth box14. In this way, the oil catch unit15captures the scooped-up oil OL, and functions as an oil supply unit to distribute the scooped-up oil OL to various locations within the power transmission device1. In the fourth box14of the body box10, the peripheral wall parts148,149are provided to surround the outer circumference of the large pinion gear431that rotates integrally with the differential case50(seeFIG.27toFIG.29). The plate member8is fixed by bolts to the boss parts18provided in the peripheral wall parts148,149(seeFIG.34). The internal space of the fourth box14is partitioned into the first gear chamber Sb1and the second gear chamber Sb2by the plate member8. The peripheral wall parts148,149surround the outer circumference of the teeth431aprovided on the outer circumference of the large pinion gear431with a gap open. The peripheral wall parts148,149form an arc shape along the revolution orbit of the outer circumference of the large pinion gear431that revolves around the rotation axis X. Here, the hook parts81c,82c,83c,84c,85cprovided in the plate member8are internally fitted in the rib parts148c,149cprovided on the peripheral wall parts148,149. For that reason, the oil OL scooped up by the revolving large pinion gear431is made to not easily leak radially outward from the portion of the peripheral wall parts148,149surrounding the outer circumference edge80cof the plate member8. In the present embodiment, the breather chamber16is formed above the peripheral wall part149. The breather chamber16is positioned at the top part of the second gear chamber Sb2partitioned by the plate member8. Here, the breather holes165,165communicating between the breather chamber16and the second gear chamber Sb2(seeFIG.34) are open more to the wall part120side than the plate member8in the rotation axis X direction. For that reason, when the planetary reduction gear4rotates around the rotation axis X, the oil OL scooped up by the stepped pinion gear43is made to not easily reach the breather chamber16even when it flows to the second gear chamber Sb2side from the first gear chamber Sb1. As described above, the power transmission device1of the present embodiment has the following configuration. (1) The power transmission device1comprisesthe planetary reduction gear4(gear mechanism),the wall part120that overlaps the planetary reduction gear4in the rotation axis X direction (axial direction), andthe plate member8(plate) that is provided between the wall part120and the planetary reduction gear4in the rotation axis X direction, inside the body box10(box). The interior of the body box10is partitioned by the plate member8into the first gear chamber Sb1(first chamber) in which the planetary reduction gear4is arranged and the second gear chamber2(second chamber) that uses the wall part120as a portion of the wall. The body box10has a breather hole165in the second gear chamber Sb2(second chamber) (seeFIG.34). By configuring in this way, at the top part of the fourth box14of the body box10, inflow of the oil OL inside the first gear chamber Sb1to the second gear chamber Sb2is prevented by the plate member8. Thus, it is possible to suppress infiltration of the oil OL scooped up by the planetary reduction gear4to the breather hole165using the plate member8. The power transmission device1of the present embodiment has the following configuration. (2) The breather hole165is configured by the notch part161provided on the top part of the body box10and the wall part120. The breather chamber16is formed by joining the peripheral wall part141and the wall part160of the fourth box14and the wall part120of the second box12. The breather hole165is formed at a position closer to the wall part120than the plate member8. By configuring in this way, the breather hole165is arranged at a position almost up to the wall part120. As a result, it is possible to suppress infiltration of the oil OL to the breather hole165. The power transmission device1of the present embodiment has the following configuration. (3) The planetary reduction gear4(gear mechanism) has the stepped pinion gear43(pinion gear) having the large pinion gear431and the small pinion gear432. The planetary reduction gear4has the ring gear42that engages with the small pinion gear432. The fourth box14of the body box10has the breather chamber16that communicates with the breather hole165above the revolution orbit of the large pinion gear431. The fourth box14of the body box10has the peripheral wall part149that serves as the roof part projecting in the rotation axis X direction between the breather chamber16and the revolution orbit of the large pinion gear431. The small pinion gear432is surrounded by the ring gear42, and there is relatively little scattering of the oil OL from the small pinion gear432. The large pinion gear431is exposed in the outer circumference direction, so when configured as described above, by providing the peripheral wall part149which serves as the roof part at the outer circumference of the large pinion gear, it is possible to reduce the oil OL scattering from the large pinion gear431toward the breather hole165. The power transmission device1of the present embodiment has the following configuration. (4) The plate member8has hook parts81c,82c,83c,84c,85c, that project in the rotation axis X direction, and that are positioned between the peripheral wall part149(roof part) and the revolution orbit of the large pinion gear431. By configuring in this way, by providing the hook parts81c,82c,83c,84c,85con the plate member8, it is possible to further reduce the oil OL that scatters from the large pinion gear431toward the breather hole165. In particular, the hook part85cof the plate member8is provided below the breather chamber16in the vertical line VL direction. This hook part85chas a range in the circumference direction that is wider than the other hook parts81c,82c,83c,84c. Also, the hook part85cis internally fitted in the rib part149cof the peripheral wall part149. For that reason, it is possible to suppress the amount of the oil OL that passes through the gap between the peripheral wall part149and the plate member8, and that moves to the outer diameter side (breather chamber16). As a result, it is possible to suitably prevent the oil OL from reaching the breather hole165of the breather chamber16. The power transmission device1of the present embodiment has the following configuration. (5) In the power transmission device1, the motor2is arranged to the upstream side of the planetary reduction gear4on the transmission route of the rotational drive power. The planetary reduction gear4overlaps the motor2in the rotation axis X direction. The power transmission device1is the power transmission device1for a single axle electric vehicle. By configuring in this way, it is possible to provide a compact power transmission device. In the embodiment noted above, seen from the fourth box14, an example was shown of a case in which the motor2is provided at the back side of the wall part120(right side inFIG.2), but it is also possible to provide the motor2at the front side of the wall part120. Above, embodiments of the invention of the present application were explained, but the invention of the present application is not limited only to the modes shown in the embodiments. It can be modified as appropriate within the scope of the technical concepts of the invention. EXPLANATION OF CODES 1: Power transmission device;10: Body box (box);120: Wall part;14: Fourth box;149: Peripheral wall part (roof part);16: Breather chamber;161: Notch part;165: Breather hole;2: Motor;4: Planetary reduction gear (gear mechanism);42: Ring gear;43: Stepped pinion gear (pinion gear);431: Large pinion gear;432: Small pinion gear;8: Plate member (plate);81c,82c,83c,84c,85c: Hook part; Sb1: First gear chamber (first chamber); Sb2: Second gear chamber (second chamber); and X: Rotation axis. | 83,133 |
11859708 | DETAILED DESCRIPTION The following description relates to methods and systems for providing adjustable lubrication to a tandem axle with disconnect functionality. For example, a vehicle system may include a tandem axle and a lubrication system, as shown inFIG.1. In particular, the tandem axle may include a disconnect feature, so that the tandem axle may transition between operating in a first tandem axle configuration (e.g., a 6×4 axle configuration) and a second tandem axle configuration (e.g., a 6×2 axle configuration), as shown inFIG.2. A lubrication system, such as shown inFIG.3, may provide engine oil to an axle sump of the tandem axle in order to reduce component degradation and increase axle performance. However, based on the tandem axle configuration, a different amount of engine oil may be desired. As such, the amount of engine oil in the axle sump may be adjusted based on the tandem axle configuration. For example, while operating with the 6×4 axle configuration, more engine oil may be desired in the axle sump, as shown inFIG.4A. Further, while operating with the 6×2 axle configuration, less engine oil may be desired in the axle sump, as shown inFIG.4B. The amount of engine oil in the axle sump may be adjusted according to a method500shown inFIG.5, and a prophetic example timeline for operating a motor vehicle with a tandem axle and a lubrication system for the tandem axle is shown inFIG.6. FIG.3is drawn approximately to scale. However, other relative dimensions may be used, in other embodiments. Referring toFIG.1, an embodiment of a system in which a tandem axle may be installed is shown. Specifically,FIG.1shows a block diagram of an embodiment of a vehicle system100, herein depicted as a motor vehicle106(e.g., automobile), configured to run on a road102via a plurality of wheels, including wheel121, wheel122, and wheel123. For example, motor vehicle106includes a total of six wheels, with half shown in the side view ofFIG.1. As an example, motor vehicle106may be a heavy-duty truck, such as may be employed for transporting goods across long distances. For example, motor vehicle106may include at least 3 axles, each axle connected to at least two wheels. As depicted, the motor vehicle106includes an engine104. The engine includes a plurality of cylinders101(only one representative cylinder shown inFIG.1) that each include at least one intake valve103, at least one exhaust valve105, and at least one fuel injector107. Each intake valve, exhaust valve, and fuel injector may include an actuator that may be actuated via a signal from a controller110of the engine104. In other non-limiting embodiments, the engine104may be used in medium duty vehicles, light duty vehicles, off-highway vehicles, and the like. The engine104receives intake air for combustion from an intake passage114. The intake passage114includes an air filter that filters air from outside of the motor vehicle. Exhaust gas resulting from combustion in the engine is supplied to an exhaust passage116. Exhaust gas flows through the exhaust passage116and out of an exhaust system of the motor vehicle. Combustion in the cylinder drives rotation of a crankshaft164. In one example, the engine is a diesel engine that combusts air and diesel fuel through compression ignition. In another example, the engine is a dual or multi-fuel engine that may combust a mixture of gaseous fuel and air upon injection of diesel fuel during compression of the air-gaseous fuel mix. In other non-limiting embodiments, the engine may additionally or alternatively combust fuel including gasoline, kerosene, natural gas, biodiesel, or other petroleum distillates of similar density through compression ignition and/or spark ignition. As depicted inFIG.1, the engine is coupled to an electric power generation system that includes an alternator/generator124. For example, the engine is a diesel and/or natural gas engine that generates a torque output that is transmitted to the alternator/generator124, which is mechanically coupled to the crankshaft164, as well as to at least one of the plurality of wheels to provide motive power to propel the motor vehicle. The alternator/generator124produces electrical power that may be stored and applied for subsequent propagation to a variety of downstream electrical components. In one example, the alternator/generator124may be coupled to an electrical system126. The electrical system126may include one or more electrical loads configured to run on electricity generated by the alternator/generator124, such as vehicle headlights, a cabin ventilation system, and an entertainment system, and may further include an energy storage device (e.g., a battery) configured to be charged by electricity generated by the alternator/generator124. In some examples, the vehicle may be a diesel electric vehicle, and the alternator/generator124may provide electricity to one or more electric motors to drive the wheels (e.g., including wheel121, wheel122, and wheel123). For example, when a clutch is engaged, the crankshaft164is mechanically coupled to a transmission170. Transmission170may be a gearbox, a planetary gear system, or another type of transmission. The powertrain may be configured in various manners including as a parallel, a series, or a series parallel hybrid vehicle. Further, transmission170may be coupled to a tandem axle172, which may provide motive power to the plurality of wheels. For example, the tandem axle may comprise two axles (e.g., a first axle and a second axle), each axle coupled to at least two of the plurality of wheels, for converting torque from the transmission170to rotational motion. Further, as will be elaborated with respect toFIG.2, tandem axle172includes a disconnect feature, so that the tandem axle may transition between operating with a 6×2 axle configuration and a 6×4 axle configuration. For example, while operating with the 6×2 axle configuration, only the first axle may be provided with torque. While operating with the 6×4 axle configuration, both of the first axle and the second axle may be provided with torque. As an example, operating with the 6×2 axle configuration may increase vehicle efficiency at high vehicle speeds, but may lead to a decrease in traction, as only two of the six wheels112are provided with torque. As another example, operating with the 6×4 axle configuration may increase traction, as four of the six wheels are provided with torque. However, operating with the 6×4 axle configuration may be decrease fuel efficiency, relative to operating with the 6×2 axle configuration. In order to transition between operating with the 6×4 axle configuration and the 6×2 axle configuration, the controller110may transmit a signal to the tandem axle causing the tandem axle to activate the disconnect feature. In some embodiments, the vehicle system may further include an aftertreatment system coupled in the exhaust passage116. In one embodiment, the aftertreatment system may include one or more emission control devices. Such emission control devices may include a selective catalytic reduction (SCR) catalyst, a three-way catalyst, a NOxtrap, or various other devices or exhaust aftertreatment systems. In another embodiment, the aftertreatment system may additionally or alternatively include a diesel oxidation catalyst (DOC) and a diesel particulate filter (DPF). As depicted inFIG.1, the vehicle system further includes a cooling system150(e.g., an engine cooling system). The cooling system150circulates coolant through the engine104to absorb waste engine heat and distribute the heated coolant to a heat exchanger, such as a radiator152(e.g., a radiator heat exchanger). In one example, the coolant may be water or antifreeze. In another example, the coolant may be a mixture of water and antifreeze. A fan154may be coupled to the radiator152in order to maintain an airflow through the radiator152when the vehicle is moving slowly or stopped while the engine104is running. In some examples, fan speed may be controlled by the controller110. Coolant that is cooled by the radiator152may enter a tank (not shown). The coolant may then be pumped by a water, or coolant, pump156back to the engine or to another component of the vehicle system. Coolant may be pumped via a series of water lines, such that one or more water lines fluidically couples the radiator to the pump, one or more water lines fluidically couples the pump to the engine, and one or more water lines fluidically couples the engine104to the radiator. In some examples, the water lines may be fabricated from a flexible material, such as polyurethane or rubber, for example. In other examples, the water lines may be fabricated from an inflexible material, such as copper or steel. Further, as depicted inFIG.1, the vehicle system includes a lubrication system178for delivering a lubricant, such as engine oil, to various parts of the engine system. For example, as shown, lubrication system178routes oil to the engine104, where it may circulate through various components in order to reduce component wear. The oil may be routed to the engine via a pump, in some examples. In other examples, the oil may be routed to the engine via a gravity feed system. After circulating through the engine, oil may drain back to the lubrication system and recirculated. For example, after circulating through the engine, oil may pass through an oil filter in order to remove debris and other contaminants. In some examples, lubrication system178may include a means for cooling the oil before recirculated. Further, as shown inFIG.1, the lubrication system178routes lubricating oil to the tandem axle172, described above. In some examples, the tandem axle172may include an adjustable lubrication system for controlling oil distribution in the tandem axle. For example, the adjustable lubrication system of tandem axle172may include an axle sump and an external reservoir, as elaborated below with respect toFIG.3. In some examples, lubrication system178and may periodically drain and recirculate oil to the tandem axle, in order to maintain a desirable level of oil quality. In some examples, lubrication system178may route oil to additional engine components not shown inFIG.1. The controller110may be configured to control various components related to the motor vehicle. For example, controller110may be a microcomputer, including a microprocessor unit, input/output ports, an electronic storage medium for executable programs (e.g., executable instructions) and calibration values stored in non-transitory read-only memory. As an example, various components of the vehicle system may be coupled to the controller110via a communication channel or data bus. In one example, the controller110includes a computer control system. Controller110may receive various signals from sensors of the vehicle system. In some examples, the controller110may include more than one controller each in communication with one another, such as a first controller to control the engine and a second controller to control other operating parameters of the vehicle (such as engine load, engine speed, brake torque, etc.). The first controller may be configured to control various actuators based on output received from the second controller and/or the second controller may be configured to control various actuators based on output received from the first controller. The controller110may receive information from a plurality of sensors and may send control signals to a plurality of actuators. The controller110, while overseeing control and management of the engine and/or vehicle, may be configured to receive signals from a variety of engine sensors, as further elaborated herein, in order to determine operating parameters and operating conditions, and correspondingly adjust various engine actuators to control operation of the engine and/or vehicle. For example, the controller110may receive signals from various engine sensors including, but not limited to, measurements of engine speed, engine load, intake manifold air pressure, boost pressure, exhaust pressure, ambient pressure, ambient temperature, exhaust temperature, particulate filter temperature, particulate filter back pressure, engine coolant pressure, or the like. Additional sensors, such as coolant temperature sensors, may be positioned in the cooling system. Correspondingly, the controller110may control the engine and/or the vehicle by sending commands to various components such as the alternator/generator124, fuel injectors107, valves, coolant pump156, or the like. For example, the controller110may control the operation of a restrictive element (e.g., such as a valve) in the engine cooling system. Other actuators may be coupled to various locations in the vehicle. Turning now toFIG.2, another view of vehicle system100is shown, including tandem axle172with the disconnect feature. Components shown inFIG.2may be substantially identical to components shown inFIG.1, and as such, like components may be numbered the same and not reintroduced. As shown, each of the six wheels, wheel111, wheel112, wheel113, wheel121, wheel122, and wheel123, is coupled to an axle. Two wheels (e.g., wheel111and wheel121) are coupled to a front axle204. For example, the front axle may not be provided with torque, and may be a steering axle. For example, the front axle may be coupled to a steering system (not shown) for changing a direction of the vehicle106. Further, tandem axle172includes a driveshaft214, a first axle206, a second axle208, and a disconnect joint216. The first axle206is coupled to wheel112and wheel122, and the second axle208is coupled to wheel113and wheel123. Further, the first axle206may include a first differential210, and the second axle208may include a second differential212. As shown, engine104is coupled to transmission170via crankshaft164, which may transfer torque to driveshaft214. For example, transmission170may include gears for adjusting an amount of torque provided to the driveshaft. For example, each of the first differential210and the second differential212is configured to transfer rotational energy to the drive wheel via axle shafts. To accomplish the aforementioned rotational energy transfer functionality, each of the first differential210and the second differential212may include gears (e.g., ring gear, bevel gear, planetary gears, etc.), a housing, and the like. To elaborate, the differential may be a locking, non-locking, or limited slip-type differential, for instance. Additionally, in one example, the axles (e.g., the first axle206, the second axle208, and the front axle204) may be beam axles. However, independent suspension designs have also been envisioned. Further, the disconnect joint216may selectably couple a first connection shaft218to a second connection shaft220. For example, while operating with the 6×4 axle configuration, the disconnect joint216may mechanically couple the first connection shaft218to the second connection shaft220, so that torque is provided to both of the first axle206and the second axle208. However, while operating with the 6×2 axle configuration, the disconnect joint216may disconnect the first axle206from the second axle208, so that torque is provided to the first axle206, but not to the second axle208. Providing torque to an axle includes providing motive force to wheels coupled to the axle. For example, while operating with the 6×4 axle configuration, four wheels (e.g., wheel112, wheel122, wheel113, and wheel123) may be provided with motive force, and while operating with the 6×2 axle configuration, two wheels (e.g., wheel112and wheel122) may be provided with motive force. The state of the disconnect joint216(e.g., connected or disconnected) may be adjusted in response to a signal from controller110. For example, controller110may determine that operating with the 6×4 axle configuration is indicated when a vehicle speed is below a threshold vehicle speed, and may send a control signal to disconnect joint216to connect the first connection shaft218to the second connection shaft220, so that both of the first axle206and the second axle208are provided with torque. As another example, controller110may determine that operating with the 6×2 axle configuration is indicated, such as when the vehicle speed exceeds the threshold vehicle speed, and may send a control signal to disconnect joint216to disconnect the first connection shaft218from the second connection shaft220, so that the first axle206is provided with torque and the second axle208is not provided with torque. In some examples, the tandem axle system may transition between the 6×4 axle configuration and the 6×2 axle configuration in response to a user input. For example, a push button may be included in a vehicle cabin, and the controller may transition the tandem axle between the 6×4 axle configuration in response to a signal from the push button. As an example, during inclement weather (e.g., such as icy road conditions), the 6×4 axle configuration may be desired although the vehicle speed is above the threshold vehicle speed. Thus, the user may depress the push button, or another user input, in order to transition the tandem axle to the 6×4 axle configuration. In some examples, a tandem axle system may be configured so that the second axle208is provided with torque while operating with the 6×2 axle configuration, rather than the first axle206. In such an embodiment, while operating with the 6×2 axle configuration, the disconnect joint216may couple the second axle208to the powertrain (e.g., to power from the drive shaft), while disconnecting the first axle206from the powertrain, so that wheel113and wheel123are provided with motive power, while wheel112and wheel122are not provided with motive power. Including a tandem axle system with a disconnect feature, such as the tandem axle172shown inFIGS.1and2, may enable the vehicle to employ (e.g., operate with) the 6×2 axle configuration in some operating conditions, and to employ the 6×4 axle configuration in other operating conditions. For example, the tandem axle may transition between operating with the 6×2 axle configuration and the 6×4 axle configuration in order to increase the efficiency of the vehicle during high-speed operating condition while providing additional traction in low-speed operating conditions or inclement weather. Therefore, including a tandem axle with a disconnect feature in a vehicle may increase customer satisfaction, vehicle efficiency, and overall vehicle performance. However, an amount of lubrication provided to the tandem axle while operating with the 6×4 axle configuration may not be suitable for efficient operation with the 6×2 axle configuration, and the amount of lubrication provided to the tandem axle while operating with the 6×2 axle configuration may not be suitable for reducing component degradation while operating with the 6×4 axle configuration. For example, the tandem axle may include an axle sump, and a higher oil level in the axle sump may be indicated while operating with the 6×4 axle configuration, relative to the 6×2 axle configuration. As an example, vehicle efficiency with the 6×2 axle configuration may be decreased while the oil level in the axle sump is high. As another example, an incidence of component degradation may be increased with the 6×4 axle configuration while the oil level is low. Therefore, an adjustable lubrication system is included in a tandem axle with a disconnect feature, according to an embodiment of the present disclosure. Specifically, the adjustable lubrication system may enable an amount of lubrication in the axle sump and the external reservoir may be adjusted based on an axle configuration of the tandem axle (e.g., one of the 6×4 axle configuration and the 6×2 axle configuration), as will be described below with respect toFIGS.4A and4B. For example, the adjustable lubrication system includes an axle sump, an electric pump, an external reservoir for engine oil, and a gravity feed selectably coupling the external reservoir to an axle sump, the gravity feed controlled by a valve. Therefore,FIG.3shows a partial view300of an adjustable lubrication system301for a tandem axle of a vehicle.FIG.3shows example configurations with relative positioning of the various components. If shown directly contacting each other, or directly coupled, then such elements may be referred to as directly contacting or directly coupled, respectively, at least in one example. Similarly, elements shown contiguous or adjacent to one another may be contiguous or adjacent to each other, respectively, at least in one example. As an example, components laying in face-sharing contact with each other may be referred to as in face-sharing contact. As another example, elements positioned apart from each other with only a space there-between and no other components may be referred to as such, in at least one example. As yet another example, elements shown above/below one another, at opposite sides to one another, or to the left/right of one another may be referred to as such, relative to one another. Further, as shown in the figures, a topmost element or point of element may be referred to as a “top” of the component and a bottommost element or point of the element may be referred to as a “bottom” of the component, in at least one example. As used herein, top/bottom, upper/lower, above/below, may be relative to a vertical axis of the figures and used to describe positioning of elements of the figures relative to one another. As such, elements shown above other elements are positioned vertically above the other elements, in one example. As yet another example, shapes of the elements depicted within the figures may be referred to as having those shapes (e.g., such as being circular, straight, planar, curved, rounded, chamfered, angled, or the like). Further, elements shown intersecting one another may be referred to as intersecting elements or intersecting one another, in at least one example. Further still, an element shown within another element or shown outside of another element may be referred as such, in one example. FIG.3shows components of adjustable lubrication system301, which may provide lubrication (e.g., such as engine oil) to engine components. For example, adjustable lubrication system301may be fluidically coupled to a main lubrication system of an engine, such as lubrication system178described with respect toFIGS.1and2, and may provide lubrication to a tandem axle system, such as tandem axle172described with respect toFIGS.1and2. For example, the engine lubrication system may flow oil to the adjustable lubrication system301, and the adjustable lubrication system301may ensure circulation of oil in the tandem axle, based on the selected axle configuration. In particular, adjustable lubrication system301includes an electric pump308for pumping engine oil to an axle sump304of the tandem axle system through a first oil passage (not shown). The axle sump304may directly provide oil to components of the tandem axle. The electric pump308may be driven by an electrical system of the vehicle (e.g., such as electrical system126ofFIG.1) and may include an electric motor, housing, chambers, pistons, seals, etc. to achieve oil flow adjustment functionality. Further, adjustable lubrication system301includes an external reservoir306for storing engine oil. The external reservoir306may be a sealed reservoir for storing additional oil, so that the oil level in the axle sump304may be increased when indicated. For example, external reservoir306is selectably fluidically coupled to the axle sump304via a second oil passage302. The oil passage302may be coupled to the external reservoir306via a first attachment joint310, and the second oil passage302may be coupled to the axle sump304via a second attachment joint312. For example, the second oil passage302is a gravity feed, and includes a solenoid valve (not shown inFIG.3). When the solenoid valve is in an open position, the drain line may allow oil to flow from the external reservoir to the axle sump, and when the solenoid valve is in a closed position, the drain line may not allow oil to flow from the external reservoir to the axle sump. For example, a position of the solenoid valve may be controlled by a controller, such as controller110ofFIGS.1and2. The output of the electric pump308may also be controlled via a controller such as the controller110ofFIGS.1and2. Axle sump304may provide lubrication to components of the tandem axle via splash lubrication, for example. Further, adjustable lubrication system301may be adjusted based on a configuration of the tandem axle. For example, the tandem axle may include a disconnect feature (e.g., such as the tandem axle172with disconnect functionality described with respect toFIGS.1and2), and may transition between operating with two powered axles (e.g., the 6×4 axle configuration) and one powered axle (e.g., the 6×2 axle configuration). As an example, while with the 6×2 axle configuration, the tandem axle may provide torque to one axle. As another example, while operating with the 6×4 axle configuration, the tandem axle may provide torque to two axles. For example, a controller (e.g., such as controller110described with respect toFIGS.1and2) may control the tandem axle to transition between the 6×2 axle configuration and the 6×4 axle configuration based on one or more engine operating conditions, such as vehicle speed. Specifically, the 6×2 axle configuration may be indicated when the vehicle speed exceeds a threshold vehicle speed, and the 6×4 axle configuration may be indicated when the vehicle speed is at or below a threshold vehicle speed. Further, in some examples, other parameters may be used in addition to or as an alternative to vehicle speed, in order to determine whether the 6×2 axle configuration or the 6×4 axle configuration is indicated. As one example, the additional tractive power of the 6×4 axle configuration may be indicated when inclement weather (e.g., icy and/or wet road conditions) is detected. As another example, a vehicle user may input a command to transition between the 6×4 axle configuration and the 6×2 axle configuration via an input device (e.g., push button, touch screen, lever, etc.). In some examples, an oil level in the axle sump304may be monitored by at least one level sensor, such as a level sensor314. For example, level sensor314is optionally coupled to the axle sump304, and may transmit a signal corresponding to an oil level in the axle sump to a controller, such as controller110ofFIG.1. For example, by monitoring the oil level in the axle sump304, the oil level may be more accurately controlled. Further, in some examples, a level sensor316is optionally included in the external reservoir306. In other examples, a level sensor may not be included in the axle sump, and the controller may estimate an oil level in the axle sump based on oil temperature, oil age, a road grade, pump operation, and a valve position. For example, the controller may estimate an oil viscosity based on oil temperature and oil age, may estimate an oil pressure based on the road grade (e.g., the grade of the road during vehicle operation). Using the estimated oil viscosity and oil pressure, the controller may estimate an oil flow rate based on pump operation and the valve position. In some examples, the controller may estimate the axle sump level based in part on a pump operating time and/or an amount of open time for the valve. Next,FIGS.4A and4Bshow components an adjustable lubrication system401for a tandem axle during vehicle operation. For example, adjustable lubrication system401may be used as adjustable lubrication system301ofFIG.3. As elaborated above, it may be advantageous to adjust an amount of lubricant (e.g., oil) in an axle sump of a tandem axle based on the selected axle configuration (e.g., one of the 6×4 axle configuration and the 6×2 axle configuration. Specifically, less oil in the axle sump (e.g., a lower oil level in the axle sump) may be desired while operating with the 6×2 axle configuration, and more oil in the axle sump (e.g., a higher oil level in the axle sump) may be desired while operating with the 6×4 axle configuration. Adjustable lubrication system401is shown identically inFIGS.4A and4B, with the exception of a distribution of oil. As shown inFIGS.4A and4B, adjustable lubrication system401includes an axle sump404for lubricating the tandem axle, and an external reservoir402for storing additional oil. Further, the external reservoir402is coupled to the axle sump404by a first oil passage410and a second oil passage412. The first oil passage410includes an electric pump406that, when activated, may pump oil from the axle sump404to the external reservoir402. Specifically, when the electric pump406is activated, oil may be pumped from the axle sump404to the external reservoir402. The second oil passage412includes a valve408, the position of the valve controlled by a solenoid. For example, when the valve is in an open position, oil may drain from the external reservoir402to the axle sump404through second oil passage412. Further, when the valve is in a closed position, oil may not drain from the external reservoir402to the axle sump404through the second oil passage412. Specifically, second oil passage412may be a gravity feed, and oil may drain from the external reservoir402to the axle sump404via gravitational force when the valve408is in the open position. The position of the valve is controlled by an electronically actuated solenoid. For example, a controller, such as controller110ofFIGS.1and2, may send a control signal to the solenoid in order to adjust the position of the valve408. For example, the first oil passage410couples the axle sump404to the external reservoir402when the electric pump406is activated. Said differently, activating electric pump406causes oil to flow from the axle sump404to the external reservoir. Further, the second oil passage412couples the axle sump404to the external reservoir402when the valve408is in the open position. For example, opening valve408causes oil to flow from the external reservoir to the axle sump. As such, a flow of oil in to and out of the axle sump404may be controlled by adjusting a status of electric pump406(e.g., whether the electric pump is activated or deactivated) and the position of valve408(e.g., open or closed). By adjusting the flow of oil into and out of the axle sump, an axle sump level416(e.g., a volume of oil in the axle sump) may be controlled. In some examples, a level sensor426may optionally be coupled to axle sump404in order to monitor axle sump level416. For example, level sensor426may be communicatively coupled to a controller of the vehicle. FIG.4Ashows the adjustable lubrication system401while the tandem axle operates with the 6×4 axle configuration. As elaborated above, a higher oil level in the axle sump is indicated while operating with the 6×4 axle configuration, relative to operating with the 6×2 axle configuration. For example, when the tandem axle operates with the 6×4 axle configuration, the electric pump406is not activated (e.g., oil is not pumped out of axle sump404into external reservoir402), and the valve408is in the open position, so that oil flows from the external reservoir402to the axle sump404. Therefore, as shown, an external reservoir level414is low, while the axle sump level416is high. For example, maintaining a high axle sump level416while operating with the 6×4 axle configuration may increase durability of the tandem axle. Further, after the axle sump level416is at or above a first threshold level422, the valve408may be closed in order to maintain the axle sump level416just above the first threshold level422. In one example, the first threshold level422may be a pre-determined axle sump level for operating with the 6×4 axle configuration. In another example, the first threshold level422may be determined based on vehicle operating conditions, such as oil temperature, road grade, engine speed, and the like. As an example, when the oil level in the axle sump404reaches the first threshold oil level422, the solenoid may actuate in order to close valve408, so that no additional oil flows into the axle sump404. As one example, a controller may determine to close valve408based on a signal from level sensor426corresponding to axle sump level416at or above the first threshold level422. FIG.4Bshows the adjustable lubrication system401while the tandem axle operates with the 6×2 axle configuration. For example, when the tandem axle operates with the 6×2 axle configuration, the electric pump406is activated so that oil is pumped from the axle sump404to the external reservoir402. Further, valve408is in the closed position, so that oil does not drain from the external reservoir402to the axle sump404. Therefore, the axle sump level416while operating with the 6×2 axle configuration decreases relative to the axle sump level while operating with the 6×4 axle configuration (e.g., as shown inFIG.4A), and the external reservoir level414while operating with the 6×2 axle configuration increases relative to the external reservoir level while operating with the 6×4 axle configuration (e.g., as shown inFIG.4A). Specifically, the electric pump406may remain activated until the axle sump level416is at or below a second threshold level424. For example, the second threshold level424may be a pre-determined axle sump level for operating with the 6×2 axle configuration. As another example, the second threshold level424may be determined based on engine operating conditions, or may be adjusted based on an adjustment to the first threshold level422. Further, the second threshold level424may be less than the first threshold level422. After the oil level in the axle sump404is at or below the second threshold level, the electric pump406may turn off, and the valve408may remain closed, in order to maintain the oil level in the axle sump. For example, a controller may determine to deactivate electric pump406based on a signal from level sensor426corresponding to an axle sump level416at or below the second threshold level424. In another embodiment, adjustable lubrication system401may include a continuous gravity feed system, so that oil continuously flows into the axle sump404, and the electric pump406periodically pumps a portion of oil out of the axle sump in order to maintain the axle sump level at the desired level. For example, such a system may not include a valve408, and electric pump406may periodically be activated in order to maintain the oil level in the axle sump at the desired level based on the axle configuration. Further, in some examples, adjustable lubrication system401may include a valve that continuously feeds oil back to the axle sump during vehicle operation in order to refresh the oil in the axle sump. Next,FIG.5shows an example method500for operating an engine system to transition adjust an oil level in an axle sump based on an axle configuration of a tandem axle. For example, the tandem axle may have a disconnect feature, and as such, may operate in a first tandem axle configuration (e.g., a 6×4 axle configuration) and a second tandem axle configuration (e.g., a 6×2 axle configuration). In order to increase vehicle efficiency and decrease component wear, the adjustable lubrication system may be adjusted so that an oil level in the axle sump of the tandem axle is lower while operating with the 6×2 axle configuration, relative to the oil level in the axle sump while operating with the 6×4 axle configuration. Method500will be described with respect to the motor vehicle106shown inFIGS.1and2with the adjustable lubrication system301shown inFIG.3, although method500may be applied in other systems that include a tandem axle with a disconnect feature and an adjustable lubrication system. Instructions for carrying out method500and the rest of the methods included herein may be executed by a controller based on instructions stored on a memory of the controller and in conjunction with signals received from sensors of the vehicle system, such as the sensors described with reference toFIG.1. The controller may employ actuators of the vehicle system, such as an electric pump (e.g., electric pump308ofFIG.3or electric pump406ofFIGS.4A and4B) and a valve (e.g., valve408ofFIGS.4A and4B) to adjust engine operation according to the methods described below. At502, method500includes estimating and/or measuring engine operating conditions. The operating conditions may include, for example, vehicle speed, engine speed, engine load, a tandem axle configuration (e.g., one of the first tandem axle configuration and the second tandem axle configuration), an axle sump level, and an external reservoir level. The operating conditions may be measured by one or more sensors communicatively coupled to the controller or may be inferred based on available data. For example, the axle sump level may describe a volume of oil in the axle sump, and the controller may determine the axle sump level based on a level sensor coupled to the axle sump. Further, the external reservoir level may describe a volume of lubricant (e.g., such as oil) in an external reservoir selectably coupled to the axle sump, and the controller may determine the external reservoir level based on a level sensor of the external reservoir. As another example, the controller may estimate the axle sump level based on the operating conditions such as oil temperature. For example, the controller may input an oil temperature, an oil age, a road grade, and an axle configuration into one or more look-up tables, maps, or functions, which may output an axle sump level. At504, method500includes determining whether the tandem axle is operating with the 6×4 axle configuration. For example, operating with the 6×4 axle configuration may include coupling both axles of the tandem axle to a driveshaft, such that each axle of the tandem axle (e.g., a front axle and a rear axle) are powered. For example, operating with the 6×4 axle configuration may provide additional traction for low speed operation. As another example, operating with the 6×4 axle configuration may provide additional traction in situations such as winter-weather driving and uphill driving, when additional traction may be desirable. As an example, the tandem axle may operate with the 6×4 axle configuration in response to a vehicle speed below a threshold vehicle speed. For example, the threshold vehicle speed may be a positive, non-zero speed below which operating with the 6×4 axle configuration is indicated, and above which operating with the 6×2 axle configuration is indicated. If method500determines that the axle is operating with the 6×4 axle configuration at504, method500continues to506, and includes adjusting the adjustable lubrication system for operating with the 6×4 axle configuration by maintaining the electric pump off and maintaining the valve open. For example, while operating with the 6×4 axle configuration, additional oil in the axle sump may be indicated in order to increase component durability. For example, because both the forward axle and the rear axle are powered while operating with the 6×4 axle configuration, additional load may be placed on axle components. By providing additional oil, component degradation may be decreased while operating with the 6×4 axle configuration. Thus, the electric pump is maintained off, so that oil is not pumped from the axle sump to the external reservoir. Further, the valve is maintained open, so that additional engine oil may flow from the external reservoir to the axle sump through a return line. Specifically, when the valve is open, the return line fluidically couples the external reservoir to the axle sump, and a fluid pressure differential between the external reservoir and the axle sump causes oil to flow from the external reservoir to the axle sump. For example, the return line may be a gravity feed, so that oil flows from the external reservoir to the axle sump when the valve is open. As an example, a position of the valve is controlled via a solenoid, and the controller may adjust a control signal to the solenoid so that the valve remains open. At508, method500includes determining whether the oil level in the axle sump exceeds a first threshold oil level in the axle sump. For example, the first threshold oil level in the axle sump may be a positive, non-zero oil level above which no additional oil is indicated. For example, the first threshold oil level in the axle sump may be a pre-determined amount of oil in the axle sump for ideal operation with the 6×4 axle configuration. For example, when the axle sump level is below the first threshold oil level, additional oil from the external reservoir may be indicated, and when the axle sump level is at or above the first threshold oil level, no additional oil from the external reservoir may be indicated. In some examples, the controller may determine the oil level in the axle sump based on a signal from a level sensor coupled to the axle sump (e.g., such as level sensor426shown inFIG.4), while in other examples, the oil level in the axle sump may be estimated by the controller based on engine operating conditions (e.g., such as oil temperature). If, at508, method500determines that the oil level in the axle sump does not exceed the first threshold oil level, method500continues to509, and includes maintaining the current lubrication scheme. For example, the controller may maintain the lubrication system for the 6×4 axle configuration, such as by maintaining the pump off and maintaining the valve open. For example, if the controller determines that the oil level in the axle sump is less than the first threshold oil level, the controller may continue to maintain the valve in an open position so that oil may continue to flow from the external reservoir into the axle sump. If method500determines, instead, that the oil level in the axle sump exceeds the first threshold oil level at508, method500continues to510, and includes closing the valve. For example, if the controller determines that the oil level in the axle sump is at or above the first threshold oil level, the controller may determine that no additional oil is indicated in the axle sump and as such, may close the valve. For example, closing the valve may prevent additional oil from flowing from the external reservoir to the axle sump. For example, the controller may adjust the control signal to the solenoid controlling the position of the valve so that the valve moves to a closed position, sealing the return line in order to prevent additional oil from flowing to the axle sump. As an example, after closing the valve, the tandem axle may continue to operate with the 6×4 axle configuration, with a relatively high oil level in the axle sump. Method500may then end. If method500determines that the tandem axle is not operating with the 6×4 axle configuration at504(e.g., the tandem axle is operating with the 6×2 axle configuration), method500continues to512and includes adjusting the adjustable lubrication system for operating with the 6×2 axle configuration by closing the valve and activating the electric pump. For example, while operating with the 6×2 axle configuration, less oil in the axle sump may be indicated. As such, the controller may adjust the valve and the electric pump in order to decrease the oil level in the axle sump, leading to a corresponding increase in the oil level in the external reservoir. For example, by closing or maintaining closed the valve, the controller may prevent oil from flowing out of the external reservoir into the axle sump. As an example, the controller may adjust the control signal to the solenoid controlling the valve so that the valve closes. Further, the controller may activate the electric pump in order to pump oil out of the axle sump to the external reservoir. At514, method500includes determining whether the oil level in the axle sump is less than or equal to a second threshold oil level. For example, the second threshold oil level may be a positive, non-zero oil level ideal for axle operation with the 6×2 axle configuration. As an example, the second threshold oil level is less than the first threshold oil level, so that the amount of oil in the axle sump while operating with the 6×2 axle configuration is less than the oil level in the axle sump while operating with the 6×4 axle configuration. For example, while operating with the 6×2 axle configuration, the rear axle is disconnected from the driveshaft. As such, decreasing the amount of oil in the axle sump may increase efficiency without increasing component wear. As an example, the controller may determine whether the oil level in the axle sump is less than or equal to the second threshold oil level based on a level sensor in the axle sump. As another example, the controller may determine whether the oil level in the axle sump is less than or equal to the second threshold oil level based on a level sensor in the external reservoir. If method500determines that the oil level in the axle sump is above the second threshold oil level at514, method500continues to515and includes maintaining the current lubrication control scheme. For example, the controller may continue to operate the adjustable lubrication system for the 6×2 axle configuration. For example, the controller may continue to operate the electric pump, and may continue to maintain the valve closed. As such, the oil level in the axle sump may continue to decrease, and the oil level in the external reservoir may increase correspondingly. If method500determines that the oil level in the axle sump is at or below the second threshold oil level at514, method500continues to516and includes deactivating the electric pump. For example, when the oil level in the axle sump is at or below the second threshold oil level, the controller determines that removing additional oil from the axle sump is not indicated. As such, the controller may deactivate the electric pump so that no additional oil is pumped from the axle sump to the external reservoir. For example, the controller may adjust the control signal to the electric pump so that the pump deactivates. As an example, after deactivating the electric pump at516, the tandem axle may continue to operate with the 6×2 axle configuration, and the lubrication system may be adjusted for operating with the 6×2 axle configuration (e.g., with a relatively low oil level in the axle sump). Method500may then end. In some examples, method500may run continuously during engine operation, so that the lubrication system may be adjusted based on an axle configuration of the tandem axle. Further, in another embodiment, the lubrication system may not include a valve, and as such, oil may continuously drain from the external reservoir to the axle sump. In such an embodiment, the electric pump may periodically activate in order to maintain an oil level in the axle sump according to the axle configuration. In yet another embodiment, the valve may be an electric valve with multiple positions. For example, in a first position, the electric valve may slowly feed oil into the axle sump while operating with the 6×2 axle configuration in order to refresh oil in the axle sump. Further, in a second position, the electric valve may allow a larger portion of oil in the external reservoir to flow to the axle sump, such as during a hill climb or upon returning to operating with the 6×4 axle configuration. Therefore, multiple configurations of electric pumps and valves are envisioned without deviating from the scope of the present disclosure. Further, additional methods for adjusting a lubrication system of a tandem axle are envisioned, such as methods providing for refreshing oil in the axle sump, without deviating from the scope of the present disclosure. In this way, an oil level in an axle sump of a tandem axle with a disconnect feature may be adjusted based on the selected axle configuration, which may increase efficiency while operating with the 6×2 axle configuration while reducing an incidence of component wear while operating with the 6×4 axle configuration. For example, components of the adjustable lubrication system, such as an electric pump and a valve, may be adjusted based on the axle configuration so that the oil level in the axle sump is higher while operating with the 6×4 axle configuration, relative to operating with the 6×2 axle configuration. Next,FIG.6shows a prophetic example timeline for transitioning an engine between a first tandem axle configuration and a second tandem axle configuration. The engine may be engine104shown inFIGS.1and2, for example, and controlled by controller110ofFIGS.1and2. Further, the engine may include a tandem axle with disconnect, such as tandem axle172ofFIGS.1and2, and a lubrication system, such as lubrication system178ofFIGS.1and2. For example, the tandem axle may transition between operating in a first tandem axle configuration (e.g., a 6×4 axle configuration) and a second tandem axle configuration (e.g., a 6×2 axle configuration), as described with respect toFIG.2. Further, in response to the tandem axle transitioning between the 6×2 axle configuration and the 6×4 axle configuration, operation of the lubrication system may be adjusted, as elaborated above with respect to method500ofFIG.5. A tandem axle configuration is shown in plot602, an electric pump status is shown in plot604, a valve position is shown in plot606, an axle sump level is shown in plot608, an external reservoir level is shown in plot610, and a vehicle speed is shown in plot612. Further, a first threshold axle sump level is shown by dashed line614, a second threshold axle sump level is shown by dashed line616, and a threshold vehicle speed is shown by dashed line618. For all of the above, the horizontal axis represents time, with time increasing along the horizontal axis from left to right. The vertical axis represents each labeled parameter. For plots608,610, and612, a magnitude of the parameter increases up the vertical axis from bottom to top. For plot602, the vertical axis shows whether the tandem axle is operating with the 6×4 axle configuration (“6×4”) or the 6×2 axle configuration (“6×2”). For plot604, the vertical axis shows whether the electric pump is on (“On”) or off (“Off”). Further, for plot606, the vertical axis shows whether the valve is in an open position (“Open”) or a closed position (“Closed). Prior to time t1, the vehicle speed (plot612) is below the threshold vehicle speed (dashed line618), and as a result, the tandem axle operates in the 6×4 axle configuration (plot602). In response, the lubrication system is adjusted for the 6×4 axle configuration. In particular, the electric pump is off (plot604). Further, because the axle sump level (plot608) is above the first threshold axle sump level (dashed line614), the valve is maintained in a closed position (plot606), so that no additional oil flows from the external reservoir to the axle sump. As a result, a large volume of oil remains in the axle sump, maintaining the axle sump level high (plot608), while the amount of oil in the external reservoir remains at a low level (plot610). For example, while operating with the 6×4 axle configuration, the high oil level in the axle sump may increase tandem axle efficiency, such as by reducing friction between components of the tandem axle. At time t1, the vehicle speed (plot612) increases above the threshold vehicle speed (dashed line618). In response, the tandem axle transitions to operating with the 6×2 axle configuration (plot602). For example, the threshold vehicle speed (dashed line618) may be a speed at which the additional traction offered by the 6×4 axle configuration is not necessary, and at which vehicle efficiency may be increased by operating with the 6×2 axle configuration. In some examples, vehicle speed may be one of a plurality of factors in determining to transition between operating with the 6×4 axle configuration and the 6×2 axle configuration. Further, in some examples, the vehicle may transition between operating with the 6×4 axle configuration and the 6×2 axle configuration in response to a user input. Due to the tandem axle transitioning to the 6×2 axle configuration, the lubrication system is adjusted for the 6×2 axle configuration. For example, while operating with the 6×2 axle configuration, the tandem axle may operate with less oil in the axle sump. As such, the electric pump is turned on (plot604) and the valve position remains closed (plot606). For example, due to the operation of the electric pump, oil may be pumped from the axle sump to the external reservoir via the electric pump. Accordingly, the axle sump level begins to decrease (plot608) and the external reservoir level begins to increase (plot610). For example, decreasing the amount of oil in the axle sump may increase vehicle efficiency while operating with the 6×2 axle configuration. Between time t1and time t2, the vehicle speed (plot612) remains above the threshold vehicle speed (dashed line618), the tandem axle continues to operate with the 6×2 axle configuration (plot602), and the electric pump remains on (plot604). As a result, the axle sump level continues to decrease (plot608) between time t1and time t2, while the external reservoir level (plot610) increases proportionally. However, at time t2, the axle sump level (plot608) decreases below the second threshold axle sump level (dashed line616). In response, the electric pump turns off at time t2(plot604), so that no additional oil is pumped from the axle sump to the external reservoir level. Between time t2and time t3, the vehicle speed (plot612) remains above the threshold vehicle speed (dashed line618), so that that the tandem axle continues to operate in the 6×2 axle configuration (plot602). However, because the pump is off (plot604) between time t2and time t3, the axle sump level (plot608) remains roughly constant below the second threshold axle sump level (dashed line616). Likewise, the external reservoir level (plot610) remains constant between time t2and time t3. At time t3, the vehicle speed (plot612) decreases below the threshold vehicle speed (dashed line618). In response, the tandem axle transitions from operating with the 6×2 axle configuration to operating with the 6×4 axle configuration (plot602) in order to provide additional traction, for example. As a result, the lubrication system adjusts for the 6×4 axle configuration, including maintaining the pump off (plot604). Further, increase the axle sump level for operating with the 6×4 axle configuration, the valve position opens at time t3, so that oil flows from the external reservoir to the axle sump. Accordingly, between time t3and time t4, the axle sump level (plot608) increases, as the external reservoir level decreases. At time t4, the axle sump level (plot608) increases above the first threshold axle sump level (dashed line614), while the tandem axle continues operating with the 6×4 axle configuration (plot602). In response, the valve moves to a closed position (plot606), so that the axle sump level (plot608) remains constant after time t4. In this way, a tandem axle with a disconnect feature may be operated with a first oil sump level while operating with the 6×2 axle configuration, and a second oil sump level while operating with the 6×4 axle configuration. Therefore, the tandem axle with an adjustable lubrication system may operate with increased efficiency in the 6×2 axle configuration, while reducing an incidence of component wear in the 6×4 axle configuration. For example, by providing an adjustable lubrication system with an external oil reservoir, an electric pump, and a drain line selectably coupling the external reservoir to the axle sump, an oil level in the axle sump may be adjusted based on the selected axle configuration. Therefore, the oil level in the axle sump may be decreased in the 6×2 axle configuration in order to increase vehicle efficiency, and the oil level in the axle sump may be increased in the 6×4 axle configuration in order to provide additional lubrication and reduce component wear. Overall, the vehicle may be provided with the benefits of the 6×2 axle configuration at high speeds and the benefits of the 6×4 axle configuration at low speeds, which may increase vehicle performance and customer satisfaction. The technical effect of providing an adjustable lubrication system in a vehicle including a tandem axle with a disconnect feature is that vehicle efficiency may be increased while operating with a 6×2 axle configuration, and component wear may be reduced while operating with the 6×4 axle configuration. For example, an axle sump of the tandem axle with the disconnect feature may be provided with a first oil level while operating with the 6×2 axle configuration, and a second oil level while operating with the 6×4 axle configuration. As an example, a method comprises: adjusting an oil level in an axle sump of a tandem axle based on an axle configuration of the tandem axle, the axle sump selectably coupled to an external reservoir via a first oil passage and a second oil passage, the first oil passage including an electric pump, the second oil passage including a valve, and the tandem axle coupled to a drivetrain of a motor vehicle. In the preceding example, additionally or optionally, while the tandem axle operates with a first axle configuration, a drive shaft of an engine provides torque to a first axle and a second axle, each of the first axle and the second axle coupled to at least two wheels; and while the tandem axle operates with a second axle configuration, the drive shaft of the engine provides torque to the first axle and does not provide torque to the second axle. In one or both of the preceding examples, additionally or optionally, adjusting the oil level in the axle sump of the tandem axle based on an axle configuration of the tandem axle includes: responsive to the tandem axle transitioning from operating with the first axle configuration to operating with the second axle configuration, flowing oil from the axle sump to the external reservoir through the first oil passage by activating the electric pump, and blocking flow through the second oil passage by closing the valve; and responsive to the oil level in the axle sump at or below a first threshold oil level while the tandem axle operates with the second axle configuration, blocking flow through the first oil passage by deactivating the electric pump. In any or all of the preceding examples, additionally or optionally, adjusting the oil level in the axle sump of the tandem axle further includes: responsive to the tandem axle transitioning from operating with the second axle configuration to operating with the first axle configuration, flowing oil from the external reservoir to the axle sump through the second oil passage by opening the valve; and responsive to the oil level in the axle sump at or above a second threshold oil level while the tandem axle operates with the first axle configuration, blocking flow through the second oil passage by closing the valve. In any or all of the preceding examples, additionally or optionally, the first threshold oil level is lower than the second threshold oil level. In any or all of the preceding examples, additionally or optionally, the tandem axle transitions from the first axle configuration to the second axle configuration responsive to at least one of a vehicle speed above a threshold vehicle speed, a user input, and a road condition, and the tandem axle transitions from the second axle configuration to the first axle configuration responsive to at least one of a vehicle speed below the threshold vehicle speed, the user input, and the road condition. In any or all of the preceding examples, additionally or optionally, the second oil passage is a gravity feed. In any or all of the preceding examples, additionally or optionally, the oil level in the axle sump is determined based on a signal from a level sensor, the level sensor coupled to the axle sump. As another example, a method comprises: responsive a tandem axle transitioning from a 6×4 axle configuration to a 6×2 axle configuration, adjusting an oil level in an axle sump of the tandem axle to a first threshold level, the axle sump of the tandem axle selectably coupled to an external reservoir; and responsive to the tandem axle transitioning from the 6×2 axle configuration to the 6×4 axle configuration, adjusting the oil level in the axle sump of the tandem axle to a second threshold level, the second threshold level higher than the first threshold level. In the preceding example, additionally or optionally, the tandem axle is coupled to a drive shaft of a motor vehicle, the drive shaft providing torque to a first axle while operating with the 6×2 axle configuration, and the drive shaft providing torque to each of the first axle and a second axle while operating with the 6×4 axle configuration. In one or both of the preceding examples, additionally or optionally, the axle sump is selectably coupled to the external reservoir via a first oil passage and a second oil passage, the first oil passage including an electric pump, and the second oil passage including a valve, the valve actuatable between an open position and a closed position. In any or all of the preceding examples, additionally or optionally, when activated, the electric pump flows oil from the axle sump to the external reservoir through the first oil passage and, when not activated, the electric pump does not flow oil from the axle sump to the external reservoir through the first oil passage. In any or all of the preceding examples, additionally or optionally, adjusting the oil level in the axle sump of the tandem axle to the first threshold level includes: responsive to the oil level in the axle sump above the first threshold level, flowing oil from the axle sump to the external reservoir through the first oil passage by activating the electric pump; blocking oil from flowing from the external reservoir to the axle sump through the second oil passage by closing the valve; and responsive to the oil level in the axle sump at or below the first threshold level, deactivating the electric pump. In any or all of the preceding examples, additionally or optionally, adjusting the oil level in the axle sump of the tandem axle to the second threshold level includes: responsive to the oil level in the axle sump below the second threshold level, flowing oil from the external reservoir to the axle sump through the second oil passage by opening the valve; and responsive to the oil level in the axle sump at or above the second threshold level, closing the valve. In any or all of the preceding examples, additionally or optionally, the oil level is determined based on a signal from a level sensor coupled to the axle sump. As yet another example, a system comprises: a tandem axle, the tandem axle coupled to a powertrain of a motor vehicle; an axle sump fluidically coupled to the tandem axle; an external reservoir; a first oil passage selectably coupling the external reservoir to the axle sump via an electric pump; a second oil passage selectably coupling the external reservoir to the axle sump via a valve; and a controller including instructions stored in non-transitory memory that, when executed, cause the controller to: adjust an oil level in the axle sump based on an axle configuration of the tandem axle, the oil level adjusted differently while operating with a first axle configuration relative to operating with a second axle configuration. In the preceding example, additionally or optionally, the tandem axle transitions from the first axle configuration to the second axle configuration in response to a vehicle speed exceeding a threshold vehicle speed, and the tandem axle transitions from the second axle configuration to the first axle configuration in response to the vehicle speed below the threshold vehicle speed. In one or both of the preceding examples, additionally or optionally, the first axle configuration includes providing torque to each of a first axle and a second axle, and the second axle configuration includes providing torque to a first axle while not providing torque to the second axle. In any or all of the preceding examples, additionally or optionally, to adjust the oil level in the axle sump based on the axle configuration of the tandem axle, the controller includes further instructions stored in non-transitory memory that, when executed, cause the controller to: responsive to the tandem axle transitioning from the first axle configuration to the second axle configuration, flowing oil from the axle sump to the external reservoir through the first oil passage by activating the electric pump; and responsive to the tandem axle transitioning from the second axle configuration to the first axle configuration, flowing oil from the external reservoir to the axle sump through the second oil passage by opening the valve. In any or all of the preceding examples, additionally or optionally, the oil level in the axle sump is determined based off at least one of a signal from a level sensor coupled to the axle sump, an oil temperature, an oil age, and a road gradient (e.g., grade). Note that the example control and estimation routines included herein can be used with various engine and/or vehicle system configurations. The control methods and routines disclosed herein may be stored as executable instructions in non-transitory memory and may be carried out by the control system including the controller in combination with the various sensors, actuators, and other engine hardware. The specific routines described herein may represent one or more of any number of processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. As such, various actions, operations, and/or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Likewise, the order of processing is not necessarily required to achieve the features and advantages of the example embodiments described herein, but is provided for ease of illustration and description. One or more of the illustrated actions, operations, and/or functions may be repeatedly performed depending on the particular strategy being used. Further, the described actions, operations, and/or functions may graphically represent code to be programmed into non-transitory memory of the computer readable storage medium in the engine control system, where the described actions are carried out by executing the instructions in a system including the various engine hardware components in combination with the electronic controller. It will be appreciated that the configurations and routines disclosed herein are exemplary in nature, and that these specific embodiments are not to be considered in a limiting sense, because numerous variations are possible. For example, the above technology can be applied to V-6, I-4, I-6, V-12, opposed 4, and other engine types. Moreover, unless explicitly stated to the contrary, the terms “first,” “second,” “third,” and the like are not intended to denote any order, position, quantity, or importance, but rather are used merely as labels to distinguish one element from another. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations, and other features, functions, and/or properties disclosed herein. As used herein, the term “approximately” is construed to mean plus or minus five percent of the range unless otherwise specified. The following claims particularly point out certain combinations and sub-combinations regarded as novel and non-obvious. These claims may refer to “an” element or “a first” element or the equivalent thereof. Such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and sub-combinations of the disclosed features, functions, elements, and/or properties may be claimed through amendment of the present claims or through presentation of new claims in this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, also are regarded as included within the subject matter of the present disclosure. | 68,878 |
11859709 | The following descriptors may be used in connection with the drawings to describe various embodiments of the present invention.1: motor driven power steering device10: steering wheel20: column shaft30: rack bar40: controller100: motor driving unit110: motor120: reducer121: worm gear123: worm wheel130: bearing140: rotation member141: rotation body143: fixing hole145: blade150: lubrication agent pocket151: pocket housing153: center hole155: inlet157: outlet DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS Embodiments of the present invention will be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention. In order to elucidate embodiments of the present invention, parts that are not related to the description will be omitted. Like reference numerals designate like elements throughout the specification. Further, the size and thickness of each of the elements that are displayed in the drawings are arbitrarily described for better understanding and ease of description, the present invention is not limited by the described size and thickness, and the thickness of layers, films, panels, regions, etc., are exaggerated for clarity. Hereinafter, a motor driven power steering device according to embodiments of the present invention will be described in detail with reference to the attached drawings. FIG.1is a perspective view showing a configuration of a motor driven power steering device according to an embodiment of the present invention. As shown inFIG.1, a motor driven power steering (MDPS) device1according to an embodiment of the present invention includes a steering wheel10, a column shaft20, a motor driving unit100, a rack bar30, and a controller40. The steering wheel10controls the driving direction of the vehicle by the operation of the driver. The column shaft20is connected to the steering wheel10, and when the driver rotates the steering wheel10, a torque is transmitted to the rack bar30through the column shaft20, and the steering angle of the steering wheel10is changed according to the left and right movement of the rack bar30. The motor driving unit boo is installed on the column shaft20and applies an auxiliary torque to the column shaft20to reduce the steering torque of the driver. To this end, the motor driving unit100may include a motor110generating power and a reducer120for deceleration of a rotation speed of the motor110. The controller40controls the torque and the speed of the motor driving unit100based on the steering angle of the steering wheel10detected through the sensor. FIG.2is a view showing a configuration of a motor driving unit according to an embodiment of the present invention.FIG.3is a perspective view showing some configurations ofFIG.2.FIG.4is a partial perspective view enlarging a display part ‘X’ ofFIG.3. Referring toFIG.2toFIG.4, the motor driving unit100may include a motor110that generates power and a reducer120(speed reducer) that is connected to the motor110to decelerate the speed of the motor110and increase the torque of the motor110. The reducer120may include a worm gear121that is installed inside the housing of the reducer120, and a worm wheel123that is geared with the worm gear121. The worm gear121is coupled to the drive shaft of the motor110and may be rotatably mounted to the reducer120housing via a bearing130. The end of the worm gear121(the opposite side end of the motor110) may be mounted to face the downward direction (or a gravity direction) of the vehicle. The worm wheel123is gear-engaged with the worm gear121, and a lubrication agent such as grease may be applied to the worm wheel123and the worm gear121. The reduction ratio of the motor110is determined by the gear ratio between the worm gear121and the worm wheel123. A rotation member140is installed between the end of the worm gear121and the bearing130. The rotation member140may be installed by being press-fitted onto the shaft of the worm gear121. FIG.5is a perspective view showing a configuration of a rotation member according to an embodiment of the present invention. Referring toFIG.5, the rotation member140is press-fitted to the shaft of the worm gear121to be installed and rotates integrally with the worm gear121. The rotation member140includes a rotation body141and at least one blade145formed on the rotation body141. A fixing hole143is formed in the center of the rotation member140, and the fixing hole143is press-fitted to the shaft of the worm gear121so that the rotation member140may be fixedly installed on the worm gear121. The rotation body141is press-fitted to the shaft of the worm gear121through the fixing hole143and is approximately formed in a disk shape. A blade145is formed to be protruded from the rotation body141in the direction toward the motor110, and a plurality of blades may be formed as needed. The blade145may be formed on the upper surface of the rotation body141(or the opposite side of the bearing130). A plurality of blades145may be formed on the rotation body141at equal intervals in the circumferential direction. FIG.6is a perspective view showing a configuration of a lubrication agent pocket according to an embodiment of the present invention. Referring toFIG.6, the lubrication agent pocket150may include a pocket housing151, and an inlet155and an outlet157formed in the pocket housing151. The pocket housing151is fixedly installed inside the reducer120housing. The pocket housing is formed in the shape of an empty cylinder with the inside, and a rotation member is rotatably disposed inside the pocket housing. In the center of the pocket housing, a central hole153into which the shaft of the worm gear is inserted is formed. The inlet155is formed on the upper part of the pocket housing151and is opened toward the axial direction of the worm gear121(or the direction toward the motor110). The lubrication agent (e.g., the grease) applied to the worm gear121and the worm wheel123may be inflowed into the pocket housing151through the inlet155. The outlet157is formed on the side of the pocket housing151and is opened toward the worm wheel123. The lubrication agent (e.g., the grease) inflowed into the pocket housing151may be discharged toward the worm wheel123through the outlet157. Hereinafter, the operation of the motor driven power steering device1according to an embodiment of the present invention as described above is described in detail with reference to the attached drawings. FIG.7is a perspective view showing a configuration of a rotation member and a lubrication agent pocket according to an embodiment of the present invention. Referring toFIG.7, first, when the motor driving unit100is assembled, after the lubrication agent is applied between the worm gear121and the worm wheel123, in the reducer120housing, the motor110, the worm gear121, the worm wheel123, the rotation member140, the lubrication agent pocket150, and the bearing130are assembled inside the reducer120housing. Specifically, the worm wheel123is rotatably assembled on the reducer120housing, and the lubrication agent pocket150is fixedly installed on the reducer120housing. In a state that the worm gear121is press-fitted and coupled to the drive shaft of the motor110, the end of the worm gear121is inserted into the central hole153of the lubrication agent pocket150. The rotation member140is press-fitted to the shaft of the worm gear121to be fixedly installed, and the shaft of the worm gear121is assembled to the reducer120housing through the bearing130. If the worm gear121and worm wheel123are gear assembled, a lubrication agent (e.g., grease) is applied to the worm gear121and the worm wheel123. When the motor110operates, the worm gear121and the worm wheel123are engaged and rotated, and the worm gear121and the worm wheel123are rotated smoothly by the applied lubrication agent. Since the worm gear121is disposed toward the downward direction (or the direction of gravity), the lubrication agent applied to the worm gear121and the worm wheel123flows downward by gravity. The downwardly flowing lubrication agent inflows through the inlet155of the lubrication agent pocket150into the interior of the pocket housing151(referring to step (a) ofFIG.8). The lubrication agent inflowed into the pocket housing151of the lubrication agent pocket150is disposed inside the pocket housing151and no longer flows downward by the rotation body141of the rotation member140that rotates integrally with the worm gear121(referring to step (b) ofFIG.8). The blade145of the rotation member140circulates the lubrication agent inflowed into the inside of the pocket housing151and exhausts it to the outlet157of the pocket housing151. Accordingly, the lubrication agent inflowed into the pocket housing151is discharged toward the worm wheel123through the outlet157of the pocket housing151(referring to FIG. step (c) ofFIG.8). According to the motor driven power steering device1according to an embodiment of the present invention as described above, the lubrication agent applied between the worm gear121and the worm wheel123does not flow into the bearing130by the rotation member140that is press-fitted to the shaft of the worm gear121and rotates integrally. And the lubrication agent applied between the worm gear121and the worm wheel123is temporarily inflowed into the pocket housing151of the lubrication agent pocket150, and then is discharged in the direction of the worm wheel123by the blade145of the rotation member140. As such, by recirculating the lubrication agent applied to the worm gear121and the worm wheel123, noise and vibration generated between the worm gear121and the worm wheel123may be reduced. While this invention has been described in connection with what is presently considered to be practical embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. On the contrary, it is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | 10,258 |
11859710 | DETAILED DESCRIPTION OF THE DRAWINGS As set out at the beginning, the present document is consequently concerned with enabling the user of a vehicle to operate an automatic transmission in a manual shifting mode in an efficient way even when there is no dedicated hardware operating element available for manual shifting. In this connection,FIG.1shows components, given by way of example, of a vehicle100. In particular,FIG.1shows a drive engine104(in particular an internal combustion engine) of the vehicle100, which is set up to drive the vehicle100. Furthermore, the vehicle100comprises an automatic transmission103, which is set up to change the transmission ratio between the shaft of the drive motor104and a driven axle of the vehicle100. The transmission103may have for example 2 or more, 4 or more, 5 or more, or 6 or more gears (for forward travel). Furthermore, the vehicle100may comprise a clutch102(for example as part of the transmission103) to decouple the drive engine104from the driven axle of the vehicle100for a gear change or to couple it thereto. FIG.2shows a driver's position200, given by way of example, of a vehicle100, which comprises an automatic transmission103. In particular,FIG.2shows a steering wheel220for steering the vehicle100, which is typically arranged on a dashboard202of the vehicle100. In the central console of the vehicle100, a gear selection operating element210, in particular a gear selector lever or a gear selector switch, may be arranged. A gear selector lever or a gear selector switch is described by way of example hereinafter. However, the aspects described in this document apply generally for a gear selection operating element. In the case of an automatic transmission103, typically different drive positions215, such as for example the drive positions “N”, “D”, “R”, “L”, and/or “P”, can be set by way of the gear selector lever210. In the drive position “N”, the drive engine104is typically decoupled and the transmission lock of the transmission103is typically deactivated. In the drive position “P”, the drive engine104is typically decoupled and the transmission lock of the transmission103is typically activated. In the drive position “D”, the drive engine104is typically coupled to the driven axle for forward travel. In the drive position “L”, the drive engine104is typically coupled to the driven axle for forward travel, but has a lower gear than in the drive position “D” (for example to provide an engine braking function when driving downhill). In the drive position “R”, the drive engine104is typically coupled to the driven axle for reverse travel. The respectively set drive position215can be indicated by an indicating element216(for example by illumination of a letter for the respectively set drive position215). It should be pointed out that the drive position “P” can possibly be set by way of a separate button (and not by way of the gear selector lever210). The gear selector lever210is preferably designed as monostable, so that the gear selector lever210moves back into a base location or base position after a deflection. By deflecting the gear selector lever210in a first (for example in a forward) direction211, it can be brought about that the drive positions215can gradually be set from the drive position “L” to the drive position “P” (for example according to the series of drive positions L, D, N, R, P). By deflecting the gear selector lever210in an (opposite) second (for example in a reverse) direction212, it can be brought about that the drive positions215can gradually be set from the drive position “P” to the drive position “L” (for example according to the series of drive positions P, R, N, D, L). Each change of the drive position215can typically be brought about here by a relatively short deflection (for example having a trigger duration of approximately 1 second) in one of the two directions221,212. The drive positions215can be changed by way of the deflection of the gear selector lever215by repeated deflection in the first direction211from a first limiting drive position (for example the drive position “L” or “D”) up to the second limiting drive position (for example the drive position “P” or “N”). Starting from the second limiting drive position, typically no further drive position change can be brought about by a deflection in the first direction211. In a corresponding way, the drive positions215can be changed by way of the deflection of the gear selector lever215by repeated deflection in the second direction212from the second limiting drive position (for example the drive position “P” or “N”) up to the first limiting drive position (for example the drive position “L” or “D”). Starting from the first limiting drive position, typically no further drive position change can be brought about by a deflection in the second direction212. The driver's position200may also comprise a (possibly touch-sensitive) screen240, which is for example arranged on the dashboard202and/or on the central console of the vehicle100. The screen240may be designed to provide a graphical user interface241. The user interface241may comprise one or more virtual operating elements242,243, which can be actuated or touched by a user in order to initiate an action of the vehicle100. Furthermore, the user interface241may comprise one or more indicating elements244, by way of which graphical information can be output to the user of the vehicle100. An interaction with the graphical user interface241may take place by way of one or more virtual operating elements242,243or by way of a mechanical controller245(for example by way of a rotary pushbutton). The mechanical controller245enables a user to make inputs that lead to a change on the graphical user interface241(for example for selecting a menu item indicated on the user interface241) and possibly an action of the vehicle100(in particular a manual gear change). The control unit101of the vehicle100may be set up to detect that the gear selector lever210is transferred from the drive position “D” into the drive position “L” in the second direction212. In response to that, it may be brought about that a graphical user interface241is provided on the screen240and enables the user of the vehicle100to shift the transmission103manually in a manual shifting mode. In particular, in response to the detected deflection of the gear selector lever210into the drive position “L”, the transmission103may possibly be transferred from automatic operation or an automatic mode into manual operation or a manual mode. The graphical user interface241may comprise a first (virtual) operating element242, which enables the user to make manual gear changes in a first direction (for example shifting up), and comprise a second operating element243, which enables the user to make manual gear changes in an (opposite) second direction (for example shifting down). Thus, a manual shifting mode can be provided in an efficient way. The low-gear function, i.e. the drive position “L”, of a transmission103typically serves for using the engine braking when driving downhill or the like. In order to boost or reduce the engine braking after selecting the gear stage “L”, virtual operating elements242,243on a screen240of the vehicle100can be actuated by the user. In particular, the manual shifting mode may be provided in such a way that, starting from the forward drive position “D”, the transmission mode can be switched over to a low-gear mode “L” by renewed actuation of the gear selector switch210in the direction of drive position D/L (for example to the rear). The indicator231in the instrument cluster and/or the indicator232in the gearshift pattern of the gear selector switch210may then change to “L”. After the switchover to the L mode has taken place, a menu241for the manual shifting of the transmission gears may be shown on the screen240. This menu241can be used for manually adjusting the gears of the transmission103by way of a controller (for example by way of a rotary pushbutton not shown)245and/or by virtual operating elements242,243. A virtual operating element242“+” may be provided for shifting up the gears, and a virtual operating element243“−” may be provided for shifting down the gears. Thus, the behavior of the transmission103during manual shifting can be replicated by way of a hardware operating element. The user may possibly leave the screen menu241. In this case, the manual shifting mode may be operated with automatic enforced shifting up or enforced shifting down of the transmission103when rotational-speed limits are reached as a result of a change in the speed of the vehicle100. It is in this way possible to provide a manual shifting mode in which nevertheless (for safety reasons) an automatic gear change takes place if the speed of the vehicle100leaves the permissible speed range for the currently set gear. The control unit101may be set up to determine that the traveling speed of the vehicle100leaves the permissible speed range for the currently set gear. In response to that, an automatic gear change may be brought about even when the transmission103is in the manual shifting mode. Thus, the operational safety of the vehicle100can be increased further. The gear indicator231in the instrument cluster may change from an indication of the respectively set drive position to a representation of the currently set gear (for example Mx, where x is the currently set gear). The indicator232in the gearshift pattern of the gear selector switch210may indicate that the transmission103is in a manual shifting mode (for example by showing the letter “M”). In this way it is possible to provide one or more indicating elements231,232by which it can be indicated whether the transmission103is in the automatic shifting mode or in the manual shifting mode. Furthermore, the respectively (manually) set gear of the transmission103can be indicated in an indicating element231(if the transmission103is in the manual shifting mode). This allows the comfort for the user of the vehicle100to be increased. The low-gear mode and/or the manual shifting mode may be left by the gear selector switch210being actuated in the direction of the drive position “D/L” (to the rear), i.e. in the second direction212. Furthermore, the low-gear mode and/or the manual shifting mode can be left by some other drive position (for example D, P, N or R) being set. The menu241for the manual shifting mode may possibly be provided by default when the drive position “L” is selected. It may possibly be made possible to deactivate the provision of the menu241and/or the manual shifting mode by setting a preference (for example in a setting menu for vehicle settings). As already set out above, the drive position “L” typically serves for using the engine braking for instances of driving downhill. The user interface241may be constructed in such a way that it enables the user to increase or reduce the degree of deceleration brought about by the engine braking. For example, a first (virtual) operating element242may be provided, by which the engine braking can be boosted (and thereby the traveling speed of the vehicle100is reduced). Furthermore, a second (virtual) operating element243may be provided, by which the engine braking can be reduced (and thereby the traveling speed of the vehicle100increased). It may possibly be indicated in an indicating element244how the traveling speed can be influenced by the operating elements242,243. The actuation of an operating element242,243effectively leads to a manual gear change. For the user, however, boosting or reducing the engine braking is typically more intuitive, so that the comfort for the user can be increased. After switching over to the L mode has taken place, a menu241for engine braking can consequently be shown on the screen240. This menu241can be used for adjusting the engine braking by way of a controller245(for example by way of a rotary pushbutton) and/or by way of virtual operating elements242,243. With a higher engine braking setting, the vehicle speed decreases and, with a lower engine braking setting, the vehicle speed increases. The setting of the engine braking brings about shifting of the gears in the transmission103as long as the respective gears are permissible at the current speed of the vehicle100. FIG.3shows a flow diagram of a method300, given by way of example, for operating an automatic transmission103of a vehicle100. The method300may be performed by a control unit101of the vehicle100. The automatic transmission103may be designed to be operated in an automatic shifting mode, in which the gears of the transmission103can be automatically adapted to the respective driving situation (in particular when the transmission103is in the drive position “D”. Furthermore, the transmission103may be designed to be operated in a manual shifting mode, in which the gears of the transmission103can be manually set by the driver of the vehicle100and/or adapted to the respective driving situation. The vehicle100comprises a gear selection operating element210(in particular a gear selector lever), which enables a user (in particular the driver) of the vehicle100to set different drive positions215of the transmission103by actuating the gear selection operating element210. In this case, the gear selection operating element210may be designed in a cost-efficient way in such a way that no manual gear changes can be brought about by the gear selection operating element210(apart from the setting of the drive positions215). The method300comprises determining301that a drive position “L” has been set by the gear selection operating element210. Alternatively or additionally, it may be determined in the course of the method300that the transmission103is in the drive position “L”. The drive position “L” may in this case be a so-called “low-gear” drive position, in which the transmission103tends to be in a relatively low gear, in order in particular to provide engine braking when driving downhill. The method300also comprises, in response to the determining, the provision302of a graphical user interface241on a screen240of the vehicle100. In this case, the graphical user interface241is designed to make manual shifting of gears of the transmission103possible by making inputs on the graphical user interface241. The graphical user interface241may for example be provided as soon as and/or precisely when the gear selection operating element210brings about the change (from the drive position “D”) to the drive position “L”. By the measures described in this document, a manual shifting mode of the transmission103can be provided in an efficient way even when using a monostable gear selector switch or gear selector lever210(with only a single gate). The present invention is not restricted to the exemplary embodiments shown. In particular, it should be noted that the description and the figures are only intended to illustrate the principle of the proposed methods, devices, and systems on the basis of an example. | 15,088 |
11859711 | DETAILED DESCRIPTION Advantages and features of the present disclosure and methods of accomplishing the same may be understood more readily by reference to the following detailed description of exemplary embodiments and the accompanying drawings. The present disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the concept of the disclosure to those skilled in the art, and the present disclosure will only be defined by the appended claims. Throughout the specification, like reference numerals in the drawings denote like elements. In some embodiments, well-known steps, structures and techniques will not be described in detail to avoid obscuring the disclosure. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. Embodiments of the disclosure are described herein with reference to plan and cross-section illustrations that are schematic illustrations of idealized embodiments of the disclosure. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments of the disclosure should not be construed as limited to the particular shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. In the drawings, respective components may be enlarged or reduced in size for convenience of explanation. Hereinafter, the present disclosure will be described with reference to the drawings for describing a transmission device for a vehicle and an operating method thereof according to embodiments of the present disclosure. FIG.1is a block diagram showing the configuration of a transmission device for a vehicle according to an embodiment of the present disclosure,FIG.2is a schematic diagram showing a transmission device for a vehicle according to an embodiment of the present disclosure,FIG.3is a perspective view showing a transmission device for a vehicle according to an embodiment of the present disclosure,FIG.4is a side view showing a transmission device for a vehicle according to an embodiment of the present disclosure, andFIG.5is a plan view showing a transmission device for a vehicle according to an embodiment of the present disclosure. Referring toFIGS.1to5, the vehicle transmission device1according to an embodiment of the present disclosure may include a vehicle state detector100, a transmission operation unit200, and a position adjusting unit300. In the embodiment of the present disclosure, an example in which the vehicle transmission device1is installed on the center console C between the center fascia and the console box of a vehicle will be described, but the present disclosure is not limited thereto. The vehicle transmission device1may be installed in various positions that can be easily accessed by a driver for transmission operation. The vehicle state detector100may detect at least one state of the vehicle in order for activation of the transmission operation unit200, and the activation of the transmission operation unit200may be understood that it is switched to a state that enables the driver to perform transmission operation. In the embodiment of the present disclosure, an example in which the vehicle state detector100detects a plurality of different vehicle states will be described. This configuration may allow the transmission operation unit200to be disposed at any one of a plurality of different positions depending on the vehicle state detected by the vehicle state detector100, and a detailed description thereof will be described later below. The vehicle state detector100may detect a first state and a second state. In the first state, the ignition of the vehicle may be turned off or the vehicle may in in an ignition preparation state. In the second state, the ignition of the vehicle may be turned on. However, the vehicle state to be detected by the vehicle state detector100is not limited to the above-described examples, and the vehicle state to be detected by the vehicle state detector100may be added, deleted, or changed depending on a vehicle state that is required for activation of the transmission operation unit200. The first state may include a case, in which the ignition of the vehicle is turned off and the operation (e.g., driving) of the vehicle is not expected, and also a case, in which the operation (e.g., driving) of the vehicle is expected even though the ignition of the vehicle is turned off. The latter case may be referred to as a ignition preparation state. In particular, the first state may be understood as a state when the engine is not operating for the case of internal combustion engine vehicles or a state when the vehicle is not drivable for the case of electric vehicles. The second state may be understood as a state when the engine is operating for the case of internal combustion engine vehicles or a state when the vehicle is drivable for the case of electric vehicles. In addition, the ignition preparation state may be understood as a state in which the driving of the vehicle is expected in the near future, such as when the vehicle's door opens, a driver with a smart key approaches the vehicle, a driver is detected within the vehicle, or the brake is applied, while the ignition of the vehicle is turned off. The detection result of the vehicle state detector100may be delivered to a controller such as an ECU, and the controller may be configured to generate a control signal for adjusting the position of the transmission operation unit200based on the detected vehicle state. The transmission operation unit200may enable the driver's transmission operation, and in particular, the position thereof may be adjusted depending on the vehicle state detected by the vehicle state detector100to allow the driver to recognize the vehicle state. The transmission operation unit200may be connected with a transmission unit400via a shaft410for a transmission function, and as the transmission operation unit200rotates about a rotation axis Ax, one of the plurality of transmission stages may be selected. In the embodiment of the present disclosure, as the transmission operation unit200rotates in the first direction, the transmission stage may be selected in the order of reverse (R), neutral (N), and drive (D) stages, and as the transmission operation unit200rotates in the second direction, the transmission stage may be selected in the order of D, N, and R. However, the present disclosure is not limited thereto, and the selectable transmission stages may be variously changed based on the rotation of the transmission operation unit200, and additionally, some transmission stages such as the parking (P) stage may be selected by a button or a switch provided separately from the transmission operation unit200. In addition, in the embodiment of the present disclosure, a case in which the first direction is a clockwise direction and the second direction is a counterclockwise direction will be described as an example. The transmission unit400may output a transmission signal that corresponds to the position of the transmission operation unit200, and the transmission signal output from the transmission unit400may be delivered to a transmission system to cause the transmission stages to be selected in accordance with the stage selected by the transmission operation unit200. FIGS.6to8are plan views illustrating a transmission unit according to an embodiment of the present disclosure. Referring toFIGS.6to8, the transmission unit400according to an embodiment of the present disclosure may include a rotating member420that rotates integrally with the shaft410and a detent groove430that generates a feeling of operation (e.g., haptic feedback) when the rotating member420is rotated. When the transmission operation unit200is rotated, since the rotation member420is rotated by the rotation of the shaft410that is coupled to the transmission operation unit200, and a bullet421disposed at an end of the rotation member420moves while maintaining contact with the detent groove430, the feeling of operation may be generated according to the shape of the contact surface of the bullet421in the detent groove430. In particular, since the bullet421is elastically supported along the radial direction with respect to the rotation axis Ax by an elastic member (e.g., a coil spring disposed within a cavity formed in the rotation member420while applying an elastic force against the bullet421inserted in the rotation member420), it is possible to maintain a state in contact with the detent groove430when the shaft410rotates. The detent groove430may generate the feeling of operation when the transmission operation unit200rotates, and may also return the transmission operation unit to a resting position (e.g., a default position) to select a transmission stage when an external force is applied to the transmission operation unit200is removed. More specifically, the resting position refers to a position at which the transmission operation unit200rests without an external force being applied thereto, and if the positions to be returned are the same when the external force applied to the transmission operation unit200is removed regardless of the rotation direction of the transmission operation unit200, the resting position may have one position. If the positions to be returned are different when the external force applied to the transmission operation unit200is removed, the resting position may have two or more different positions. Hereinafter, in the embodiment of the present disclosure, an example in which the resting position of the transmission operation unit200is different depending on the rotation direction of the transmission operation unit200will be described, and accordingly, the resting position of the transmission operation unit200is referred to a NULL stage, which may correspond to the transmission stage selected immediate prior to returning to the resting position. In particular,FIGS.6to8show an example in which a plurality of detent grooves431and432respectively corresponding to Nr and Nd stages are included as the NULL stage. As such, when the external force is removed after the transmission operation unit200is rotated to the D stage, the bullet421may return to the detent groove431that corresponds to the Nd stage among the plurality of detent grooves431and432due to, for example, the spring action of the elastic member disposed within the rotation member420. On the other hand, when the external force is removed after the transmission operation unit200is rotated to the R stage, the bullet421may return to the detent groove432that corresponds to the Nr stage among the plurality of detent grooves431and432. Both the Nd and Nr stages may be understood as the N stage, and in response to the external force applied to the transmission operation unit200being removed (i.e., when the driver releases the transmission operation unit200after turning it toward the right end or the left lend), the transmission operation unit200may be returned to the resting position, the transmission stage may be selected based on the above-described order of transmission stage selection. For example, when the transmission operation unit200is rested at the Nd stage after the transmission operation unit200is rotated in the first direction to select the D stage and then is released, the driver may rotate the transmission operation unit200in the second direction to select the transmission stage in the order of Nr and R stages. On the other hand, when the transmission operation unit200is rested at the Nr stage after the transmission operation unit200is rotated in the second direction to select the R stage and then is released, the driver may rotate the transmission operation unit200in the first direction to select the transmission stage in the order of Nd and D stages. Accordingly, the Nd and D stages may be understood to have the same rotation direction but different rotation angles for the transmission operation unit200, and similarly, Nr and R stages may be also understood to have the same rotation direction but different rotation angles for the transmission operation unit200. A first contact surface431amay be formed in the first direction from the detent groove431that corresponds to the Nd stage among the plurality of detent grooves431and432, and a second contact surface432amay be formed in the second direction from the detent groove432that corresponds to the Nr stage. The first contact surface431may be formed to be radially closer to the rotation axis Ax of the transmission operation unit200as it moves away from the detent groove431that corresponds to the Nd stage, and similarly, the second contact surface432may be formed to be radially closer to the rotation axis Ax of the transmission operation unit200as it moves away from the detent groove432that corresponds to the Nr stage. As the position of the bullet421in contact with the first contact surface431aor the second contact surface432abecomes closer to the rotation axis Ax, the elastic deformation of the elastic member that elastically supports the bullet421may increase, leading to increase of the restoring force. In turn, the increased restoring force may act to return the bullet421to one of the plurality of detent grooves431and432in response to the external force being removed. FIG.6shows an example, in which the bullet421is inserted and disposed in the detent groove that corresponds to the Nd stage among the plurality of detent grooves431and432. In this case, as shown inFIG.7, if the external force is applied to rotate the transmission operation unit200in the second direction to select the R stage, and then is removed, the bullet421may be returned to be inserted into and disposed at the detent groove432that corresponds to the Nr stage among a plurality of detent grooves431and432. In the above-described embodiment, an example in which the transmission operation unit200is returned to the resting position when the external force applied to the transmission operation unit200to select the transmission stage is removed has been described, but the present disclosure is not limited thereto. In some embodiments, the transmission operation unit200may maintain a position that corresponds to the selected transmission stage, and in this case, an additional detent groove that corresponds to the selected transmission stage may be formed along the rotation direction of the transmission operation unit200. The position of the transmission operation unit200may be adjusted to a first position or a second position. Hereinafter, the first position may collectively refer to a state in which a transmission operation is not required, that is, a position of the transmission operation unit200that disables the driver's transmission operation, and the second position may collectively refer to a state in which a transmission operation is required, that is, the position of the transmission operation unit200that enables the driver' transmission operation. In the embodiment of the present disclosure, when the vehicle ignition is turned on, the transmission operation unit200may be switched to the second position so that the driver can easily recognize that the ignition of the vehicle is turned on. In other words, in the case of an internal combustion engine vehicle, when the ignition of the vehicle is turned on, the driver can recognize that the ignition of the vehicle is turned on due to the engine noise or vibration, or the like, whereas in the case of electric vehicles, which use the driving force of the motor as a power source, vibration or the like is not generated. As such, it may be more difficult for the driver to recognize whether the ignition of the vehicle is turned on. Thus, in the embodiment of the present disclosure, when the ignition of the vehicle is turned on, the position of the transmission operation unit200may be changed so that the driver can easily recognize that the vehicle's ignition is turned on in the electric vehicles, as well as in the internal combustion engine vehicles. The position adjusting unit300may adjust the position of the transmission operation unit200so that the transmission operation unit200may be slidingly moved to the first position or the second position according to a control signal from the controller. In the embodiment of the present disclosure, an example in which when the transmission operation unit200is slidingly moved to the second position, the default transmission stage is P or N stage will be described. Further, an example in which when at least one transmission condition such as the vehicle speed, application of the brake, or the like is satisfied, selection of another transmission stage is possible will be described. The position adjusting unit300may include a driving unit310and a guide unit320. The driving unit310may generate a driving force for adjusting the position of the transmission operation unit200, and the guide unit320may adjust the position of the transmission operation unit200by the driving force from the driving unit310. When a driving force is generated from the driving unit310, the guide unit320may allow the transmission operation unit200to be slidingly moved. Hereinafter, an example in which the transmission operation unit200is slidingly moved substantially in the horizontal direction by the guide unit320will be described. In other words, the transmission operation unit200may be seated on a seating cover500that allows the transmission operation unit200to be seated at the first position and prevents the inside components from being visible to the outside. At the second position, at least a portion of the transmission operation unit200may be disposed so as to be exposed from the seating cover500so that the driver can grab the transmission operation unit200to perform the transmission operation. In this case, an opening that enables sliding movement of the transmission operation unit200may be formed in the seating cover500, and the shaft410may be connected to the transmission operation unit200through the opening. Further, at the second position, the guide unit320may allow at least a portion of the transmission operation unit200to be disposed at a different height than the first position in a direction perpendicular to the direction of the sliding movement of the transmission operation unit200, so that the driver can more easily grab the transmission operation unit200to perform the transmission operation. For example, since it is difficult for the driver to hold the transmission operation unit200when the entirety of the transmission operation unit200is seated on (e.g., abutting) the seating cover500, in the embodiment of the present disclosure, the transmission operation unit200may be slidingly moved so that at least a portion thereof may be raised to allow the driver to grab the transmission operation unit200more easily and to perform the transmission operation. The guide unit320may include a lead screw321and a nut member322. The lead screw321may be rotated with respect to the rotation axis311of the driving unit310, and the nut member322may be moved along the rotation axis direction of the lead screw321when the lead screw321rotates. In addition, the nut member322may include a guide groove322a, in which the guide protrusion440that is formed on the transmission unit400is inserted and disposed. Accordingly, as the nut member322moves along the rotation axis direction of the lead screw321, the transmission operation unit200may be slidably moved in the direction of the rotation axis of the lead screw321. At this time, the guide protrusion440may move along the guide rail441formed in the transmission housing (not shown), and both ends of the guide rail441may be formed to have different heights with respect to the rotation axis of the lead screw321, and the guide protrusion440may have different heights when disposed at a proximate end of the guide rail441and when disposed at a distal end of the guide rail500. In addition, as the both ends of the guide rail441are formed to have different heights, the guide groove322aformed in the nut member322may be formed to be elongated in the vertical direction so that the guide protrusion440can be moved up and down in the vertical direction with respect to the nut member322. At this time, the upward and downward movement of the guide protrusion440is merely an example since the guide protrusion440slidingly moves in the horizontal direction. However, the direction, in which the guide protrusion440actually moves up and down, may vary depending on the sliding direction of the guide protrusion440. Therefore, when the transmission operation unit200is at the first position, the guide protrusion440may be disposed at the proximate end of the guide rail441, and at the same time disposed at the lower end of the guide groove332a. When the transmission operation unit200is moved to the second position by the position adjusting unit300, the guide protrusion440may be disposed at the distal end of the guide rail441, and at the same time, at the upper end of the guide groove332a, as shown inFIGS.9to12. Such a configuration may allow the driver to hold the transmission operation unit200more easily to perform transmission operation. As described above, when the position of the transmission operation unit200is adjusted from the first position to the second position, the driver may hold the transmission operation unit200and may rotate it in the first direction or the second direction with respect to the axis of rotation Ax to select R, N, or D stages, as shown inFIG.13. In addition, the transmission operation unit200may include a light emitting module210for forming a lighting image of a predetermined shape. For example, the light emitting module210may form a lighting image for a welcoming function that facilitates communication between the vehicle and the driver by letting the vehicle to react as if welcoming the driver in the first state. In this case, the light emitting module210may form a lighting image having at least one color in at least some portion. In the second state, the light emitting module210may display a lighting image I that indicates the current transmission stage so as to aid the driver to more easily recognize the current transmission stage selected by the driver, as shown inFIG.14.FIG.14is an example where the D stage is selected. On the other hand, when the ignition of the vehicle is turned off due to the end of vehicle driving, the light emitting module210may forms a lighting image of a predetermined color so that the driver can recognize that the vehicle ignition is turned off, and/or may gradually increase or decrease the brightness of the lighting image. In the above-described embodiment, although an example in which when the ignition of the vehicle is turned on, the transmission operation unit200is slidingly moved by the guide unit320, and at the same time, at least a portion thereof is raised and lowered so that the transmission operation unit200is disposed at the first position or the second position has been described. However, this is only an example for helping understanding of the present disclosure, and the present disclosure is not limited thereto. The sliding movement of the transmission operation unit200may be omitted, and the transmission operation unit200may be raised and lowered depending on the first position and the second position. In some embodiments, the raising and lowering of the transmission operation unit200may be omitted, and the transmission operation unit200may be slidingly moved to the first position and the second position without substantially changing its height. In the above-described the vehicle transmission device1of the present disclosure, the transmission operation unit200has different positions depending on the vehicle state, so that the driver can easily recognize the on/off state of the ignition of the vehicle in an electric vehicle as well as in an internal combustion engine vehicle. Therefore, the driver may more easily recognize that the ignition of the vehicle is turned on, such as in an electric vehicle, and such a function may prevent accidents against humans and vehicles due to the driver's inability to recognize the ignition. In concluding the detailed description, those skilled in the art will appreciate that many variations and modifications can be made to the exemplary embodiments without substantially departing from the principles of the present disclosure. Therefore, the disclosed exemplary embodiments of the disclosure are used in a generic and descriptive sense only and not for purposes of limitation. | 25,701 |
11859712 | DESCRIPTION OF EMBODIMENTS Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings. The embodiment described below is an example and does not limit the present invention. First, with reference toFIG.1, a description will be given of an overall configuration of automatic transmission1according to an embodiment of the present invention. As illustrated inFIG.1, automatic transmission1is a dual clutch type transmission. A left side inFIG.1is a front side of automatic transmission1, whereas a right side inFIG.1is a rear side of automatic transmission1. Automatic transmission1includes first clutch10, second clutch20, and transmission section30. Automatic transmission1is mounted on, for example, a vehicle such as a truck (not illustrated). In addition, drive wheels are coupled, via a propeller shaft, differential and a drive shaft which are not illustrated, to an output-side of transmission section30so that power can be transmitted. First clutch10is, for example, a wet multi-plate clutch that is hydraulically actuated and includes a plurality of input-side clutch plates11and a plurality of output-side clutch plates12. Input-side clutch plate11rotates integrally with output shaft2of a power source (e.g., an engine or a motor, neither is illustrated). Output-side clutch plate12rotates integrally with first input shaft31of transmission section30. First clutch10is energized in a disconnection direction by a return spring (not illustrated) and enters a connected state when a control hydraulic pressure is supplied into a hydraulic-oil chamber of a piston (not illustrated) and the piston moves to bring input-side clutch plates11and output-side clutch plates12into pressure-contact with each other. When first clutch10enters the connected state, a drive force of the power source is transmitted to first input shaft31. Connection and disconnection of first clutch10are controlled by control section40. Second clutch20is provided on an outer circumferential side of first clutch10. In the present embodiment, a description will be given with an example in which second clutch20is provided on an outer circumferential side of first clutch10; however, an arrangement relationship between first clutch10and second clutch20is not limited to this arrangement. For example, second clutch20may be provided on a front side or a rear side of first clutch10. Second clutch20for example, a wet multi-plate clutch that is hydraulically actuated and includes a plurality of input-side clutch plates21and a plurality of output-side clutch plates22. Input-side clutch plate21rotates integrally with output shaft2of the power source. Output-side clutch plate22rotates integrally with second input shaft32of transmission section30. Second clutch20is energized in a disconnection direction by a return spring (not illustrated) and enters a connected state when a control hydraulic pressure is supplied into a hydraulic-oil chamber of a piston (not illustrated) and the piston moves to bring input-side clutch plates21and output-side clutch plates22into pressure-contact with each other. When second clutch20enters the connected state, a drive force of the power source is transmitted to second input shaft32. Connection and disconnection of second clutch20are controlled by control section40. Transmission section30includes first input shaft31connected to an output side of first clutch10and second input shaft32connected to an output side of second clutch20. Transmission section30includes first counter shaft33and second counter shaft34which are arranged in parallel to first input shaft31and second input shaft32. Transmission section30further includes output shaft35provided coaxially with first input shaft31and second input shaft32. First input shaft31is pivotably supported by a transmission case (not illustrated) via a bearing (not illustrated). Second input-side gear52athat functions as a reverse gear is fixed to an intermediate portion in a front-rear direction of first input shaft31. First synchronizer hub61aof first synchromesh mechanism61(to be described later) is fixed on a rear stage of second input-side gear52aof first input shaft31. Between second input-side gear52aand first synchronizer hub61a, third input-side gear53ais provided to be relatively rotatable to first input shaft31. On a rear stage of first synchronizer hub61a, fourth input-side gear54ais provided relatively rotatable to first input shaft31. Second input shaft32is a hollow shaft into which first input shaft31is inserted and is pivotably supported so as to be relatively rotatable by first input shaft31via a bearing (not illustrated). First input-side gear51ais fixed to a rear end portion of second input shaft32. First input-side gear51ais provided on the front side of second input gear52a. First counter shaft33is pivotably supported by the transmission case (not illustrated) via a bearing (not illustrated). First counter gear51b, third synchronizer hub63aof third synchromesh mechanism63(to be described later), sixth counter gear56b, and seventh counter gear57bare fixed to first counter shaft33in this order from the front side. First counter gear51bis always in mesh with first input-side gear51a. First input-side gear51aand first counter gear51bconstitute first gear train51. Between first counter gear51band third synchromesh mechanism63, second counter gear52bis provided to be relatively rotatable to first counter shaft33. Second counter gear52bis always in mesh with second input-side gear52avia reverse idler gear52c. Second input-side gear52a, reverse idler gear52c, and second counter gear52bconstitute reverse gear train52. Second counter shaft34is provided between third synchromesh mechanism63and sixth counter gear56b. Second counter shaft34is a hollow shaft into which first counter shaft33is inserted and is pivotably supported so as to be relatively rotatable by first counter shaft33via a bearing (not illustrated). Third counter gear53bis fixed to a front-side portion of second counter shaft34. Third counter gear53bis always in mesh with third input-side gear53a. Third input-side gear53aand third counter gear53bconstitute second gear train53. Fourth counter gear54bis fixed on a rear stage of third counter gear53bof second counter shaft34. Fourth counter gear54bis always in mesh with fourth input-side gear54a. Fourth input-side gear54aand fourth counter gear54bconstitute third gear train54. Fifth counter gear55bis fixed to a rear end portion of second counter shaft34. Output shaft35is pivotably supported by the transmission case (not illustrated) via a bearing (not illustrated). Second synchronizer hub62aof second synchromesh mechanism62(to be described later) is fixed to a front end portion of output shaft35. Fourth synchronizer hub64aof fourth synchromesh mechanism64(to be described later) is fixed on a rear stage of second synchronizer hub62aof output shaft35. Between second synchronizer hub62aand fourth synchronizer hub64a, first output-side gear55ais provided to be relatively rotatable to output shaft35. First output-side gear55ais always in mesh with fifth counter gear55b. First output-side gear55aand fifth counter gear55bconstitute fourth gear train55. Between first output-side gear55aand fourth synchronizer hub64a, second output-side gear56ais provided to be relatively rotatable to output shaft35. Second output-side gear56ais always in mesh with sixth counter gear56b. Second output-side gear56aand sixth counter gear56bconstitute fifth gear train56. On a rear stage of fourth synchronizer hub64a, third output-side gear57ais provided to be relatively rotatable to output shaft35. Third output-side gear57ais always in mesh with seventh counter gear57b. Third output-side gear57aand seventh counter gear57bconstitute sixth gear train57. Transmission section30includes first synchromesh mechanism61, second synchromesh mechanism62, third synchromesh mechanism63, and fourth synchromesh mechanism64. First synchromesh mechanism61includes first synchronizer hub61a, first synchronizer sleeve61b, first dog gear61c, and second dog gear61d. As described above, first synchronizer hub61ais fixed to first input shaft31. First synchronizer sleeve61bis provided to surround first synchronizer hub61a. First synchronizer sleeve61bhas internal spline teeth engaged with external spline teeth of first synchronizer hub61a. First synchronizer sleeve61brotates integrally with first synchronizer hub61aand is movable with respect to first synchronizer hub61ain the front-rear direction. First dog gear61cis provided on a rear side of third input-side gear53a. Second dog gear61dis provided on a front side of fourth input-side gear54a. Synchronizer rings (not illustrated) are provided one each between first synchronizer hub61aand first dog gear61cand between first synchronizer hub61aand second dog gear61d. The internal spline teeth of first synchronizer sleeve61bare selectively engageable with either one of external spline teeth of first dog gear61cor external spline teeth of second dog gear61d. First synchromesh mechanism61is configured to synchronously couple first input shaft31selectively to third input-side gear53aor fourth input-side gear54ain response to first synchronizer sleeve61bbeing moved by a shift fork (not illustrated) and engaged with first dog gear61cor second dog gear61d. An actuation of first synchromesh mechanism61is controlled by control section40. Second synchromesh mechanism62includes second synchronizer hub62a, second synchronizer sleeve62b, third dog gear62c, and fourth dog gear62d. As described above, second synchronizer hub62ais fixed to output shaft35. Second synchronizer sleeve62bis provided to surround second synchronizer hub62a. Second synchronizer sleeve62bhas internal spline teeth engaged with external spline teeth of second synchronizer hub62a. Second synchronizer sleeve62brotates integrally with second synchronizer hub62aand is movable with respect to second synchronizer hub62ain the front-rear direction. Third dog gear62cis provided on a rear end portion of first input shaft31. Fourth dog gear62dis provided on a front side of first output-side gear55a. Synchronizer rings (not illustrated) are provided one each between second synchronizer hub62aand third dog gear62cand between second synchronizer hub62aand fourth dog gear62d. The internal spline teeth of second synchronizer sleeve62bare selectively engageable with either one of external spline teeth of third dog gear62cor external spline teeth of fourth dog gear62d. Second synchromesh mechanism62is configured to synchronously couple output shaft35selectively to first input shaft31or first input-side gear55ain response to second synchronizer sleeve62bbeing moved by a shift fork (not illustrated) and engaged with third dog gear62cor fourth dog gear62d. An actuation of second synchromesh mechanism62is controlled by control section40. Third synchromesh mechanism63includes third synchronizer hub63a, third synchronizer sleeve63b, fifth dog gear63c, and sixth dog gear63d. As described above, third synchronizer hub63ais fixed to first countershaft33. Third synchronizer sleeve63bis provided to surround third synchronizer hub63a. Third synchronizer sleeve63bhas internal spline teeth engaged with external spline teeth of third synchronizer hub63a. Third synchronizer sleeve63brotates integrally with third synchronizer hub63aand is movable with respect to third synchronizer hub63ain the front-rear direction. Fifth dog gear63cis provided on a rear side of second counter gear52b. Sixth dog gear63dis provided on a front end portion of second counter shaft34. Synchronizer rings (not illustrated) are provided one each between third synchronizer hub63aand fifth dog gear63cand between third synchronizer hub63aand sixth dog gear63d. The internal spline teeth of third synchronizer sleeve63bare selectively engageable with either one of external spline teeth of fifth dog gear63cor external spline teeth of sixth dog gear63d. Third synchromesh mechanism63is configured to synchronously couple first counter shaft33selectively to second counter gear52bor second counter shaft34in response to third synchronizer sleeve63bbeing moved by a shift fork (not illustrated) and engaged with fifth dog gear63cor sixth dog gear63d. An actuation of third synchromesh mechanism63is controlled by control section40. Fourth synchromesh mechanism64includes fourth synchronizer hub64a, fourth synchronizer sleeve64b, seventh dog gear64c, and eighth dog gear64d. As described above, fourth synchronizer hub64ais fixed to output shaft35. Fourth synchronizer sleeve64bis provided to surround fourth synchronizer hub64a. Fourth synchronizer sleeve64bhas internal spline teeth that engage with the external spline teeth of fourth synchronizer hub64a. Fourth synchronizer sleeve64brotates integrally with fourth synchronizer hub64aand is movable with respect to fourth synchronizer hub64ain the front-rear direction. Seventh dog gear64cis provided on a rear side of second output-side gear56a. Eighth dog gear64dis provided on a front side of third output-side gear57a. Synchronizer rings (not illustrated) are provided one each between fourth synchronizer hub64aand seventh dog gear64cand between fourth synchronizer hub64aand eighth dog gear64d. The internal spline teeth of fourth synchronizer sleeve64bare selectively engageable with either one of external spline teeth of seventh dog gear64cand external spline teeth of eighth dog gear64d. Fourth synchromesh mechanism64is configured to synchronously couple output shaft35selectively to second output-side gear56aor third output-side gear57ain response to fourth synchronizer sleeve64bbeing moved by a shift fork (not illustrated) and engaged with seventh dog gear64cor eighth dog gear64d. An actuation of fourth synchromesh mechanism64is controlled by control section40. Shift position detection section41detects a shift position selected by an operation of a driver on a shift lever (not illustrated). Shift position detection section41is connected to control section40. The configuration of automatic transmission1according to the present embodiment has been described above. Note that,FIG.1is a diagram for describing the configuration of automatic transmission1, and thus, the respective positions of first synchronizer sleeve61b, second synchronizer sleeve62b, third synchronizer sleeve63b, fourth synchronizer sleeve64b, which are configured to be movable, are not engaged with any of the dog gears. First input shaft31, second input shaft32, first counter shaft33, second counter shaft34, and output shaft35described above are examples of a rotary shaft of the present invention; in the following description, these shafts may be collectively referred to as the rotary shaft. Moreover, first input-side gear51a, second input-side gear52a, third input-side gear53a, fourth input-side gear54a, first counter gear51b, second counter gear52b, third counter gear53b, fourth counter gear54b, fifth counter gear55b, sixth counter gear56b, reverse idler gear52c, first output-side gear55a, second output-side gear56a, and third output-side gear57adescribed above are examples of a gear of the present invention; in the following description, these gears may be collectively referred to simply as the gear. Furthermore, first synchromesh mechanism61, second synchromesh mechanism62, third synchromesh mechanism63, and fourth synchromesh mechanism64described above are examples of a synchromesh mechanism of the present invention; in the following description, these mechanisms may be collectively referred to simply as the synchromesh mechanism. <Control by Control Section40> Hereinafter, a control by control section40will be described. Control section40controls actuation of first clutch10or second clutch20and actuation of the respective synchromesh mechanisms, and thereby controls a speed shifting operation in automatic transmission1. More specifically, for example, when actuating first synchromesh mechanism61, automatic transmission1moves first synchronizer sleeve61bby controlling a hydraulic actuator (not illustrated) that moves the shift fork (not illustrated), and engages first synchronizer sleeve61bwith first dog gear61cor second dog gear61d, and thereby causes synchromesh mechanism61to synchronously couple first input shaft31selectively to third input-side gear53aor fourth input-side gear54a. Control section40controls a synchromesh mechanism based on a shift position detected by shift position detection section41to couple the desired rotary shaft with the desired gear, and thereby switches automatic transmission1to the desired speed shifting stage. In particular, control section40actuates first synchromesh mechanism61and puts the other synchromesh mechanisms into a neutral state when shift position detection section41detects a change to a neutral position. Note that, the neutral state of a synchromesh mechanism means a state in which a coupling between the rotary shaft and the gear made by the synchromesh mechanism is released. That is, control section40does not release all of the couplings between the rotary shafts and the gears made by the synchromesh mechanism even when the neutral position is selected by the driver, but a point corresponding to synchromesh mechanism61is left coupled. Incidentally, application of this control is not limited to when detecting a change to the neutral position of the shift lever; the control may be applied when detecting a change to a shift lever position causing a situation in which the drive force of the drive source is not transmitted to output shaft35, for example, a parking position which is a shift lever position for parking in a common automatic transmission. Hereinafter, a description will be given of a control by control section40in a case where a neutral or parking position is detected by shift position detection section41in automatic transmission1according to the embodiment of the present invention. FIG.2is a flowchart for describing a control by control section40in a case where a neutral or parking position by shift position detection section41. In step S1, control section40receives, from shift position detection section41, a signal indicating that a neutral or parking position has been detected. Thus, control section40detects that the shift lever has been operated to the neutral or parking position by the driver. Incidentally, the driver operates the shift lever to the neutral or parking position in the following cases, for example. The first case is when the driver parks a vehicle equipped with automatic transmission1. In such a case, the driver generally operates the shift lever to the neutral or parking position and operates a parking brake to park. The second case is when it is assumed in advance that the vehicle cannot be started for a while, such as in signal waiting or congestion. In such a case, the driver may operate the shift lever to the neutral or parking position and set a foot brake, the parking brake, or the like into an actuated state. When it is detected that the shift lever has been operated in the neutral or parking position in step S1in this manner, control section40, in step S2, actuates first synchromesh mechanism61and puts second synchromesh mechanism62, third synchromesh mechanism63, and fourth synchromesh mechanism64into a neutral state. As described above, actuation of first synchromesh mechanism61is to move and thus engage first synchronizer sleeve61bwith first dog gear61cor second dog gear61d. Here, as an example, control section40engages first synchronizer sleeve61bwith second dog gear61d. That is, in step S2, control section40controls first synchromesh mechanism61to synchronously couple between first input shaft31and fourth input-side gear Ma. In step S3, control section40maintains an actuated state of first synchromesh mechanism61which has been actuated in step S2. As a result, first synchromesh mechanism61remains actuated, and first input shaft31and fourth input-side gear Ma remain in a synchronously coupled state, while the shift position is in the neutral or parking position. Such control allows first synchromesh mechanism61to remain in the actuated state at the neutral or parking position of the shift lever.FIG.3is a schematic view for describing an actuated state of first synchromesh mechanism61at the neutral or parking position of automatic transmission1according to the embodiment of the present invention. InFIG.3, first synchronizer sleeve61bis moved to be engaged with second dog gear61das described above. DESCRIPTION OF EFFECT In the following, a specific description will be given of an effect generated by the control by control section40described inFIG.2in automatic transmission1according to the embodiment of the present invention. When it is detected that the driver has operated the shift lever to a drive position in a vehicle parked or stopped with the shift lever in the neutral or parking position, control section40performs a starting control for automatic transmission1. The starting control is a control to establish a drive force transmission path of a predetermined speed shifting stage. Note that, in the following description, the speed shifting stage used when starting the vehicle will be described as a starting stage. It should be noted that a method for determining which starting stage control section40uses is not particularly limited in the present invention when the shift lever is operated by the driver from the neutral or parking position to the drive position. A starting stage may be determined by control section40by using, for example, a method in which the driver optionally selects by the shift lever or an input means (not illustrated), a method of determining one speed shifting stage for starting in advance, or a method in which weight of the vehicle is measured by a sensor (not illustrated) or the like, and the starting stage is determined at the time of starting based on the vehicle weight. First Example As the first example, a case where the first speed shifting stage is used as the starting stage will be described. FIG.4is a schematic view of a drive force transmission path at the first speed shifting stage. In the first speed shifting stage illustrated inFIG.4, first clutch10is connected, first input shaft31and fourth input-side gear54aare coupled by first synchromesh mechanism61, second counter shaft34and first counter shaft33are coupled by third synchromesh mechanism63, and second output-side gear56aand output shaft35are coupled by fourth synchromesh mechanism64. That is, the drive force transmission path of the first speed shifting stage is a path passing through in the following order; first clutch10→first input shaft31→first synchromesh mechanism61→third gear train54→second counter shaft34→third synchromesh mechanism63→first counter shaft33→fifth gear train56→fourth synchromesh mechanism64→output shaft35. InFIG.4, the drive force transmission path of the first speed shifting stage is illustrated by a thick solid line. That is, upon detecting that the shift lever has been operated from the neutral or parking position to the drive position, control section40actuates third synchromesh mechanism63and fourth synchromesh mechanism64while maintaining the actuated state of first synchromesh mechanism61. When first clutch10is connected in this condition, the drive force is transmitted to output shaft35, and thus the vehicle is started at the first speed shifting stage. As described above, in automatic transmission1according to the embodiment of the present invention, first synchromesh mechanism61remains in the actuated state while the shift lever is in the neutral or parking position; thus, in a case of starting at the first speed shifting stage, the number of synchromesh mechanisms to be actuated is two (third synchromesh mechanism63and fourth synchromesh mechanism64). On the other hand, in a case of starting at the first speed shifting stage from a state in which the shift lever is in the neutral or parking position while none of the synchromesh mechanisms is actuated, the number of synchromesh mechanisms to be actuated is three (first synchromesh mechanism61, third synchromesh mechanism63, and fourth synchromesh mechanism64). Hence, in automatic transmission1according to the embodiment of the present invention, as compared with the case of starting from a state in which no synchromesh mechanism is actuated at the neutral or parking position of the shift lever, the time required until starting at the first speed shifting stage is possible from the operation of the shift lever can be shortened by the amount of actuation time of first synchromesh mechanism61. Incidentally, here, it is assumed that simultaneously actuating a plurality of synchromesh mechanisms is difficult because rotational frequencies of the rotary shaft and the gear need to be matched. From the above, it is possible to start the vehicle immediately without causing the driver to feel discomfort even when, for example, the driver performs a start operation (stepping on an accelerator pedal) immediately after the operation of the shift lever. Second Example As the second example, a case where the third speed shifting stage is used as the starting stage will be described. FIG.5is a schematic view of a drive force transmission path at the third speed shifting stage. In the third speed shifting stage illustrated inFIG.5, first clutch10is connected, first input shaft31and fourth input-side gear54aare coupled by first synchromesh mechanism61, and first output-side gear55aand output shaft35are coupled by second synchromesh mechanism62. That is, the drive force transmission path of the third speed shifting stage is a path passing through in the following order; first clutch10→first input shaft31→first synchromesh mechanism61→third gear train54→second counter shaft34→fourth gear train55→second synchromesh mechanism62→output shaft35. InFIG.5, the drive force transmission path of the third speed shifting stage is illustrated by a thick solid line. That is, upon detecting that the shift lever has been operated from the neutral or parking position to the drive position, control section40actuates second synchromesh mechanism62while maintaining the actuated state of first synchromesh mechanism61. When first clutch10is connected in this condition, the drive force is transmitted to output shaft35, and thus the vehicle is started. As described above, in automatic transmission1according to the embodiment of the present invention, first synchromesh mechanism61remains in the actuated state while the shift lever is in the neutral or parking position; thus, in a case of starting at the third speed shifting stage, the number of synchromesh mechanisms to be actuated is only one (second synchromesh mechanism62). On the other hand, in a case of starting at the third speed shifting stage from a state in which the shift lever is in the neutral or parking position and none of the synchromesh mechanisms is actuated, the number of synchromesh mechanisms to be actuated is two (first synchromesh mechanism61and second synchromesh mechanism62). Hence, similar to the above first example, in automatic transmission1according to the embodiment of the present invention, as compared with the case of starting from the state in which no synchromesh mechanism is actuated at the neutral or parking position of the shift lever, the time required until starting is possible from the operation of the shift lever can be shortened by the amount of actuation time of first synchromesh mechanism61. Thus, it is possible to start the vehicle immediately without causing the driver to feel discomfort even when, for example, the driver performs a start operation (stepping on an accelerator pedal) immediately after the operation of the shift lever. Third Example As the third example, a case where the second speed shifting stage is used as the starting stage will be described.FIG.6is a schematic view of a drive force transmission path at the second speed shifting stage. In the second speed shifting stage illustrated inFIG.6, second clutch20is connected, and second output-side gear56aand output shaft35are coupled by fourth synchromesh mechanism64. That is, the drive force transmission path of the second speed shifting stage is a path passing through in the following order; second clutch20→second input shaft32→first gear train51→first counter shaft33→fifth gear train56→fourth synchromesh mechanism64→output shaft35. InFIG.6, the drive force transmission path of the second speed shifting stage is illustrated by a thick solid line. That is, upon detecting that the shift lever has been operated from the neutral or parking position to the drive position, control section40actuates fourth synchromesh mechanism64while maintaining the actuated state of first synchromesh mechanism61. When second clutch20is connected in this condition, the drive force is transmitted to output shaft35, and thus the vehicle is started. In the manner described above, in automatic transmission1according to the embodiment of the present invention, the actuated state of first synchromesh mechanism61is maintained even after starting at the second speed shifting stage. However, as described above, when starting at the second speed shifting stage, first synchromesh mechanism61is not included in the drive force transmission path. Hence, unlike the first and third examples, even in automatic transmission1according to the embodiment of the present invention, the time required until starting is possible from the operation of the shift lever cannot be shortened. However, when it becomes necessary for the vehicle to immediately upshift to the third speed shifting stage in response to, for example, the driver stepping on the accelerator pedal greatly after the vehicle is started at the second speed shifting stage, the time required until the speed shifting from the second speed shifting stage to the third speed shifting stage is possible can be shortened in automatic transmission1according to the embodiment of the present invention. The reasons are as follows. Generally, in a dual clutch type transmission, when speed shifting to a certain speed shifting stage, a synchromesh mechanism not included in the drive force transmission path of the present speed shifting stage while included in a path of the next stage is actuated in advance for the purpose of performing the speed shifting to the next stage promptly. Such an operation is generally referred to as a preliminary shifting (hereinafter, may be referred to as a “pre-shift”) or the like. Although a description has been omitted, for example, at the time of starting at the third speed shifting stage in the second example described above, a pre-shift operation to the fourth speed stage is performed after the drive force transmission path of the third speed shifting stage is established. The pre-shift operation to the fourth speed stage is an operation specifically for coupling between first counter shaft33and second counter shaft34by third synchromesh mechanism63. Automatic transmission1after the pre-shift is illustrated inFIG.5. Similarly, when starting at the second speed shifting stage, the pre-shift to the third speed shifting stage is performed after the drive force transmission path of the second stage is established. Comparing automatic transmission1of the third speed shifting stage illustrated inFIG.5with automatic transmission1of the second speed shifting stage illustrated inFIG.6, the number of synchromesh mechanisms to be actuated at the time of pre-shift is two (synchromesh mechanism not included in the drive force transmission path of the second speed shifting stage while included in the drive force transmission path of the third speed shifting stage); i.e., first synchromesh mechanism61and second synchromesh mechanism62. As described above, in automatic transmission1according to the embodiment of the present invention, the actuated state of first synchromesh mechanism61is maintained even after starting at the second speed shifting stage. Hence, in the pre-shift to the third speed shifting stage after the drive force transmission path of the second speed shifting stage is established, a synchromesh mechanism to be actuated is second synchromesh mechanism62alone. Thus, in automatic transmission1according to the embodiment of the present invention, the time required until the speed shifting to the third speed shifting stage is possible after starting at the second speed shifting stage can be shortened by the amount of actuation time of first synchromesh mechanism61, compared with the case of starting from the state in which no synchromesh mechanism is actuated at the neutral or parking position of the shift lever. As a result, in automatic transmission1according to the embodiment of the present invention, even when it becomes necessary to upshift to the third speed shifting stage immediately after starting at the second speed shifting stage, it is possible to immediately upshift without causing the driver to feel discomfort. As above, a description has been given in detail of the effect of performing the control for actuating first synchromesh mechanism61such that first synchronizer sleeve61bis engaged with second dog gear61dwhen the shift lever is in the neutral or parking position neutral or parking position in automatic transmission1according to the embodiment of the present invention. Incidentally, in the above description, the effect is described as obtainable when starting at the first speed shifting stage, the second speed shifting stage, or the third speed shifting stage, but a similar effect can be obtained when starting at another speed shifting stage. The similar effect is, for example, an effect in which the time required from the operation of the shift lever to the start can be shortened in a case where first synchromesh mechanism61is included in the drive force transmission path of the starting stage. Moreover, the similar effect is, for example, an effect in which the time required until the speed shifting to the next stage is possible after starting at the starting stage can be shortened in a case where first synchromesh mechanism61is not included in the drive force transmission path of the starting stage while first synchromesh mechanism61is included in the drive force transmission path of the next stage. In addition, the above description has assumed that first synchromesh mechanism61is actuated so that first synchronizer sleeve61bengages with second dog gear61dwhen the shift lever is in the neutral or parking position, but the present invention is not limited to this. That is, control section40may actuate another synchromesh mechanism when the shift lever is in the neutral or parking position. An example of the other synchromesh mechanism includes, for example, third synchromesh mechanism63. The reasons are as follows. For the viewpoint of safety, the drive force of the drive source must not be transmitted to output shaft35when the shift lever is in the neutral or parking position, even in a case where first clutch10or second clutch20is connected for any reason. From this viewpoint, a synchromesh mechanism that may be actuated by control section40when the shift lever is in the neutral or parking position is a synchromesh mechanism other than the synchromesh mechanisms (second synchromesh mechanism62and/or fourth synchromesh mechanism64) that synchronously couples between output shaft35and the output-side gear (first output-side gear55a, second output-side gear56a, and/or third output-side gear57a). That is, in automatic transmission1configured as illustrated in, for example,FIG.1, first synchromesh mechanism61and third synchromesh mechanism63are examples of a synchromesh mechanism to be actuated by control section40when the shift lever is in the neutral or parking position. Note that, second synchromesh mechanism62or fourth synchromesh mechanism64is an example of an output-side synchromesh mechanism of the present invention. In a case where control section40actuates third synchromesh mechanism63such that third synchronizer sleeve63bengages with sixth dog gear63d, and maintains this state while the shift lever is in the neutral or parking position, the time required from the operation of the shift lever to the start can be shortened, upon selecting the first speed shifting stage as the starting stage. Note that, when the shift lever is in the neutral or parking position, a synchromesh mechanism to be actuated by control section40may not be one and may be a plurality. That is, in the above-mentioned examples, both first synchromesh mechanism61and third synchromesh mechanism63may be actuated. In such a case, when the first speed shifting stage is selected as the starting stage, the time required from the operation of the shift lever to the start can be further shortened. The above description has assumed that second synchromesh mechanism62cannot be actuated by control section40when the shift lever is in the neutral or parking position because second synchromesh mechanism62may synchronously couple between output shaft35and first output-side gear55a. However, second synchromesh mechanism62may be actuated, provided that first synchromesh mechanism61and third synchromesh mechanism are not actuated when the shift lever is in the neutral or parking position. Specifically, when the shift lever is in the neutral or parking position, control section40may actuate second synchromesh mechanism62such that second synchronizer sleeve62bengages with fourth dog gear62d. First input shaft31and second input shaft32are not coupled to output shaft35unless first synchromesh mechanism61and the third synchromesh mechanism are actuated, so that the drive force is not transmitted to output shaft35even when first clutch10or second clutch20is connected. In such a case, at the time of starting, for example, at the third speed shifting stage, the time required from the operation of the shift lever to the start can be shortened. <Operational Effect> Automatic transmission1according to an embodiment of the present invention includes: a plurality of rotary shafts including output shaft35that outputs a drive force; a plurality of gears including an output-side gear (first output-side gear55a, second output-side gear56a, and/or third output-side gear57a) provided on output shaft35; a plurality of synchromesh mechanisms including an output-side synchromesh mechanism (second synchromesh mechanism62and/or fourth synchromesh mechanism64) that couples between output shaft35and an output-side gear; shift position detection section41that detects which of a plurality of shift positions including a neutral position and a parking position is selected; and control section40that actuates at least one of the plurality of synchromesh mechanisms (first synchromesh mechanism61and/or third synchromesh mechanism63) other than the output-side synchromesh mechanism to couple between at least one of the plurality of rotary shafts other than the output shaft and at least one of the plurality of gears other than the output-side gear, in a case where the neutral position or the parking position is detected by shift position detection section41. With such a configuration, when the synchromesh mechanism included in the drive force transmission path of the starting stage is actuated, the time required from the operation of the shift lever to the start can be shortened. On the other hand, when the synchromesh mechanism not included in the drive force transmission path of the starting stage is actuated, the time required until the speed shifting to the next stage is possible after starting at the starting stage can be shortened. <Variation> Hereinabove, various embodiments have been described with reference to the drawings, the present disclosure is not limited to such examples. It will be apparent to those skilled in the art may arrive at various modifications or variations at within the scope of the claims, and it is naturally understood that they are also within the technical scope of the present disclosure. In addition, the components in the above embodiments may be optionally combined without departing from the spirit and scope of the disclosure. In the above-mentioned embodiments, a description has been given by adopting a dual clutch type transmission as an example of automatic transmission1, but the present invention is not limited to this. The present invention can be applied to an automatic transmission equipped with a synchromesh mechanism (synchronization mechanism). In the above-mentioned embodiment, as illustrated in, for example,FIG.1, a description has been given of automatic transmission1including two clutches, seven gear trains, two input shafts, two counter shafts and one output shaft, but the automatic transmission of the present invention is not limited to such a configuration. The number of clutches, gear trains, and rotary shafts may be changed as appropriate. This application is based upon Japanese Patent Application No. 2019-057110, filed on Mar. 25, 2019, the entire contents of which are incorporated herein by reference. INDUSTRIAL APPLICABILITY The present disclosure can provide an automatic transmission that brings suitable drivability. REFERENCE SIGNS LIST 1Automatic transmission2Drive source output shaft10First clutch11Input-side clutch plate12Output-side clutch plate20Second clutch21Input-side clutch plate22Output-side clutch plate30Transmission section31First input shaft32Second input shaft33First counter shaft34Second counter shaft35Output shaft40Control section41Shift position detection section51First gear train51aFirst input-side gear51bFirst counter gear52Reverse gear train52aSecond input-side gear52bSecond counter gear52cReverse idler gear53Second gear train53aThird input-side gear53bThird counter gear54Third gear train54aFourth input-side gear54bFourth counter gear55Fourth gear train55aFirst output-side gear55bFifth counter gear56Fifth gear train56aSecond output-side gear56bSixth counter gear57Sixth gear train57aThird output-side gear57bSeventh counter gear61First synchromesh mechanism61aFirst synchronizer hub61bFirst synchronizer sleeve61cFirst dog gear61dSecond dog gear62Second synchromesh mechanism62aSecond synchronizer hub62bSecond synchronizer sleeve62cThird dog gear62dFourth dog gear63Third synchromesh mechanism63aThird synchronizer hub63bThird synchronizer sleeve63cFifth dog gear63dSixth dog gear64Fourth synchromesh mechanism64aFourth synchronizer hub64bFourth synchronizer sleeve64cSeventh dog gear64dEighth dog gear | 42,934 |
11859713 | DETAILED DESCRIPTION OF THE INVENTION The method according to the invention serves for hysteresis compensation in an actuator3and a selector fork1that guides a sliding sleeve2(FIG.1) and is adjustable via the actuator3. The selector fork1can be moved by means of the actuator3into two different shift positions, namely a first shift position xDecoup and a second shift position xCoup. The first shift position xDecoup of the selector fork1corresponds to a neutral position and the second shift position xCoup corresponds to a gear position. The actuator3can, to this end, be actuated into a first position phiDecoup, resulting in the selector fork1being moved into the first shift position xDecoup. Furthermore, the actuator3can be actuated into a second position phiCoup, resulting in the selector fork1being moved into the second shift position xCoup. If the selector fork1is in a shift position xCoup, xDecoup, it is mechanically released via mechanical releasing of the actuator3. The actuator3is subject to open-loop or closed-loop control via a control unit (not illustrated in detail) which contains a state machine4(FIG.2). The particular state of the system, i.e. the particular shift position xCoup, xDecoup of the selector fork1, is mapped by the state machine4, which determines a correction of the position setting for the actuator3on account of its current and future state. The starting point is a non-linear system in which the actuator3is intended to exactly position the selector fork1although it exhibits mechanical backlash phiBL (FIG.3). In the graph inFIG.4, a shift position of the selector fork xDgClu (y axis) is plotted versus a position of the actuator phiAtr (x axis). The selector fork1is moved into the first shift position xDecoup via the actuation of the actuator3into the first position phiDecoup. The selector fork1is moved into the second shift position xCoup via the actuation of the actuator3into the second position phiCoup. The selector fork1has to be positioned exactly in the first shift position xDecoup, i.e. the neutral position, and in the second shift position xCoup, namely the gear position. Then, the actuator3is mechanically released, i.e. moved into the middle of the mechanical backlash phiBL. The particular position of the actuator3is described by the value phiAtr (FIG.4; x axis). The target position phiAtrReq for the actuator can thus be formulated as follows (FIG.3), phiAtrReq=phiTarget+signBL*phiBL/2 wherein phiTarget=phiDeCoup or phiCoup, as the first position phiDecoup or the second position phiCoup of the actuator3, depending on the shifting request. A sign signBL is generated by the state machine4, and it can adopt the values +1, 0 and −1 (FIG.3). To describe the sequence of the method by way of example, the starting point is an uncoupled state, with the actuator3released (FIG.2, “ForceFree Decoupled”). If a shifting request (FIG.2,FIG.3, step C1) is detected, the state machine4changes to the “Coupling” status and thus sets the desired position, namely phiTarget=phiCoup, and the associated sign, namely signBL=+1, (FIG.3). Once the desired position of the actuator3has been set by closed-loop control, the actuator3and thus the selector fork1can start to be released (FIG.2,FIG.3, step C2) until phiTarget=phiCoup with the sign signBL=0 (FIG.2, “ForceFree Coupled”). If a shifting request in the opening direction (FIG.2,FIG.3, step C3) is now detected, the state machine4changes to the “Decoupling” status and sets the desired position, namely phiTarget=phiDecoup, and the associated sign, namely signBL=−1. Once the target position has been reached, the actuator3and thus the selector fork1is released, namely until phiTarget=phiDecoup with the sign signBL=0 (FIG.2, “ForceFree Decoupled”). It is possible to abort the shifting operation (FIG.2,FIG.3, steps C5and C6) at any time. The backlash is always correctly passed through. If further system states are added, only the target position and the associated sing need to be added to the table. In this way, the hysteresis curve (FIG.2) is always correctly passed through and the exact position of the selector fork1can be determined at any time. | 4,183 |
11859714 | DETAILED DESCRIPTION OF EMBODIMENTS Hereafter, an example is explained of when a power transmission device of the present embodiment is a belt-type continuously variable transmission1for a vehicle. In the explanation hereafter, as terminology for explaining the positional relationship of the constituent elements, when “orthogonal” and “parallel” are used, these do not mean “orthogonal” and “parallel” in the strictest meaning with respect to an axis (line) or surface used as a reference. Cases of being orthogonal with a slight tilt or being parallel with a slight tilt with respect to an axis (line) or surface used as a reference are not excluded. These cases are also included in the terms “orthogonal” and “parallel.” FIG.1is a drawing that schematically shows the arrangement of each constituent element of the continuously variable transmission1inside a transmission case2. InFIG.1, a variator20, a gear train21, a final gear22, and a differential device23are shown in simplified form with virtual lines. FIG.2is a drawing for explaining the continuously variable transmission1, and is a perspective view of the continuously variable transmission1when seen from the A-A direction inFIG.1. In this specification and in the drawings, the vehicle longitudinal direction (first direction) and the vehicle lateral direction (second direction) mean the directions seen by a driver riding in the vehicle. As shown inFIG.1, the variator20as the power transmission mechanism of the continuously variable transmission1has a primary pulley201, a secondary pulley202, and a power transmission member203. As the power transmission member203, it is possible, for example, to use a belt configured with plate-shaped elements (not illustrated) having slits at both sides layered and arranged in a ring shape, with each element inserted in the slits and bound into an annular ring. The primary pulley201has the rotational drive force of a drive source (not illustrated) inputted and rotates around a rotation axis X1(axis center of the primary pulley201). The secondary pulley202is provided to be able to rotate around a rotation axis X2(axis center of the secondary pulley202) that is parallel to the rotation axis X1. These rotation axes X1, X2are parallel to the vehicle lateral direction (left-right direction inFIG.2). The power transmission member203is wound around the outer periphery of the primary pulley201and the outer periphery of the secondary pulley202. The rotational drive force inputted to the primary pulley201is transmitted to the secondary pulley202via the power transmission member203. In the variator20, when the rotational drive force is transmitted from the primary pulley201to the secondary pulley202, the winding radius of the power transmission member203in the primary pulley201and the winding radius of the power transmission member203in the secondary pulley202are changed. As a result, the rotational drive force inputted to the primary pulley201is shifted at a desired gear ratio, and is transmitted to the secondary pulley202. The gear ratio is determined according to the winding radius of the power transmission member203in the primary pulley201and the secondary pulley202. The winding radius is determined by a transmission controller9based on the travelling state, etc., of a vehicle in which the continuously variable transmission1is mounted. The rotational drive force transmitted to the secondary pulley202is ultimately transmitted to drive wheels (not illustrated) via a gear train21, a final gear22, and a differential device23. An outer peripheral wall25of the transmission case2has a first chamber S1that houses the variator20, the gear train21, the final gear22, and the differential device23formed inside the transmission case2. As shown inFIG.2, the transmission case2has a side cover3attached from one side (right side in the drawing) sandwiching the transmission case2. Furthermore, a converter housing4is attached from the other side (left side in the drawing). The continuously variable transmission1is attached to the drive source (not illustrated) in a state with the overlapping direction of the transmission case2, the side cover3, and the converter housing4aligned in the vehicle lateral direction (vehicle width direction). As shown inFIG.1, the transmission case2has a peripheral wall part26surrounding a lower opening250of the transmission case2. An oil pan27is attached from the lower side in the vertical line VL direction to the peripheral wall part26of the transmission case2. The oil pan27blocks the lower opening250of the transmission case2in a state fixed to the peripheral wall part26. The oil pan27forms a third chamber S3that becomes a storage space for hydraulic oil OL (oil) at the bottom of the transmission case2. A control valve unit5is arranged inside the third chamber S3. The control valve unit5is configured with an upper valve51and a lower valve52overlapping. A separator plate (not illustrated) is provided between the upper valve51and the lower valve52. The upper valve51and the lower valve52each have an oil passage (not illustrated) formed inside, and together with the separator plate configure a hydraulic control circuit. The control valve unit5is housed in the third chamber S3in a state with the overlapping direction of the upper valve51and the lower valve52aligned in the vertical line VL direction. In the present embodiment, in the interior space of the transmission case2, the upper side of the vertical line VL direction is the first chamber S1, and the lower side is the third chamber S3. The capacity of the first chamber S1is set to be sufficiently larger than the capacity of the third chamber S3. As shown inFIG.1, the region at the front side of the vehicle in the outer peripheral wall25(left side in the drawing) is a partition wall part251extending in the vertical line VL direction. The partition wall part251has an oil cooler OC and an electric oil pump6mounted. In the partition wall part251, the electric oil pump6is provided further to the oil pan27side (lower side in the vertical line VL direction) than the oil cooler OC. The partition wall part251has a first wall252on which the oil cooler OC is mounted, and a second wall253on which the electric oil pump6is mounted. The second wall253is positioned below the first wall252in the vertical line VL direction. As shown inFIG.1, a bulging region261that bulges to the vehicle front side is provided on the peripheral wall part26surrounding the lower opening250of the transmission case2. The bulging region261bulges to the vehicle front side more than the partition wall part251. A wall part28that surrounds the electric oil pump6is provided in the region between the bulging region261and the oil cooler OC in the vertical line VL direction. In the transmission case2, the region surrounded by the wall part28is a second chamber S2that becomes the housing space for the electric oil pump6. A lid part7is attached from the vehicle front side (left side inFIG.1) to the wall part28. FIG.3is a main part enlarged view of the continuously variable transmission1and shows the lid part7separated from the transmission case2, and is also an exploded perspective view showing the lid part7disassembled. FIG.4is a drawing for explaining the lid part7, and is a schematic diagram of cross section B-B inFIG.1. For convenience of explanation, bolts are omitted inFIGS.3and4. FIG.5is a schematic diagram for explaining the arrangement of the wire harness, and is a drawing seen from the vehicle front side around the electric oil pump6and the control valve unit5. To make the positional relationship easier to understand, the transmission case2is shown by virtual lines. FIG.6is a schematic diagram for explaining the arrangement of the wire harness, and is a drawing seen from the A-A arrow direction inFIG.5. InFIG.6, for convenience of explanation, a connector part91of the transmission controller9is shown by virtual lines, and the outline of the electric oil pump6arranged at the paper surface back side of a side plate61is shown by dashed lines. FIG.7is a schematic diagram for explaining the arrangement of the wire harness, and is a perspective view seen from the A-A arrow direction inFIG.6. InFIG.7, to make the positional relationship easier to understand, the connector part91of the transmission controller9is shown by virtual lines. As shown inFIG.3, the wall part28has an upper wall part281extending from the partition wall part251to the vehicle front side. The wall part28also has a lower wall part282provided integrally with the bulging region261, and side wall parts283,284that connect the end parts of the upper wall part281and the lower wall part282to each other, and that extend in the vertical line VL direction. The wall part28is formed in a cylindrical shape from the upper wall part281, the lower wall part282, and the side wall parts283,284. The second chamber S2is a space surrounded by the upper wall part281, the lower wall part282, and the side wall parts283,284. The upper wall part281configuring a portion of the wall part28is provided in a range covering the upper side of the electric oil pump6. The upper wall part281extends to the vehicle front side from the boundary of the abovementioned first wall252and the second wall253(seeFIG.1). As shown inFIG.2, a bulging wall8described later is adjacent to one side (right side in the drawing) of the wall part28in the vehicle lateral direction. The bulging wall8is positioned at the side cover3side of the wall part28in the vehicle lateral direction. As shown inFIG.1, a communication hole282ais provided in the region positioned below the oil pan27in the wall part28. The communication hole282ais formed to straddle the lower wall part282and the second wall253. The communication hole282acommunicates between the second chamber S2surrounded by the wall part28, and the third chamber S3surrounded by the oil pan27. Inside the second chamber S2, the electric oil pump6is fixed straddling the second wall253and the upper valve51of the control valve unit5. In addition to the electric oil pump6, a connector terminal C1and a power supply connector C5are housed inside the second chamber S2(seeFIG.5). The connector terminal C1is a connection terminal for connecting wiring extending from the control valve unit5side to the transmission controller9described later. The power supply connector C5is a connection terminal for supplying power supplied via a power supply line12described later to the electric oil pump6. In the present embodiment, the connector terminal C1and the power supply connector C5are each attached to a component (side plate61) on the electric oil pump6. The connector terminal C1and the power supply connector C5are positioned at a prescribed position within the second chamber S2. As shown inFIG.1, the wall part28surrounding the second chamber S2opens to outside of the transmission case2. The opening of the wall part28is blocked by the lid part7fixed to a tip surface28aof the vehicle front side (left side in the drawing) of the wall part28. A seal ring Ca that surrounds the wall part28across the entire periphery is fitted on the tip surface28aof the vehicle front side of the wall part28. The lid part7is fixed to the wall part28by a bolt (not illustrated), etc., in a state with the seal ring Ca interposed between it and the wall part28. [Lid Part] As shown inFIG.3, the lid part7is configured from a first wall part71, a second wall part72, and a third wall part73. The lid part7is formed with the first wall part71, the second wall part72, and the third wall part73overlapped in order in the vehicle longitudinal direction. As shown inFIG.4, the first wall part71has a bottom wall711formed at a size that blocks the opening of the wall part28, and a peripheral wall part712that surrounds the outer peripheral edge of the bottom wall711across the entire periphery. A flange part713that surrounds the outer periphery of the peripheral wall part712across the entire periphery is provided on the end part of the wall part28side (right side in the drawing) on the peripheral wall part712. The flange part713is joined to the wall part28from the opening direction of the second chamber S2. The bottom wall711is provided at a position separated from the flange part713side (right side in the drawing) from one end712aof the peripheral wall part712. The first wall part71has a recess714surrounded by the bottom wall711and the peripheral wall part712on the side opposite to the second chamber S2in the vehicle longitudinal direction. The recess714opens at the side opposite to the second chamber S2in the vehicle longitudinal direction. The opening of the recess714is blocked by the second wall part72. A space R71is formed between the recess714and the second wall part72. The second wall part72is configured from a bottom wall721formed at a size that blocks the opening of the recess714, and a peripheral wall part722surrounding the bottom wall721across the entire periphery. The peripheral wall part722extends in the direction separating from the first wall part71(leftward in the drawing) in the vehicle longitudinal direction. The second wall part72has a recess724surrounded by the bottom wall721and the peripheral wall part722. The recess724opens at the side opposite to the first wall part71in the vehicle longitudinal direction. The opening of the recess724is sealed by the third wall part73. A space R72is formed between the recess724and the third wall part73. The third wall part73is a plate-shaped member formed at a size that blocks the opening of the recess724, and the transmission controller9is attached to a surface73afacing the second wall part72in the vehicle longitudinal direction. The transmission controller9overlaps in the vehicle longitudinal direction with respect to the abovementioned first chamber S1and the electric oil pump6(seeFIG.1). As shown inFIG.4, the transmission controller9comprises a plate-shaped substrate90, and the connector part91that is electrically connected with wiring (not illustrated) on the substrate90. The substrate90is attached to the third wall part73in a state with the thickness direction of the substrate90aligned with the vehicle longitudinal direction. In this state, the substrate90is arranged inside the space R72in the lid part7. The connector part91is fixed to the surface on the opposite side to the third wall part73in the thickness direction of the substrate90. The connector part91extends to the second chamber S2side in the vehicle longitudinal direction. Seen from the opening side of the second chamber S2(left side in the drawing), on the bottom wall721of the second wall part72and the bottom wall711of the first wall part71, through holes721a,711aare provided at a position overlapping the connector part91. The through holes721a,711aare formed in a shape that matches the outline of the connector part91. The connector part91penetrates the bottom wall721of the second wall part72and the bottom wall711of the first wall part71at the second chamber S2side (right side in the drawing). A tip91aof the connector part91is exposed inside the second chamber S2. Inside the second chamber S2, the abovementioned connector terminal C1is internally fitted on the tip91aside of the connector part91of the transmission controller9. As a result, the connector part91and the connector terminal C1are electrically connected. Here, sealing materials Cb, Cb are provided on the inner periphery of the through holes711a,721aprovided in the bottom walls711,721, and the sealing materials Cb, Cb are press welded on the outer periphery of the connector part91. For that reason, the hydraulic oil OL inside the second chamber S2is made to pass through the gap between the inner periphery of the through holes711a,721a, and the outer periphery of the connector part91, and to not infiltrate inside the space R72that houses the transmission controller9. Furthermore, the entry of contaminants inside the second chamber S2from outside the transmission case2by passing through the gap between the inner periphery of the through holes711a,721aand the outer periphery of the connector part91is suppressed. With the lid part7, the space R71(air layer) is formed between the second chamber S2and the transmission controller9(substrate90) (seeFIG.4). When driving the continuously variable transmission1, the oil (hydraulic oil OL) used for operating and lubricating the variator20goes to high temperature. For that reason, inside the second chamber S2that houses the electric oil pump6becomes high temperature by the heat generated by the electric oil pump6and the heat of the hydraulic oil OL. With the present embodiment, the space R71is formed between the space R72that houses the transmission controller9and the second chamber S2. For that reason, the air layer inside the space R71functions as a heat insulating layer, suppressing the transmission of heat on the second chamber S2side to the substrate90of the transmission controller9. It is also possible to have a configuration in which a heat insulating material is provided in the space R71, to function even better as a heat insulating layer. Following, the positional relationship of each connector in the transmission case2is explained. As shown inFIG.5, the wall part28forms an approximately rectangular ring shape when seen from the vehicle front side. The upper wall part281and the lower wall part282in the wall part28extend aligned with the vehicle lateral direction in a state with a gap open in the vertical line VL direction. The side wall parts283,284in the wall part28each connect the end parts of the upper wall part281and the lower wall part282to each other at one side and the other side in the vehicle lateral direction, and extend aligned with the vertical line VL. The electric oil pump6housed inside the second chamber S2on the inside of the wall part28is provided with the lengthwise direction of the electric oil pump6facing aligned with the vehicle lateral direction (vehicle width direction). The electric oil pump6has the side plate61on the end part of the side wall part283side (right side inFIG.5). The power supply connector C5and the connector terminal C1are attached to a surface61afacing the side wall part283in the side plate61. Specifically, the power supply connector C5and the connector terminal C1are attached to the side plate61which is a component of the electric oil pump6side. In this state, the connector terminal C1is arranged further to the vehicle front side (paper surface front side inFIG.5) than the power supply connector C5in the vehicle longitudinal direction. The power supply connector C5is fixed by a bolt B to the electric oil pump6(side plate61) (seeFIG.7). The second chamber S2is partitioned into a first space S21and a second space S22with the side plate61of the electric oil pump6as a boundary. Using the side plate61as a reference, the electric oil pump6side in the vehicle lateral direction is the first space S21, and the connector terminal C1side is the second space S22. In the transmission case2, the bulging wall8is provided adjacent to the side wall part283. In the vehicle lateral direction, the bulging wall8bulges in the direction separating from the side wall part283(rightward inFIG.5). The bulging wall8is provided straddling the side wall part283and the bulging region261of the abovementioned peripheral wall part26(seeFIG.3). The bulging wall8is formed integrally with the side wall part283. As shown inFIG.5, the bulging wall8has an interior space S4. The interior space S4of the bulging wall8communicates between the second space S22of the second chamber S2and the abovementioned third chamber S3. A top surface8aof the bulging wall8is a flat surface orthogonal to the vertical line VL. An external connection connector K is provided on the bulging wall8. The external connection connector K penetrates the top surface8aof the bulging wall8from the lower side to the upper side in the vertical line VL direction. In this state, the external connection connector K has one side in the vertical line VL direction housed in the interior space S4, and the other side exposed to the exterior space of the transmission case2. The external connection connector K comprises a first connector K1and a second connector K2. The first connector K1is electrically connected with various electrical components (not illustrated) arranged outside the transmission case2. The second connector K2is electrically connected with a power supply (not illustrated) that supplies power to the electric oil pump6. The external connection connector K comprises terminal parts C3, C4at one side in the vertical line VL direction. The terminal parts C3, C4are respectively connected to the first connector K1and the second connector K2, and are housed inside the interior space S4. As shown inFIG.6, the terminal part C3and the terminal part C4are arranged at positions that overlap with the electric oil pump6in the paper surface front-back direction. InFIG.6, the outline of the electric oil pump6positioned at the paper surface back side is shown by dashed lines. As shown inFIG.5, with the present embodiment, the terminal part C4is arranged at a position closer to the electric oil pump6in the vehicle lateral direction than the terminal part C3. [Wire Harness] As shown inFIG.5toFIG.7, the electric oil pump6, the transmission controller9, the control valve unit5, and the external connection connector K are electrically connected via a plurality of wire harnesses (electric wires). This plurality of wire harnesses are arranged so as to pass through the abovementioned second chamber S2, third chamber S3, and interior space S4interior. As shown inFIG.5, the abovementioned control valve unit5cuts across the lower side of the electric oil pump6and the connector terminal C1in the vehicle lateral direction, and extends to the lower side of the external connection connector K. A range switching device W projects to the left side surface53of the control valve unit5. Examples of the range switching device W include known inhibitor switches, etc. As shown inFIG.6, the control valve unit5cuts across the electric oil pump6, the connector terminal C1, and the external connection connector K lower side in the vehicle longitudinal direction, and extends to the lower side of the abovementioned variator20(seeFIG.1). The control valve unit5has a first connector part52band a second connector part52con the bottom surface52aof the lower valve52in the vertical line VL direction. The first connector part52bis arranged further to the vehicle front side than the second connector part52cin the bottom surface52aof the lower valve52. The second connector part52cis arranged further to the vehicle rear side than the first connector part52bin the bottom surface52aof the lower valve52. The range switching device W is arranged between the first connector part52band the second connector part52cin the vehicle longitudinal direction. At the upper side of the control valve unit5in the vertical line VL direction, the abovementioned connector terminal C1is fixed to the side plate61of the electric oil pump6. In this state, the connector terminal C1is electrically connected with the connector part91of the transmission controller9(see virtual line inFIG.6). As shown inFIG.6, one end10aof a wire harness10and one end11aof a wire harness11are each connected to the connector terminal C1. The one ends10a,11aof the wire harnesses10,11in the connector terminal C1are connected to the region on the side opposite to the connector part91(right side inFIG.6) in the vehicle longitudinal direction. As shown inFIG.5, the other end10bof the wire harness10is connected to a connector terminal C2. The connector terminal C2is electrically connected with the first connector part52bof the control valve unit5. Thus, the wire harness10electrically connects the transmission controller9and the control valve unit5. Here, the wire harness10is connected with the transmission controller9and the control valve unit5in a state with the second space S22and the bulging wall8interior space S4interior arranged aligned in the vehicle lateral direction (seeFIG.5). In this state, the wire harness10is handled and arranged so as to cut across the side of the left side surface53of the control valve unit5in the vertical line VL direction. In other words, the wire harness10is arranged so as to not overlap the electric oil pump6in the vehicle longitudinal direction, and so as to overlap the electric oil pump6in the vehicle lateral direction. [Branch Line] Here, as shown inFIG.6, the wire harness10has a branch line101that branches from the wire harness10in the midway position in the lengthwise direction. In specific terms, as shown inFIG.6, in the wire harness10arranged cutting across the side of the control valve unit5vertically, the branch line101branches from the region overlapping the control valve unit5(the region overlapping the lower valve52inFIG.6). As shown inFIG.6, the branch line101branched from the wire harness10is arranged so as to face the bottom surface52aside of the lower valve52after cutting across a region on the lower side of the external connection connector K and the range switching device W at the vehicle rear side. A connector terminal C6connected to a tip101aof the branch line101is connected from the rear side in the vehicle longitudinal direction to the second connector part52cprojecting from the bottom surface52aof the lower valve52. As shown inFIG.6, in the wire harness11, one end11ain the lengthwise direction is connected to the connector terminal C1, and the other end11bis connected to the terminal part C3of the first connector K1of the external connection connector K. As shown inFIG.5, the wire harness11is arranged with the second space S22and the bulging wall8interior space S4interior aligned in the vehicle lateral direction, and electrically connects the transmission controller9and the first connector K1of the external connection connector K. In this state, the wire harness11is handled and arranged so as to cut across the top surface51aof the upper valve51in the vehicle lateral direction. [Power Supply Line] As shown inFIG.6, at the upper side of the control valve unit5, one end12aof the power supply line12is connected to the power supply connector C5of the electric oil pump6. An other end12bof the power supply line12is connected to the terminal part C4of the second connector K2of the external connection connector K. Therefore, the power supply line12electrically connects the electric oil pump6, and the second connector K2of the external connection connector K. As shown inFIG.5, the power supply connector C5is positioned further to the electric oil pump6side than the terminal part C4in the vehicle lateral direction. For that reason, the power supply line12is handled and arranged so that the bulging wall8interior space S4interior is aligned in the vehicle lateral direction. In this state, the power supply line12connects the electric oil pump6and the external connection connector K (second connector K2) by the shortest distance in the vehicle lateral direction. With the present embodiment, for the power supply line12, an item with a thicker diameter than the wire harnesses10,11is used. This is because a large amount of power is flowed to the electric oil pump6. As described above, the continuously variable transmission1(power transmission device) of the present embodiment has the following configuration.(1) The continuously variable transmission1hasthe first chamber S1in which the variator20(power transmission mechanism) is arranged, andthe second chamber S2in which the electric oil pump6(oil pump) is arranged. The continuously variable transmission1has the wire harness10(first electric wire), the transmission controller9(controller), and the control valve unit5(control unit) connected with the transmission controller9via the wire harness10. The wire harness10is provided inside the second chamber S2, and is arranged at a position that does not overlap with the electric oil pump6in the vehicle longitudinal direction (first direction) that is the direction facing from the electric oil pump6to the transmission controller9. The wire harness10is provided at a position that overlaps with the electric oil pump6in the direction facing from the electric oil pump6to the transmission controller9(first direction), and the wire harness10is arranged between the electric oil pump6and the transmission controller9in the first direction. In this case, the dimension in the first direction of the continuously variable transmission1increases. In light of that, by configuring as described above, when the wire harness10is arranged at a position that does not overlap with the electric oil pump6in the first direction, the electric oil pump6and the wire harness10are arranged at positions (offset positions) separated in a second direction (vehicle lateral direction) orthogonal to the first direction. In this case, it is possible to suppress an increase in the dimension in the direction facing from the electric oil pump6to the transmission controller9(first direction). The continuously variable transmission1(power transmission device) of the present embodiment has the following configuration.(2) The first chamber S1, the electric oil pump6, and the transmission controller9overlap in the vehicle longitudinal direction. The wire harness10is arranged at a position that overlaps with the electric oil pump6in the vehicle lateral direction (second direction) that intersects the vehicle longitudinal direction. The first chamber S1in which the variator20is arranged is huge compared to the electric oil pump6. For that reason, there is space (bulging wall8interior space S4) that can be effectively used on the vehicle lateral direction side (paper surface front side inFIG.1) of the electric oil pump6. In light of that, by configuring as described above, the second chamber S2is expanded to the vehicle lateral direction side, the space (interior space S4) is formed, and by arranging the wire harness10in the formed space (interior space S4), it is possible to make effective use of the layout. The continuously variable transmission1(power transmission device) of the present embodiment has the following configuration.(3) The continuously variable transmission1has the wire harness11(second electric wire), the power supply line12(third electric wire), and the external connection connector K. The wire harness11connects the transmission controller9and the external connection connector K. The power supply line12connects the electric oil pump6and the external connection connector K. The second chamber S2is partitioned into the first space S21in which the electric oil pump6is arranged, and the second space S22in which the wire harness10is arranged. The second space S22is connected to the first space S21in the vehicle lateral direction. In this case, the external connection connector K is attached to the bulging wall8that extends from the side wall part283of the wall part28that configures the second space S22. For example, when the external connection connector K is attached to the side wall part284(seeFIG.5) side of the wall part28that configures the first space S21in which the electric oil pump6is arranged, the wire harness11and the power supply line12cut across the first space S21. Having done that, since the wire harness11and the power supply line12are arranged directly near the electric oil pump6which is a heat source, the wire harness11and the power supply line12are susceptible to the effect of heat. In light of that, by configuring as described above, it is possible to reduce the effect of heat on the wire harness11and the power supply line12. The continuously variable transmission1(power transmission device) of the present embodiment has the following configuration.(4) The external connection connector K has the terminal part C3that connects with the wire harness11, and another terminal part C4that connects with the power supply line12(third electric wire). The power supply line12is arranged inside the second space S22within the second chamber S2, and is connected with the electric oil pump6. By configuring in this way, by providing the power supply line12inside the second chamber S2, it is possible to shorten the length of the power supply line12, which reduces the cost. The side wall part283of the wall part28configures the second space S22. The external connection connector K is attached to the bulging wall8extending from this side wall part283, so it is possible to reduce the effect of the heat of the electric oil pump6transmitted via the air to the power supply line12. The continuously variable transmission1(power transmission device) of the present embodiment has the following configuration.(5) The power supply line12is thicker than the wire harnesses10,11. The terminal part C4is arranged at a position closer to the electric oil pump6than the terminal part C3. In light of demand, since a larger current flows to the power supply line12than the wire harnesses10,11, the diameter is larger than that of the wire harnesses10,11. In light of that, by configuring as described above, by providing the terminal part C4(the other terminal part) of the power supply line12near the electric oil pump6, it is possible to make the thick electric wire shorter and to reduce costs. The continuously variable transmission1(power transmission device) of the present embodiment has the following configuration.(6) A portion of the branch line101that branches from the wire harness10is arranged cutting across below the external connection connector K. By configuring in this way, when branching the wire harness10, it is possible to use space effectively and suppress an increase in size. The continuously variable transmission1(power transmission device) of the present embodiment has the following configuration.(7) The continuously variable transmission1has the range switching device W. The range switching device W is positioned between a portion of the branched branch line101, and the external connection connector K with respect to the vertical line VL direction. By configuring in this way, it is possible to use space effectively and to suppress an increase in size. With the present embodiment, the explanation was with the first direction as the vehicle longitudinal direction, and the second direction as the vehicle lateral direction, but the first direction and the second direction are not limited to these. Modes of the present invention are not limited only to the modes shown in the embodiments noted above. They can be modified as appropriate within the scope of ideas of the technology of the invention. EXPLANATION OF CODES 1: Continuously variable transmission (power transmission device);5: Control valve unit (control unit);6: Electric oil pump (oil pump);8: Bulging wall;9: Transmission controller (controller);10: Wire harness (first electric wire);11: Wire harness (second electric wire);12: Power supply line (third electric wire);20: Variator (power transmission mechanism);28: Wall part;101: Branch line;283: Side wall part; C3: Terminal part; C4: Terminal part (other terminal part); K: External connection connector; S1: First chamber; S2: Second chamber; S21: First space; S22: Second space; VL: Vertical line; and W: Range switching device. | 35,637 |
11859715 | DETAILED DESCRIPTION OF THE DRAWINGS For purposes of this discussion, elements will be identified by reference characters, typically reference numerals. There are a few embodiments shown in the Figures that will be described in detail below. For purposes of simplicity, these elements will retain their reference characters throughout the discussion. If an element has characteristics that are different from one embodiment to another, those differences will be discussed when introducing the same element for the new embodiment. Referring toFIG.1A, a perspective view of one embodiment of a transmission is generally shown at10. In this Figure, the transmission10is operatively connected to a first motor12and a second motor14. Physically, the second motor14is mounted to the transmission10between the transmission10and the first motor12. The first motor12has an output (discussed subsequently) that extends through the second motor14and to the transmission10. The transmission10includes a transmission housing16having a housing cap20.FIGS.1A and1Bshow the second motor14(B-Motor) secured to the transmission housing16and the first motor12(A-Motor) secured to the second motor14(B-Motor). A first motor output shaft18of the first motor12(A-Motor) defines a length15that is longer than a length17of the first motor12. The first motor output shaft18also defines an outer diameter19at its distal end21. The second motor14(B-Motor) includes a second motor output shaft21. The second motor output shaft21defines an inner diameter23that is larger than the outer diameter19of the first motor output shaft18. The first motor output shaft18extends through and is coaxial with the second motor output shaft21. It should be appreciated by those skilled in the art that the first motor output shaft18may not extend all the way through the second motor output shaft21. In alternative embodiments that will be discussed in greater detail below, the first12and second14motors may be mounted on either side of the transmission10. Oil used to cool the transmission10, the first motor12and the second motor14is collected by a catch basin22and recirculated using a pump housed within a sump24. Because the catch basin22extends along the entire length of the transmission10, the first motor12and the second motor14, only one sump24is necessary. The transmission10has an output shaft26that extends out through the center of the housing cap20. Electrical ports28provide electrical access (power and communications) inside the first12and second14motors. The transmission10, first motor12, second motor14, and pump may be referred to as a powertrain, generally shown at30. Referring toFIGS.2and3, the powertrain30is shown mounted between two rails32,34of a vehicular frame, generally shown at36. A body40, including a passenger compartment (not shown), is shown fixedly secured to the vehicular frame36. Referring specifically toFIG.3, the transmission10is shown connected to a drive line38that drives four wheels (none shown). Referring toFIGS.4and5, the transmission10is shown in a configuration for operating with a single input. In this configuration, the single input is the first motor12fixedly secured directly to the transmission housing16in the absence of the second motor14. The first motor12is not shown inFIG.4, but the first motor output shaft18would be received by the input shaft44of the transmission10. The input shaft44is also designated as shaft “1” in the power flow shown inFIG.5. The transmission10also includes a first gearset, generally shown at46, and a second gearset, generally shown at50. The first gearset46includes first52, second54and third56rotating members. The second gearset50includes a fourth60, fifth62, and sixth64rotating members. These gearsets46,50may be any gearset that has three rotating members. Types of gearsets contemplated include, but are not limited to, Ravigneaux gearsets, Simpson gearsets and ring-carrier/ring-carrier gearsets. The gearsets46,50shown inFIGS.4and5are ring-carrier/ring-carrier gearsets. Because these gearsets46,50are ring-carrier/ring-carrier gearsets, the first52, second54and third56rotating members are a sun gear, a carrier and a ring gear, respectively. These are indicated as S1, C1, and R1for the first gearset46and S2, C2, and R2for the second gearset50. Two rotating members from the first gearset46and two rotating members from the second gearset50are fixedly secured to each other. These connections create a four-node linkage for the transmission10. As such, each pair of rotating members is represented by a single circle inFIG.5. Therefore, the first rotating member56(ring gear R1) and the fifth rotating member62(carrier C2) are fixedly secured to each other and represented by both reference numerals56and62inFIG.5, whereas the second rotating member54(carrier C1) and the sixth rotating member64(ring gear R2) are fixedly secured to each other and represented by both reference numerals54and64inFIG.5. The output shaft26of the transmission10is also fixedly secured to two rotating members, one from each gearset46,50. In the embodiment shown inFIGS.4and5, the output shaft26is fixedly secured to the third rotating member56(the ring gear R1of the first gearset46and the fifth rotating member62of the second gearset50(the carrier C2of the second gearset50). The motor12is connected directly to the fourth rotating member60of the second gearset50using the input shaft44(shaft1). The output shaft26of the transmission10is also fixedly secured to two rotating members, one from each gearset46,50. In the embodiment shown inFIGS.4and5, the output shaft26is fixedly secured to the third rotating member56(the ring gear R1of the first gearset46and the fifth rotating member62of the second gearset50(the carrier C2of the second gearset50). The motor12is connected directly to the fourth rotating member60of the second gearset50using the input shaft44(shaft1). A controllable clutch66is connected between the input shaft44(shaft1) at one end and the output shaft26(shaft3) at the other end. The controllable clutch66is also represented by the nomenclature K13because it couples shafts1and3together. Referring specifically toFIG.5, the controllable clutch66is represented by a switch70and two diodes72,74. These three elements70,72,74represent the attributes of the controllable clutch66. More specifically, the switch70signifies that the controllable clutch66may be turned on and off. The diodes72,74represent the fact that the controllable clutch66will the third rotating member56(ring gear R1), the fifth rotating member62(second carrier C2) and the output shaft26(shaft3) to lock in both directions, or to rotate freely in both directions. Therefore, when the switch70is closed, representing the active state for the controllable clutch66, the output shaft26rotates with the rotation of the input shaft44. When the switch70is open, representing an inactive state for the controllable clutch66, the output shaft26does not rotate or, alternatively, rotates based on the torques it receives from the other rotating elements52,54,60,64of the first46and second50gearsets. The transmission10also includes a first controllable brake76(B04) that couples the first rotating member52(sun gear S1) of the first gearset46to the transmission housing16. The first controllable brake76also has the symbol B04because it is a brake that connects shaft0(which is just the transmission housing16) with a fourth shaft80(shaft4). The first controllable brake76(B04) is similar to the controllable clutch66in that it is represented by two diodes82,84representing that it will lock and allow rotation in either direction. The first controllable brake76(B04) is different from the controllable clutch66in that each direction of operation can be controlled independently of the other, as represented by switches86,90. Operation of the first controllable brake76will be discussed in greater detail subsequently. This transmission10also includes a second controllable brake92(B05) which couples the second rotating member54(carrier C1) of the first gearset46and the sixth rotating member64(ring R2) of the second gearset50to the transmission housing16. The second controllable brake92differs from the first controllable brake76in that it only has the ability to control whether a notch plate94(shaft5) is rotating or if it is tied to the transmission housing16and prevented from rotating. As such, the second controllable brake92only includes a single switch96representing the two states of the second controllable clutch92(B05) as being either on or off, and two diodes100,102indicate that the second controllable brake92(B05) can lock or allow the notch plate94(shaft5) rotate in either direction. Referring toFIG.6, a lever diagram showing the transmission10having two inputs (FIG.1) is shown. The lever diagram is substantially similar to lever diagram for the single-input transmission shown inFIG.5. One difference between the two configurations is the transmission10has two input shafts44,126, wherein the first input shaft44receives torque from the first motor12(A-Motor) and the second input shaft126receives torque from the second motor14(B-Motor). Another difference between the two configurations is the use of two controllable clutches140(K23),142(K24) instead of the single controllable clutch66(K13). The output of the first motor12(A-Motor) is received by the first input shaft44(shaft1), which is fixedly secured to the fourth rotating member60(sun gear S2) of the second gearset50. The output of the second motor14(B-Motor) is received by the second input shaft126(shaft2). The second input shaft126(shaft2) is connected to the first controllable clutch140(K23) and the second controllable clutch142(K24). The first controllable clutch140(K23) operates in both directions as is indicated by the diodes144,146, which are oriented in opposite directions. A switch150illustrates that the clutch140(K23) is controllable and may be locked or allowed to rotate in both directions. The second controllable clutch142(K24) operates in both directions, as is indicated by the diodes152,154, which are oriented in opposite directions. A switch156illustrates that the controllable clutch142(K24) is controllable and may be locked or allowed to rotate in both directions. The first controllable clutch140(K23) couples the second input shaft126(shaft2) and the output shaft26(shaft3). The second controllable clutch142(K24) couples the second input shaft126(shaft2) with the fourth shaft80(shaft4). As discussed above, the output shaft26is fixedly secured to both the third rotating member56(ring R1) of the first gearset46and the fifth rotating member62(carrier C2) of the second gearset50. The transmission10also includes a first controllable brake76(B04) that couples the first rotating member52(sun gear S1) of the first gearset46to the transmission housing16. The first controllable brake76also has the symbol B04because it is a brake that connects the transmission housing16(shaft0) with a fourth shaft80(shaft4). The first controllable brake76is similar to the controllable clutches140,142in that it is represented by two diodes82,84representing operation in either direction. The first controllable brake76is different from the controllable clutches140,142in that each direction of operation can be controlled independently of the other, as represented by the two switches86,90. Operation of the first controllable brake76will be discussed in greater detail subsequently. This transmission10also includes a second controllable brake92(B05) which couples the second rotating member54(carrier C1) of the first gearset46and the sixth rotating member64(ring R2) of the second gearset50to the transmission housing16. The second controllable brake92differs from the first controllable brake76in that it only can control whether a notch plate94(shaft5) is rotating, or if it is tied to the transmission housing16and prevented from rotating. As such, the second controllable brake92only includes a single switch96representing the two states of the second controllable clutch92(B05) as being either on or off, and two diodes100,102indicate that the second controllable brake92(B05) can lock in both directions or it can move freely in both directions. Because the first46and second50gearsets are ring-carrier/ring-carrier gearsets, the connections described in the power flow inFIG.5, and the first18and second19motor output shafts are coaxial, the second motor14(B-Motor) is able to drive the output shaft26(shaft3) directly. The number of modes of operation increase due to this capability. In the embodiments shown in the Figures, the first motor output shaft18extends through the second motor output shaft19. As such, the second motor output shaft19is hollow providing a space through which the first motor output shaft18extends. InFIG.6, the steady-state lever104represent when the host vehicle is not in motion. The operational lever106represents when the vehicle is moving through the operation of the first motor12(A Motor) and/or the second motor14(B Motor). The first controllable clutch140(K23) is open as represented by the switch150being open. In addition, the second controllable clutch142(K24) is closed. Therefore, the second motor14(B Motor) is coupled to the first rotating member52(sun gear S1) of the first gearset46. The first rotating member52(sun gear S1) is not grounded to the transmission housing16because the first controllable brake76(B04) is open. Finally, the second controllable brake92(B05) is closed tying the second rotating member54(carrier C1) of the first gearset46and the sixth rotating member64(ring gear R2) of the second gearset50are ground to the transmission housing16through the notch plate94(shaft5). In this configuration, the first motor12is operating in the forward direction, indicated by arrow160, and the second motor14is operating in the reverse direction, indicated by arrow162. By way of example, and in not to be limiting, exemplary torques are provided based on the designs of the gearsets46,50and the motors12,14. Given the output of the first motor12(A Motor) provides a torque of 1000 NM on the second sun gear60(sun gear S2) and the output of the second motor14provides a torque of 1000 NM in the opposite direction on the first rotating member52(sun gear S1) results in a torque of 4272 NM on the second rotating member54(carrier C1) of the first gearset46and the sixth rotating member64(ring gear R2) of the second gearset50and an output torque of 6272 NM at the output shaft26. This is “first gear.” The transmission10is more fully described in U.S. Pat. No. 10,711,867, which is co-owned by Applicant, and the disclosure therein is expressly incorporated herein by reference. Referring toFIGS.7through11, clutch elements are shown in various stages of operation to facilitate the shifting of the transmission10into reverse from two distinct “states” of the transmission10. In the first state, the transmission is in a “drive-ready” state. For purposes of this discussion the drive-ready state is the vehicle transmission10is ready to go forward but the at least one second strut236is extended and mechanically engaged with a notch246of the notch plate250. As such, the at least one second strut236has not yet retracted in the pocket226even though the second actuator202has been deactivated. As a point of distinction, if the transmission10is in a drive hill-hold mode, the at least one second strut236is in the same position as if it were in the drive ready mode, but the at least one second actuator202is in an activated condition with the plunger of the at least one second actuator202extended into the second pocket226to prevent the at least one second strut236from retracting. The clutch elements are used for brake clutches. In the embodiment shown, the clutch elements are a part of the first controllable brake76(B04). It should be appreciated by those skilled in the art that these clutch elements could be used with any of the independently controllable clutches used in this transmission10. Referring specifically toFIG.7, the clutch elements shown include first200and second202actuators. In the embodiment shown, the first200and second202actuators are solenoids, each having a plunger204,206, respectively. The actuators200,202are fixedly secured to a pocket plate210using a mounting plate212and a plurality of bolts214(FIG.9). Electrical power to and control of the two actuators200,202come through a communications module as represented by wire harness connector216(FIG.9) as is known in the art. The plungers204,206extend through channels220,222, respectively, in the pocket plate210and into first224and second226pockets disposed adjacent an inner diameter of the pocket plate210. The channels220,222allow the plungers204,206to move axially between respective extended positions (FIG.7) wherein distal ends230,232of the plungers204,206extend into the pockets224,226of the pocket plate210, and retracted positions (FIG.9). In each of the first224and second226pockets are first234and second236struts. The struts234,236reside in the pockets224,226. In their extended positions, engagement portions240,242of the struts234,236are extend out of the pockets224,226and engage notches246in a notch plate250. Cam surfaces248,249of the first234and236struts move along interior surfaces of the pockets224,226, respectively. More specifically, the engagement portions240,242of the struts234,236engage respective notch walls238,239of the notches246. When the struts234,236pivot from their extended position to their respective retracted positions within their respective pockets224,226, they no longer engage the notch plate250. Position modules254,256identified the position of the struts234,236. The position modules254,256include sensors to sense the position or orientation of the struts234,236. Examples of position sensors are described in US patent application owned by Applicant, having Ser. No. 17/495,062, the specification of which is hereby incorporated by reference. It should be appreciated by those skilled in the art that a clutch may include a plurality of these actuator/strut pairs and only a pair of these actuator/strut assemblies are shown in the Figures for purposes of simplicity. FIG.7is a default starting position of the clutch elements using the method described herein. InFIG.7, the pocket plate210is fixed to ground (typically, the transmission housing16) and a portion of the struts (some from each direction)234,236are extended into notches246of the notch plate250. It should be appreciated by those skilled in the art that not all struts234,236need to be extended into their respective notches246—only that at least one of each pointing in opposite directions. This prevents the notch plate250from rotating in either direction. In this example, preventing the notch plate250from rotating in either direction creates a drive state for the transmission10. Said another way, the transmission10is in a forward drive gear when the notch plate250is prevented from rotating (and the other brake clutch92(B05) is also engaged). If the transmission10were used for something other than a vehicle, the condition would prevent movement of whatever the transmission10is designed to move. Turning attention toFIG.12, the method used to operate the clutch elements move from a drive condition to a reverse condition is generally shown at300. The method300begins at302when it receives a command to shift the transmission10to reverse. The method300deactivating the at least one second clutch actuator202at304. This step304is designed to release the at least one second strut236, which may or may not occur because it may or may not be loaded. Once the at least one second strut236is released, it either retracts or attempts to retract into its second pocket226. It is then determined at310whether the at least one second strut236has retracted into the second pocket226of the pocket plate210. This determination is made by the second position module256, which as discussed above, includes a sensor to determine the location of the at least one second strut236. If the at least one second strut236has not been retracted (as is shown inFIG.8), the method300, activates at312the at least one first clutch actuator200(FIG.9). This occurs when it is determined the at least one second strut236remains in its extended position out past the second pocket226(as defined by the pocket plate inner diameter244). There are times when the at least one second strut236will not retract even though the second clutch actuator202has retracted its plunger206. This occurs if the at least one second strut236is loaded. More specifically, it occurs when the engagement portion240of the at least one second strut236and the notch wall239of the notch246are abutting each other with a force that overcomes the force being applied to the at least one second strut236by a biasing spring (not shown) that biases the at least one second strut236to retract into the second pocket226absent any other forces acting on the at least one second strut236. Once the at least one first strut234is activated, a first rotational torque is applied at314to the notch plate250that is opposite of the direction of reverse (alsoFIG.9). This first rotational torque applied to the notch plate250will unload the forces acting on the at least one second strut236allowing it to retract into its at least one second pocket226(FIG.10). The first rotational torque applied at314will be gradual ramp so as to not unduly increase noise and vibration. Once the first rotational torque has been applied sufficiently, the method300loops back at316to confirm at310that the at least one second strut236has been retracted. If not, the steps312through316are repeated until confirmation that the at least one second strut236has been retracted. If the at least one second strut236has been retracted, the method300commands the first strut234to retract at320(FIG.11). Once the at least one second strut236is retracted, the torque applied the notch plate250is ramped or reduced to zero. At this point, the transmission10is either in reverse ready or reverse, depending on whether the first strut234stays extended or retracts, respectively a reverse rotational torque can be applied to the notch plate250at322. The direction of the reverse rotational torque applied is in a direction such that the transmission10is in reverse at324. The invention has been described in an illustrative manner. It is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the invention may be practiced other than as specifically described. | 22,943 |
11859716 | DETAILED DESCRIPTION, AND PREFERRED EMBODIMENTS THEREOF The present invention relates to a TCEC comprising (a) at least one infinitely variable transmission (IVT), wherein the IVT comprises at least one IVT control system, and (b) at least one vertical axis wind (or water) turbine. As used herein, the term “infinitely variable” embraces, but is not limited to, a transmission which is capable of operating at a plurality of gear ratios and in which the plurality of gear ratios are changeable in very small, possibly infinitely small, increments over a range of gear ratios. “IVT” is not intended to imply that an infinite rotation speed may be achieved, which, of course, would be impossible, only that a theoretically infinite number of ratios between the speed of the input shaft and the speed of the output shaft may be selected within a predetermined range of ratios. It should also be noted that the output shaft of IVT does not actually operate within a set range of speeds but actually operates within a range of ratios. As defined herein, a “body of water” includes, but is not limited to, a bay, a bayou, a canal, a channel, a cove, a creek, a delta, an estuary, a fjord, a gulf, a harbor, an inlet, a lake, a mill pond, an ocean, a pond, a reservoir, a river, a sea, a sound, a strait, a stream, and a tide. As defined herein, a “fluid” can be wind or water. As defined herein, “bearings” include at least one of ball bearings, air bearings, and magnetic levitation bearings. As well-known in the art, “tip speed ratio” or “TSR” is defined as the ratio between the rotating speed at the tip of the rotor and the incoming fluid speed. As defined herein, the “self-starting” capability of a VAWT is defined as that the fluid turbine can reach the desirable TSRs under nominal wind conditions without external load. As a result, the turbines can effectively harvest fluid energy when appropriate energy collectors (in the form of external load) are activated. As defined herein, the individual gears in the “pair of meshed gears” or “gear pair” in the IVT can be substantially circular or noncircular. In one embodiment, the gear pair comprises two substantially circular gears that mesh. In another embodiment, the gear pair comprises two noncircular gears that mesh. It should be understood by the person skilled in the art that a “substantially circular” gear is intended to be perfectly circular however minor manufacturing errors occurred. As defined herein, a “prime mover” includes, but is not limited to, an internal combustion engine, hydro-turbine, wind turbine, electric motor, gas turbine, and waterwheel. Vertical Axis Wind (or Water) Turbines Typically fluid (wind or water) turbines are classified into horizontal axis wind (or water) turbines (HAWTs) and vertical axis wind (or water) turbines (VAWTs) depending on the direction of the axis of rotation. Though the utility-scale HAWTs are more commonly used in wind farms due to their higher power generation capacity than that of VAWTs, VAWTs have advantages over HAWTs. Specifically, they are omni-directional, indicating that they can operate under different fluid directions without using complex yaw mechanisms. They are usually less sensitive to wake effects compared to HAWTs [Danao, 2013; Danao, 2014; Wekesa, 2014; Wekesa, 2015; Wekesa, 2016]. Appropriately designed VAWTs can effectively harvest wind or water energy at both very low (e.g., ≤1 m/s) and very high (e.g., ≥25 m/s) speeds. As a result, VAWTs are attractive for deployment in both urban and rural areas, and in offshore regions [Paraschivoiu, 2022; Islam, 2008]. Moreover, VAWTs usually have low noise emission and low radar signatures and are easy to install and maintain. There exists a great degree of versatility in the design of VAWTs. Traditionally, VAWTs can be classified into two dominant types, namely, Darrieus and Savonius type wind turbines. The Darrieus VAWT is a lift-driven fluid turbine, and usually has high energy harvesting efficiency at relatively large tip speed ratios (TSRs). However, the Darrieus VAWT suffers from self-starting issues due to the dead band of negative torque at small TSRs [Baker, 1983; Kirkle, 1991; Li, 2013; Bazilevs, 2014; Buchner, 2015], although some authors have reported unaided start-up in a steady wind [Dominy, 2007; Hill, 2009]. The Savonius VAWT falls into the category of drag-driven fluid turbines. It is self-starting, and works well at small TSRs [Nakajima, 2008; Kamoji, 2009], however, disadvantageously the energy harvesting efficiency is traditionally much lower than that of the Darrieus VAWT. None of these VAWT designs in the prior art can simultaneously resolve the many technical challenges, including self-starting, high energy efficiency, and structural stability, at realistic wind and tidal speeds. Towards that end, the present invention broadly relates to a TCEC comprising a new hybrid Darrieus-Modified-Savonius (HDMS) VAWT apparatus. In the HDMS VAWT design, an MS rotor is located in the center of a straight-bladed H-type Darrieus rotor to simultaneously enhance the self-starting capability, using the MS rotor, and maintain high energy harvesting efficiency, using the Darrieus rotor. The multi-stage HDMS VAWT can harvest aero-hydro energy efficiently under a wide range of flow conditions, while also providing good self-starting properties and enhanced structural stability. Broadly, the TCEC described herein comprises a hybrid VAWT comprising a modified-Savonius (MS) rotor in the central region and a straight bladed H-type Darrieus rotor in the surrounding annular region (seeFIGS.1A and1B), referred to hereinafter as the hybrid Darrieus-Modified-Savonius (HDMS) VAWT. The hybrid design represents a nonlinear interaction between the MS rotor and the Darrieus rotor. The HDMS VAWT described herein can be used to harvest energy using any fluid motion, including water and air motion (i.e., wind). With regards to the MS rotor10in the central region, said MS rotor comprises a plurality of blade-sets140or stages, stacked upon one another and rotatable about a common, central axis, wherein each blade-set comprises a first (i.e., top) and second (i.e., bottom) circular plate100, each plate being substantially perpendicular to the common axis. The common axis is transverse to the flow of the fluid medium. Each blade-set or stage comprises a plurality of rectangular blades or sails110, each of which is substantially the same size, emanating from the common axis and rigidly attached to the first and second circular plates. For example, the blade-set can comprise two, three, four, or more blades or sails. In one embodiment, the blade-set comprises three blades or sails arranged at approximately 120 degree angles from each other around the common axis. Each rectangular blade has a blade length and a blade height, wherein the blade height is equal to the distance between the first and second circular plates in the blade-set. Each blade in the blade-set is attached along the blade length to the first and second circular plates from the common axis to a position proximate to an edge of the circular plates, wherein the blade length is greater than the radius of the circular plates, such that the blade has to be bent or arced along the blade length to fit. In one embodiment, the blade length is about 20% to 60% longer than the radius of the circular plate, preferably about 40% to about 60%. It should be appreciated that an edge of each blade may be aligned with an edge of the circular plates, or an edge of each blade may be inset a nominal distance from the edge of the circular plates, or an edge of each blade may be outset a nominal distance from the edge of the circular plates. Each blade-set is rotated relative to the next blade-set such that the second blade set is offset relative to the first. For example, the second blade-set is rotated approximately 20-60 degrees from the first, and the third is still another approximately 20-60 degrees behind the second or approximately 40-120 degrees behind the first. It should be appreciated by the person skilled in the art that the MS rotor of the apparatus can comprise one, two, three, four, five, or more blade-sets, and that each blade-set can have substantially the same, or different, height relative to another blade-set. Further, each blade-set can comprise the same number, or a different number, of blades as the other blade-sets making up the MS rotor portion of the HDMS VAWT. The MS rotor in the central region can be built in either clockwise or anti-clockwise parities such that it rotates about the central axis in a clockwise manner or a counter clockwise manner. In one embodiment, the common axis comprises a shaft. In one embodiment, the shaft is static, or non-rotating, with the overall blade-set assembly mounted upon and rotating about the non-rotating shaft on bearings or bushings. In one embodiment, the shaft is rotatable, wherein the blade-set assembly is attached to the rotatable shaft, and the rotating shaft rotates about the central axis, as understood by the person skilled in the art. The MS rotor can further comprise a brake system, for example a hydraulic brake system, that is mounted upon the shaft with bearings to limit the rotational speed of the rotor assembly to a maximum speed at high fluid speeds, as readily determined by the person skilled in the art. It should be appreciated that although the MS rotor portion of the HDMS VAWT was disclosed as comprising a first and second circular plate per plate-set, one plate-set can share a circular plate with another plate-set, for example, the second plate of a first blade-set can be the first plate of a second blade-set. Further, it is contemplated that instead of, or in addition to, using a full circular plate, the arcuate portions of the blades can instead be “capped”150off instead, for example as illustrated inFIG.1C, which is a top view of a set of MS blades110of a blade-set. It should be appreciated that there can be one or two caps associated with the arcuate portions of the blades of a blade-set, meaning that only the top of the blades are capped, only the bottom of the blades are capped, or both the top and the bottom of the blades are capped, depending on the achievement of the greatest harvesting efficiency. With regards to the Darrieus rotor20in the surrounding annular region, preferably the Darrieus rotor is a straight bladed H-type Darrieus rotor, although it should be appreciated that a helical-type and the semicircular-type Darrieus rotor is contemplated for use in the HDMS VAWT disclosed herein. The straight-bladed H-type Darrieus rotor comprises a plurality of blades120that can rotate about the common axis. In one embodiment, the cross-section of the blade120is of a substantially symmetrical airfoil shape, although non-symmetrical airfoil blade shapes can be used. For example, a NACA 0015 airfoil blade design has generally a wide, round leading edge and a squat parabolic length in cross-section and is defined in part by a chord length, c. It should be appreciated that the shape of the airfoil blades can be adjusted as needed depending on the given fluid power generation requirements, as readily understood by the person skilled in the art. The plurality of blades is rigidly held in a position substantially parallel to the common axis. In one embodiment, each blade is attached to the blade-sets of the MS rotor using a plurality of supporting struts130. In one embodiment, each blade is preferably positioned substantially equiangular around the common axis. The Darrieus rotor of the HDMS VAWT can comprise two, three, four, or more blades positioned around the common axis. As shown inFIG.1B, the Darrieus rotor blades120are not the same longitudinal length (along the common axis) as the cumulative length of the three blade-sets140.FIG.1Bis not intended to limit the instant invention in any way; there may be more or less than three blade-sets140, more or less than three blades110per blade-set140, more or less than three Darrieus rotor blades120, and the length of the Darrieus rotor blades120can be the more than, less than, or equal to the cumulative length of the blade-sets of the MS rotor portion, as readily understood by the person skilled in the art. Preferably, the MS rotor portion and the Darrieus rotor portion are both arranged such that they are symmetrical around the common axis. An embodiment of the HDMS VAWT is shown inFIG.2, wherein the tip of the blade110in the MS rotor (wherein the blade intersects with the edge of the circular plates) was aligned with an aerodynamic center of the corresponding blade120in the Darrieus rotor. It should be appreciated that the relative position between a blade of the inner MS rotor and a blade of the outer Darrieus rotor can be adjusted relative to that illustrated inFIG.1B, for example in a range of +/−1° to 90° relative to the alignment with the aerodynamic center of the Darrieus blade, as readily determined by the person skilled in the art. The ratio of the radius Roof the Darrieus rotor blades120relative to the radius Riof the MS rotor blades110is in a range from about 1.5 to about 4, preferably about 1.5 to about 3.5, and even more preferably about 2.5 to about 3.5. The ratio of the radius Roof the Darrieus rotor blades120relative to the chord length, c, of the Darrieus blades is in a range from about 1.5 to about 4, preferably about 1.5 to about 3.5, and even more preferably about 2.5 to about 3.5. In one embodiment, the radius Riof the MS rotor blades110is substantially the same as the chord length, c, of the Darrieus blades. In another embodiment, the radius Riof the MS rotor blades110is greater than the chord length, c, of the Darrieus blades. In still another embodiment, the radius Riof the MS rotor blades110is less than the chord length, c, of the Darrieus blades. The preferred radius Riof the MS rotor blades relative to the chord length, c, of the Darrieus blades is dependent on when the energy harvesting efficiency is maximized, as readily determined by the person skilled in the art. In a preferred embodiment, the energy harvesting efficiency is achieved at TSR values greater than about 1.5, preferably greater than about 2.0, and most preferably greater than about 2.2. In one embodiment, each HDMS VAWT comprises suitable self-lubricating bushings (not shown) (e.g., bearings) to help reduce rotational friction, vibration, and noise. In one embodiment, a suitable alternator, such as, for example, a direct drive permanent magnet alternator can be used to collect and convert the rotational energy power of fluid, as harnessed by the present HDMS VAWT, into electrical energy, as readily understood by the person skilled in the art. The components of the HDMS VAWT comprise at least one of carbon composites, aluminum, and polymer materials, although other materials are contemplated. An embodiment of how the MS rotor portion of the HDMS VAWT can be found in U.S. Pat. No. 8,790,069 in the name of Bruce Elliott Anderson, which is hereby incorporated in its entirety herein. Accordingly, in a first aspect, a hybrid vertical axis wind (or water) turbine apparatus is disclosed, said apparatus comprising a modified-Savonius (MS) rotor in the central region and a straight bladed H-type Darrieus rotor in the surrounding annular region. In one embodiment, the hybrid vertical axis wind (or water) turbine apparatus comprises: (a) a first rotor system positioned in a central region and rotatable about a central axis, wherein the first rotor system comprises: a plurality of first blades, each having a concave shape that allows fluid to push on a concave side of each first blade; and a hydraulic brake system that is mounted upon the shaft with bearings; and (b) a second rotor system positioned in an annular region surrounding the first rotor system in the central region, wherein the second rotor system comprises a plurality of second blades spaced about the central axis, wherein the cross-section of each second blade is a substantially symmetrical airfoil shape. In one embodiment, the first rotor system comprises at least two blade-sets stacked vertically along the central axis, each blade-set comprising a plurality of first blades that are spaced about the central axis, wherein the at least two blade-sets are mounted upon a shaft with bearings along the central axis, wherein each first blade extends from a position proximate to the central axis out to a position distal to the central axis. In one embodiment, the plurality of first blades are equiangularly spaced about the central axis. With regards to the first rotor system, in one embodiment, each blade-set comprises a circular top plate and a circular bottom plate, wherein the circular plates are substantially perpendicular to the central axis, and wherein the plurality of first blades are positioned therebetween. In one embodiment, one plate-set can share a circular plate with another plate-set. In one embodiment, each blade-set comprises three first blades located at approximately 0 degrees, 120 degrees, and 240 degrees about the central axis. In one embodiment, each first blade is rectangular and has a first blade length and a first blade height, wherein the first blade height is equal to the distance between the circular top and bottom plates in the blade-set. In one embodiment, each first blade in the blade-set is attached along the first blade length to the top and bottom circular plates from the central axis to a position proximate to an edge of the circular plates, wherein the first blade length is greater than the radius of the circular plates, such that each first blade has to be bent or arced along the first blade length to fit, resulting in the concave shape, upon rigid positioning in the blade-set. An edge of each first blade may be aligned with an edge of the circular plates, or an edge of each first blade may be inset a nominal distance from the edge of the circular plates, or an edge of each first blade may be outset a nominal distance from the edge of the circular plates. In one embodiment, the first blades in each blade-set are offset about 20-60 degrees about the central axis from the first blades in each other blade-set. With regards to the second rotor system, in one embodiment, the plurality of second blades are straight-bladed. In one embodiment, the plurality of second blades are equiangularly spaced about the central axis. In one embodiment, each of the second blades is positioned substantially parallel to the central axis and attached to at least one blade-set of the first rotor system using at least two supporting struts. In one embodiment, the shaft can be a static non-turning shaft, and the first rotor system is mounted upon, and rotates around, the static non-turning shaft. In one embodiment, the shaft can be a rotating shaft, and the first rotor system is attached to the rotating shaft, and the rotating shaft rotates about the central axis. Preferably, the greatest energy harvesting efficiency is achieved at a tip speed ratio (TSR) values greater than about 2.0, preferably greater than 2.2. In another embodiment, the hybrid vertical axis wind (or water) turbine apparatus of the first aspect comprises: (a) a first rotor system positioned in a central region and rotatable about a central axis, wherein the first rotor system comprises:(i) at least two blade-sets stacked vertically along the central axis, each blade-set comprising a plurality of first blades that are spaced about the central axis, wherein the at least two blade-sets are mounted upon a shaft with bearings along the central axis, wherein each first blade extends from a position proximate to the central axis out to a position distal to the central axis and has a concave shape that allows fluid to push on a concave side of each first blade, and(ii) a hydraulic brake system that is mounted upon the shaft with bearings; and (b) a second rotor system positioned in an annular region surrounding the first rotor system in the central region, wherein the second rotor system comprises a plurality of second blades spaced about the central axis, wherein each of the second blades is positioned substantially parallel to the central axis and attached to at least one blade-set of the first rotor system using at least two supporting struts, wherein the cross-section of the second blade is a substantially symmetrical airfoil shape. With regards to the first rotor system, in one embodiment, each blade-set comprises a circular top plate and a circular bottom plate, wherein the circular plates are substantially perpendicular to the central axis, and wherein the plurality of first blades are positioned therebetween. In one embodiment, one plate-set can share a circular plate with another plate-set. In one embodiment, the plurality of first blades are equiangularly spaced about the central axis. In one embodiment, each blade-set comprises three first blades located at approximately 0 degrees, 120 degrees, and 240 degrees about the central axis. Each first blade is rectangular and has a first blade length and a first blade height, wherein the first blade height is equal to the distance between the circular top and bottom plates in the blade-set. In one embodiment, each first blade in the blade-set is attached along the first blade length to the top and bottom circular plates from the central axis to a position proximate to an edge of the circular plates, wherein the first blade length is greater than the radius of the circular plates, such that each first blade has to be bent or arced along the first blade length to fit, resulting in the concave shape, upon rigid positioning in the blade-set. An edge of each first blade may be aligned with an edge of the circular plates, or an edge of each first blade may be inset a nominal distance from the edge of the circular plates, or an edge of each first blade may be outset a nominal distance from the edge of the circular plates. In one embodiment, the first blades in each blade-set are offset about 20-60 degrees about the central axis from the first blades in each other blade-set. With regards to the second rotor system, in one embodiment, the plurality of second blades are straight-bladed. In one embodiment, the plurality of first blades are equiangularly spaced about the central axis. In one embodiment, the shaft can be a static non-turning shaft, and the first rotor system is mounted upon, and rotates around, the static non-turning shaft. In one embodiment, the shaft can be a rotating shaft, and the first rotor system is attached to the rotating shaft, and the rotating shaft rotates about the central axis. Preferably, the greatest energy harvesting efficiency is achieved at a tip speed ratio (TSR) values greater than about 2.0, preferably greater than 2.2. Advantageously, it was surprisingly discovered that an MS rotor with an appropriate size, when mounted in the center of a Darrieus rotor, to yield the hybrid VAWT turbine design described herein, can enhance the self-starting capability of the wind turbine system, and facilitate its acceleration to a large TSR, thus maintaining a relatively high energy harvesting efficiency under external load. Other advantages discussed herein include, but are not limited to: (a) The MS VAWT has better self-starting capability compared with the Darrieus one, especially at low wind speed. The larger the size of the inner MS rotor is, the better the observed self-starting performance. However, the inner MS rotor can also adversely affect the final angular velocity of the VAWTs. Specifically, the rotation speed that the HDMS VAWTs can reach at the end of acceleration decreases when the size of the inner MS rotor increases; (b) For a given moment of inertia that supports self-startup under free load, the final angular velocity of both MS and HDMS VAWTs under external load decreases when the damping factor increases; (c) For each type of VAWTs studied, there exists an optimum damping factor which can result in the maximum power coefficient. It was found that for the MS VAWT, the best energy harvesting performance was achieved at a small TSR (i.e., around 1.2); (d) From a measurement of the aerodynamic moment acting on different components of the HDMS VAWTs, it was found that the energy was harvested mainly by the Darrieus blades when the turbines work at the optimum TSR. The wind moment acting on the inner MS rotor increases when its size increases; while at the same time, the wind moment acting on the Darrieus blades significantly decreases due to the interaction between the MS and Darrieus blades. This results in a drop of the total energy harvest efficiency; (e) Preliminary simulation research findings indicate that the HDMS VAWT described herein can continuously harvest wind energy in a wide range of wind speeds (e.g., 1 m/s to 25 m/s), all while providing excellent self-starting capability; (f) The HDMS VAWT disclosed herein has enhanced stability, even at high wind speeds, due to the added stiffness by the inner modified Savonius rotor. The HDMS design can reduce structural vibration, thus leading to longer turbine operating lifetime. In a second aspect, the present invention relates to a method of using the hybrid vertical axis wind (or water) turbine apparatus of the first aspect to convert the potential energy of wind to mechanical/rotational energy and eventually to electrical energy. It should be appreciated that the common central axis of the HDMS VAWT can be arranged to be vertical or horizontal, relative to any surface, for example, the ground or structure, that the apparatus is being placed on. In a third aspect, the present invention relates to a method of using the hybrid vertical axis wind (or water) turbine apparatus of the first aspect to convert the potential energy of water in a body of water to mechanical/rotational energy and eventually to electrical energy. It should be appreciated that the common central axis of the HDMS VAWT can be arranged to be vertical or horizontal, relative to the surface plane of the body of water. Generally, harvesting water energy is similar to harvesting wind energy. In one embodiment, the vertical axis water turbine can be substantially, or fully, immersed in a body of water and the current will drive the turbine to rotate to generate mechanical/rotational energy (see,FIG.3). In one embodiment of the third aspect, tidal current energy is harvested using the HDMS VAWT of the first aspect. The commercialization potential for tidal energy is larger than that for other ocean energy since it can be almost perfectly forecasted over a long-time horizon and is hardly influenced by weather conditions [Uihlein, 2016]. Energy can be generated both day and night. There are vast but untapped tidal energy resources with lower tidal current speeds (1.0˜1.5 m/s) along the U.S. continental shelf edge. The HDMS VAWT described herein will provide improved turbine efficiency, leading to a significant increase in energy yield. In one embodiment, the HDMS VAWT technology described herein is used to harvest hydrokinetic energy at low tidal current speeds. FIG.4is a schematic of a proposed arrangement of a plurality of HDMS VAWT apparatuses in a “fence,” wherein each HDMS VAWT is separated from the other ones by a post. This is advantageous when the HDMS VAWT apparatus is positioned horizontally relative to the surface plane of the body of water, a building or any other surface such as the ground. In one embodiment, the HDMS VAWT apparatuses are fully submerged under the surface of the water. In one embodiment, the HDMS VAWT apparatuses and the posts are fully submerged under the surface of the water. In one embodiment, the HDMS VAWT apparatuses (and posts) are partially submerged in the water. The number of posts can be minimized, and the posts can be used to incorporate at least some of the mechanisms needed to convert the rotational energy to electrical energy. Preferably, the posts are substantially water resistant. Infinitely Variable Transmission The present inventors previously introduced an IVT in [Wang, 2016], which mechanically transmitted a variable input speed to a desired constant output speed with a continuously variable speed ratio. The continuously variable speed ratio of the IVT was adjustable by changing the crank length in the scotch yoke systems (SYSs). The noncircular gear pair was designed to eliminate speed variations of the output speed of the IVT. Advantageously, the IVT designed in [Wang, 2016] can be used for high-torque and low-speed conditions, which can allow a TCEC to virtually operate in its optimal speed range that is independent of the speed of the hydro-turbine to maximize harvesting efficiency. Since the IVT can provide a continuously variable speed ratio, it can ensure high-efficiency performance of a hydro-turbine with a variable tidal current speed. To achieve maximum efficiency over most of the working range of the hydro-turbine, it should operate at a particular value of the tip-speed ratio (TSR). The control strategy of the IVT can be achieved by accurately tracking a prescribed speed ratio reference and simultaneously reducing instantaneous fluctuations of the output speed based on the TSR of the hydro-turbine and the desired output speed of the IVT. High operation performance of IVTs can be achieved by accurately tracking a prescribed input-to-output speed ratio reference and simultaneously reducing instantaneous variations of the input-to-output speed ratio of the IVT. Towards that end, an IVT comprising a nonlinear input-to-output speed ratio control combined with an integral time-delay feedback control is described herein, wherein the input-to-output speed ratio of the IVT system is adjusted for a desired constant output rotational speed with any input and output load. In one embodiment, the input-to-output speed ratio control for the IVT system can comprise a forward speed controller for varying operating conditions, such as input speed and speed ratio changes. In one embodiment, the input-to-output speed ratio control for the IVT system can comprise a crank length controller for varying operating conditions, such as input speed and speed ratio changes. Using the presently described IVT, input-to-output speed ratios of the IVT can achieve an excellent tracking response for the desired constant output rotation speed and reduce speed fluctuations of the output speed of the IVT by the time-delay feedback control. Further, using the present invention, the input-to-output speed ratio and noises of the IVT system can, to a good extent, be eliminated or reduced by the time-delay control. The present invention presents new control strategies with closed-loop controls and an integral time-delay feedback control for the IVT system to improve its control performance. Two closed-loop controllers, a crank length controller and a forward speed controller, track the speed ratio of the IVT that corresponds to the desired rotation speed of the generator and the desired rotation speed of the hydro-turbine, respectively. The time-delay feedback control reduces fluctuations of the output speed of the IVT system. With time-delay feedback control, the resulting control strategy of the IVT system can improve control performance of its speed ratio with large speed variations that is induced by the variable input speed. For the purposes of the instant application, the invention relating to methods of use, a transmission, a transmission control system, and a computer program product according to the present invention can be implemented in any turbine-driven apparatus, for example, the VAWTs described herein. Because the IVT described herein has high efficiency for low and high fluid speeds, the IVT can be included in a power generation system such as a wind, water or hydraulic power generator, wherein the turbine in said system is selected from the group consisting of a horizontal axis fluid (wind or water) turbine, a vertical axis fluid (wind or water) turbine, and a hybrid vertical axis fluid turbine. In a first aspect, an IVT control system is described, said IVT control system comprising: a crank length controller comprising electronic components configured to:determine a desired output rotation speed of an IVT; anddetermine a control signal for a crank length control mechanism based on the determined output rotation speed; and a crank length control mechanism configured to receive the control signal and control the crank length of the IVT based on the control signal. In one embodiment, the desired output rotation speed is determined based on a desired output speed and a desired input speed of the IVT. In one embodiment, the desired output rotation speed is determined based on the equation: ℓcr*=2progwu*4inwn* wherein rogis a pitch radius of an output gear of theis a desired output speed of the IVT, inis the speed ratio of the gear pair, e.g., a noncircular gear pair, andis a desired input speed of the IVT. In one embodiment, the crank length controller is configured to: determine an estimated output rotation speed of the IVT; and determine the control signal for the crank length control mechanism based on the estimated output rotation speed. In one embodiment, the crank length controller is configured to determine the control signal based on the equation: cr=IΔwu, whereincris the crank length, I is an integral gain, and Δwuis a tracking error of the crank length controller. In one embodiment, the crank length controller is configured to change the control signal for adjusting the crank length based on an estimate of the output rotation speed of the IVT. For example, the crank length controller can be configured to use a look-up table to determine the crank length and to determine the control signal. In a second aspect, an IVT control system is described, said IVT control system comprising: an input-control module configured to control a motion conversion module of an IVT; and a forward speed controller comprising electronic components configured to:determine a crank length for the IVT, a desired modulated input speed of the input-control module, and an output torque of an output shaft of the IVT; andoutput a control signal to the input-control module based on the determined crank length, the desired modulated input speed, and the output torque. In one embodiment of the second aspect of the IVT control system, an electronic motor is included and configured to receive the control signal and to control modulation of an input rotation speed of the input-control module based on the control signal. In one embodiment, the forward speed controller comprises a time-delay feedback controller configured to: determine an input speed of the IVT; and adjust the control signal to the input-control module based on a tracking error of the output speed of the IVT. The IVT control system of the second aspect can further comprise at least one of: (I) a crank length controller comprising electronic components configured to:determine a desired output rotation speed of the IVT; anddetermine the crank length based on the desired output rotation speed; (II) a torque sensor operatively connected to the output shaft of the IVT, configured to measure the output torque of the output shaft, and configured to output a signal representative of the measured output torque to the electronic components of the forward speed controller; or (III) both (I) and (II). In a third aspect, an IVT control system is described, said IVT control system comprising a combination of the IVT control system of the first aspect and the IVT control system of the second aspect, said IVT control system thus comprising: a crank length controller comprising electronic components configured to:determine a desired output rotation speed of an IVT; anddetermine a control signal for a crank length control mechanism based on the determined output rotation speed; a crank length control mechanism configured to receive the control signal and control the crank length of the IVT based on the control signal; and an input-control module configured to control a motion conversion module of the IVT; and a forward speed controller comprising electronic components configured to:receive the crank length;determine a desired modulated input speed of the input-control module and an output torque of an output shaft of the IVT; andoutput a control signal to the input-control module based on the determined crank length, the desired modulated input speed, and the output torque. In a fourth aspect, a method for control of an IVT is described, the method comprising: determining a desired output rotation speed of the IVT; and determining a control signal for a crank length control mechanism based on the determined output rotation speed; and at a crank length control mechanism:receiving the control signal; andcontrolling the crank length of the IVT based on the control signal. The method of the fourth aspect can further comprise at least one of: (I) determining the desired output rotation speed based on a desired output speed and a desired input speed of the IVT; (II) determining the desired output rotation speed based on the equation: ℓcr*=2progwu*4inwn* wherein rogis a pitch radius of an output gear of the IVT,is a desired output speed of the IVT, inis the speed ratio of the gear pair, e.g., a noncircular gear pair, andis a desired input speed of the IVT; (III) determining an estimated output rotation speed of the IVT; and determining the control signal for the crank length control mechanism based on the estimated output rotation speed; (IV) determining the control signal based on the equation: cr=IΔwu, whereincris the crank length, I is an integral gain, and Δwuis a tracking error of the crank length controller; (V) changing the control signal for adjusting the crank length based on an estimate of the output rotation speed of the IVT; (VI) using a look-up table to determine the crank length and to determine the control signal; or (VII) any combination of (I)-(VI). In a fifth aspect, a method for control of an IVT is described, the method comprising: determining a crank length for the IVT, a desired modulated input speed of an input-control module, and an output torque of an output shaft of the IVT, wherein the input-control module is configured to control a motion conversion module of an IVT; and outputting a control signal to the input-control module based on the determined crank length, the desired modulated input speed, and the output torque. The input-control module can includes an electronic motor configured to receive the control signal and to control modulation of an input rotation speed of the input-control module based on the control signal. The method of the fifth aspect can further comprise at least one of: (I) determining a desired output rotation speed of the IVT; and determining the crank length based on the desired output rotation speed; (II) providing a torque sensor operatively connected to the output shaft of the IVT; and using the torque sensor to measure the output torque of the output shaft; (III) determining an input speed of the IVT; and adjusting the control signal to the input-control module based on a tracking error of the output speed of the IVT; or (IV) any combination of (I)-(III). In a sixth aspect, a computer program product comprising a computer readable storage medium having program instructions embodied thereon, the program instructions executable by a computing device to cause the computing device to control an IVT system or carry out a method of controlling an IVT by: determining a desired output rotation speed of an IVT; and determining a control signal for a crank length control mechanism based on the determined output rotation speed; and generating an output representative of the control signal for input into the crank length control mechanism. In one embodiment, the computer readable storage medium is non-transitory. In a seventh aspect, a computer program product comprising a computer readable storage medium having program instructions embodied thereon, the program instructions executable by a computing device to cause the computing device to control an IVT system or carry out a method of controlling an IVT by: determining a crank length for the IVT, a desired modulated input speed of an input-control module, and an output torque of an output shaft of the IVT, wherein the input-control module is configured to control a motion conversion module of an IVT; and outputting a control signal to the input-control module based on the determined crank length, the desired modulated input speed, and the output torque. In one embodiment, the computer readable storage medium is non-transitory. It should be appreciated that the IVT control systems described in the first, second and third aspects of the invention, the methods of controlling an IVT described in the fourth and fifth aspects of the invention, and the computer program products of the sixth and seventh aspects can comprise any IVT known in the art. In other words, although the instant invention will be described for use with a specific IVT, it is not limited to same. In one embodiment, the IVT control systems described in any of the first-seventh aspects of the invention comprise an IVT comprising a pair of meshed gears, an input-control module, and a motion conversion module. In another embodiment, the IVT control systems described in any of the first-seventh aspects of the invention comprise an IVT comprising a pair of meshed gears, an input-control module, and a motion conversion module, wherein the input-control module comprises a first and a second planetary gear set positioned on a secondary shaft, an active control gear positioned on a control shaft, and an idler control gear positioned on an idler shaft, wherein speeds of the control shaft and the idler shaft are controlled by an actuator, wherein the motion conversion module comprises a first and a second scotch yoke system positioned on an input shaft, a transmitting shaft, and an output shaft, wherein a driving gear is positioned on the input shaft and wherein a driven gear is positioned on the secondary shaft, wherein a combination of an input speed from the secondary shaft and speeds of the control shaft and idler shaft constitute an output from the input-control module to the motion conversion module through the first and second planetary gear sets, respectively, wherein output speeds of the first and second planetary gear sets are input speeds of the first scotch yoke system and an output speed of the second planetary gear set is directly transmitted as an input speed to the second scotch yoke system via the transmitting shaft, wherein a combination of input speeds of the first and second scotch yoke systems are converted to translational speeds which are subsequently converted to rotational speeds of four output gears positioned on the output shaft through four rack-pinion meshings, and wherein the rotational speeds of the four output gears are rectified by one-way bearings and transmitted to the output shaft as an IVT output speed. The individual gears in the “pair of meshed gears,” or “gear pair,” in the IVT can be substantially circular or noncircular. In one embodiment, the gear pair comprises two substantially circular gears. In another embodiment, the gear pair comprises two noncircular gears. Importantly, the noncircular gear pair was designed to eliminate speed variations or fluctuations of the output speed of the IVT. The input shaft is connected to a prime mover as defined herein. In one embodiment, the actuator comprises a stepper motor. The present subject matter may be a system, a method, and/or a computer program product. The computer program product may include a computer readable storage medium (or media) having computer readable program instructions thereon for causing a processor to carry out aspects of the present subject matter. The computer readable storage medium can be a tangible device that can retain and store instructions for use by an instruction execution device. The computer readable storage medium may be, for example, but is not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the foregoing. A non-exhaustive list of more specific examples of the computer readable storage medium includes the following: a portable computer diskette, a hard disk, a RAM, a ROM, an erasable programmable read-only memory (EPROM or Flash memory), a static random access memory (SRAM), a portable compact disc read-only memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanically encoded device such as punch-cards or raised structures in a groove having instructions recorded thereon, and any suitable combination of the foregoing. A computer readable storage medium, as used herein, is not to be construed as being transitory signals per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiber-optic cable), or electrical signals transmitted through a wire. Computer readable program instructions described herein can be downloaded to respective computing/processing devices from a computer readable storage medium or to an external computer or external storage device via a network, for example, the Internet, a local area network, a wide area network and/or a wireless network, or Near Field Communication. The network may comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and/or edge servers. A network adapter card or network interface in each computing/processing device receives computer readable program instructions from the network and forwards the computer readable program instructions for storage in a computer readable storage medium within the respective computing/processing device. Computer readable program instructions for carrying out operations of the present subject matter may be assembler instructions, instruction-set-architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state-setting data, or either source code or object code written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++, Javascript or the like, and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The computer readable program instructions may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider). In some embodiments, electronic circuitry including, for example, programmable logic circuitry, field-programmable gate arrays (FPGA), or programmable logic arrays (PLA) may execute the computer readable program instructions by utilizing state information of the computer readable program instructions to personalize the electronic circuitry, in order to perform aspects of the present subject matter. Aspects of the present subject matter are described herein with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the subject matter. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer readable program instructions. These computer readable program instructions may be provided to a processor of a computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. These computer readable program instructions may also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and/or other devices to function in a particular manner, such that the computer readable storage medium having instructions stored therein comprises an article of manufacture including instructions which implement aspects of the function/act specified in the flowchart and/or block diagram block or blocks. The computer readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions/acts specified in the flowchart and/or block diagram block or blocks. The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present subject matter. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions. Tidal Current Energy Converters In one aspect, a TCEC is described comprising at least one infinitely variable transmission (IVT) and at least one vertical axis water turbine (VAWT). In one embodiment, at least one IVT of the TCEC comprises a nonlinear closed-loop control combined with an integral time-delay feedback control. In one embodiment, at least one IVT of the TCEC comprises an IVT control system comprising a crank length controller. In one embodiment, at least one IVT of the TCEC comprises an IVT control system comprising a forward speed controller. In one embodiment, at least one IVT of the TCEC comprises an IVT control system comprising a crank length controller and a forward speed controller. In one embodiment, the at least one VAWT comprises a hybrid VAWT. In one embodiment, the hybrid VAWT comprises a modified-Savonius (MS) rotor in the central region and a straight bladed H-type Darrieus rotor in the surrounding annular region. In one embodiment, a common central axis of the at least one VAWT can be arranged to be vertical or horizontal, relative to any surface. In one embodiment, a common central axis of the at least one VAWT can be arranged to be vertical or horizontal, relative to the surface plane of the body of water. In one embodiment, the at least one VAWT is fully submerged in water. In one embodiment, the at least one VAWT is partially submerged in water. In one embodiment, the TCEC comprises at least one IVT comprising an IVT control system of the first aspect, said IVT control system comprising: a crank length controller comprising electronic components configured to:determine a desired output rotation speed of an IVT; anddetermine a control signal for a crank length control mechanism based on the determined output rotation speed; and a crank length control mechanism configured to receive the control signal and control the crank length of the IVT based on the control signal. In one embodiment, the TCEC comprises at least one IVT comprising an IVT control system of the second aspect, said IVT control system comprising: an input-control module configured to control a motion conversion module of an IVT; and a forward speed controller comprising electronic components configured to:determine a crank length for the IVT, a desired modulated input speed of the input-control module, and an output torque of an output shaft of the IVT; andoutput a control signal to the input-control module based on the determined crank length, the desired modulated input speed, and the output torque. In one embodiment, the TCEC comprises at least one IVT comprising an IVT control system of the first and second aspect, said IVT control systems comprising: a crank length controller comprising electronic components configured to:determine a desired output rotation speed of an IVT; anddetermine a control signal for a crank length control mechanism based on the determined output rotation speed; a crank length control mechanism configured to receive the control signal and control the crank length of the IVT based on the control signal; and an input-control module configured to control a motion conversion module of the IVT; and a forward speed controller comprising electronic components configured to:receive the crank length;determine a desired modulated input speed of the input-control module and an output torque of an output shaft of the IVT; andoutput a control signal to the input-control module based on the determined crank length, the desired modulated input speed, and the output torque. In one embodiment, the TCEC comprises at least one hybrid VAWT of the first aspect comprising: (a) a first rotor system positioned in a central region and rotatable about a central axis, wherein the first rotor system comprises: a plurality of first blades, each having a concave shape that allows fluid to push on a concave side of each first blade; and a hydraulic brake system that is mounted upon the shaft with bearings; and (b) a second rotor system positioned in an annular region surrounding the first rotor system in the central region, wherein the second rotor system comprises a plurality of second blades spaced about the central axis, wherein the cross-section of each second blade is a substantially symmetrical airfoil shape. In one embodiment, the TCEC comprises at least one hybrid VAWT of the first aspect comprising: (a) a first rotor system positioned in a central region and rotatable about a central axis, wherein the first rotor system comprises:(i) at least two blade-sets stacked vertically along the central axis, each blade-set comprising a plurality of first blades that are spaced about the central axis, wherein the at least two blade-sets are mounted upon a shaft with bearings along the central axis, wherein each first blade extends from a position proximate to the central axis out to a position distal to the central axis and has a concave shape that allows fluid to push on a concave side of each first blade, and(ii) a hydraulic brake system that is mounted upon the shaft with bearings; and (b) a second rotor system positioned in an annular region surrounding the first rotor system in the central region, wherein the second rotor system comprises a plurality of second blades spaced about the central axis, wherein each of the second blades is positioned substantially parallel to the central axis and attached to at least one blade-set of the first rotor system using at least two supporting struts, wherein the cross-section of the second blade is a substantially symmetrical airfoil shape. In one embodiment, the TCEC comprises: (A) at least one IVT comprising an IVT control system of the first aspect, said IVT control system comprising: a crank length controller comprising electronic components configured to:determine a desired output rotation speed of an IVT; anddetermine a control signal for a crank length control mechanism based on the determined output rotation speed; and a crank length control mechanism configured to receive the control signal and control the crank length of the IVT based on the control signal; and (B) at least one hybrid VAWT of the first aspect comprising: (a) a first rotor system positioned in a central region and rotatable about a central axis, wherein the first rotor system comprises: a plurality of first blades, each having a concave shape that allows fluid to push on a concave side of each first blade; and a hydraulic brake system that is mounted upon the shaft with bearings; and (b) a second rotor system positioned in an annular region surrounding the first rotor system in the central region, wherein the second rotor system comprises a plurality of second blades spaced about the central axis, wherein the cross-section of each second blade is a substantially symmetrical airfoil shape. In one embodiment, the TCEC comprises: (A) at least one IVT comprising an IVT control system of the second aspect, said IVT control system comprising: an input-control module configured to control a motion conversion module of an IVT; and a forward speed controller comprising electronic components configured to:determine a crank length for the IVT, a desired modulated input speed of the input-control module, and an output torque of an output shaft of the IVT; andoutput a control signal to the input-control module based on the determined crank length, the desired modulated input speed, and the output torque; and (B) at least one hybrid VAWT of the first aspect comprising: (a) a first rotor system positioned in a central region and rotatable about a central axis, wherein the first rotor system comprises: a plurality of first blades, each having a concave shape that allows fluid to push on a concave side of each first blade; and a hydraulic brake system that is mounted upon the shaft with bearings; and (b) a second rotor system positioned in an annular region surrounding the first rotor system in the central region, wherein the second rotor system comprises a plurality of second blades spaced about the central axis, wherein the cross-section of each second blade is a substantially symmetrical airfoil shape. In one embodiment, the TCEC comprises: (A) at least one IVT comprising an IVT control system of the first aspect, said IVT control system comprising: a crank length controller comprising electronic components configured to:determine a desired output rotation speed of an IVT; anddetermine a control signal for a crank length control mechanism based on the determined output rotation speed; and a crank length control mechanism configured to receive the control signal and control the crank length of the IVT based on the control signal; and (B) at least one hybrid VAWT of the first aspect comprising: (a) a first rotor system positioned in a central region and rotatable about a central axis, wherein the first rotor system comprises: (i) at least two blade-sets stacked vertically along the central axis, each blade-set comprising a plurality of first blades that are spaced about the central axis, wherein the at least two blade-sets are mounted upon a shaft with bearings along the central axis, wherein each first blade extends from a position proximate to the central axis out to a position distal to the central axis and has a concave shape that allows fluid to push on a concave side of each first blade, and (ii) a hydraulic brake system that is mounted upon the shaft with bearings; and (b) a second rotor system positioned in an annular region surrounding the first rotor system in the central region, wherein the second rotor system comprises a plurality of second blades spaced about the central axis, wherein each of the second blades is positioned substantially parallel to the central axis and attached to at least one blade-set of the first rotor system using at least two supporting struts, wherein the cross-section of the second blade is a substantially symmetrical airfoil shape. In one embodiment, the TCEC comprises: (A) at least one IVT comprising an IVT control system of the second aspect, said IVT control system comprising: an input-control module configured to control a motion conversion module of an IVT; and a forward speed controller comprising electronic components configured to:determine a crank length for the IVT, a desired modulated input speed of the input-control module, and an output torque of an output shaft of the IVT; and output a control signal to the input-control module based on the determined crank length, the desired modulated input speed, and the output torque; and (B) at least one hybrid VAWT of the first aspect comprising: (a) a first rotor system positioned in a central region and rotatable about a central axis, wherein the first rotor system comprises: (i) at least two blade-sets stacked vertically along the central axis, each blade-set comprising a plurality of first blades that are spaced about the central axis, wherein the at least two blade-sets are mounted upon a shaft with bearings along the central axis, wherein each first blade extends from a position proximate to the central axis out to a position distal to the central axis and has a concave shape that allows fluid to push on a concave side of each first blade, and (ii) a hydraulic brake system that is mounted upon the shaft with bearings; and (b) a second rotor system positioned in an annular region surrounding the first rotor system in the central region, wherein the second rotor system comprises a plurality of second blades spaced about the central axis, wherein each of the second blades is positioned substantially parallel to the central axis and attached to at least one blade-set of the first rotor system using at least two supporting struts, wherein the cross-section of the second blade is a substantially symmetrical airfoil shape. It should be appreciated that the embodiments of the first aspect of the TCEC can further comprise a computer program product comprising a computer readable storage medium having program instructions embodied thereon, the program instructions executable by a computing device to cause the computing device to control an IVT system or carry out a method of controlling an IVT. As seen inFIG.13, the IVT can be positioned between two VAWTs, e.g., the hybrid VAWTs described herein. In one embodiment, an IVT is positioned in or on a post supporting two hybrid VAWTs.FIG.13is not intended to limit the scope of the TCECs, which can comprise 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more, VAWTs with at least one IVT, wherein the ratio of VAWT/IVT in the TCEC is greater than or equal to 1. In one embodiment, a computing device comprising a computer program product comprising a computer readable storage medium having program instructions embodied thereon to cause the computing device to control an IVT system or carry out a method of controlling an IVT is positioned in or on the TCEC in proximity of the IVT. In one embodiment, a computing device comprising a computer program product comprising a computer readable storage medium having program instructions embodied thereon to cause the computing device to control an IVT system or carry out a method of controlling an IVT is remotely positioned relative to the location of the TCEC comprising at least one IVT. It should also be appreciated that the TCEC described herein comprising at least one infinitely variable transmission (IVT) control system and at least one vertical axis wind (or water) turbine (VAWT) can comprise any IVT known in the art or any VAWT known in the art. It should be appreciated that the method of using, and computer products of, the TCEC can correspond to the methods and computer products described herein when the TCEC comprises the specific VAWT or IVT control system, as understood by the person skilled in the art. It should further be appreciated that the TCEC can comprise the IVT control system described herein and a horizontal axis water or wind turbine, as understood by the person skilled in the art. EXAMPLE Dynamic Model of the IVT System A schematic drawing of the IVT that is presented in Wang and Zhu [Wang, 2016] is shown inFIG.5. The IVT comprises a noncircular gear pair, an input-control module (ICM), and a motion-conversion module (MCM). It should be appreciated by the person skilled in the art that the gear pair can comprise two substantially circular gears. An input rotational speed is first transmitted from the noncircular gear pair to the ICM. Driving and driven noncircular gears are installed on the input shaft and secondary shaft, respectively. With the modulation effect of the noncircular gear pair, a modulated input speed is translated to the secondary shaft in the ICM. A stepper motor mounted on the control shaft in the ICM is used to provide a control speed for adjustment of the input-to-output speed ratio of the IVT. The control speed and modulated input speed are combined by two 2K-H planetary gear sets (PGSs) on the secondary shaft in the ICM. Combined speeds of ring gears of two PGSs are transmitted to SYSs in the MCM. Two SYSs transmit the combined speeds to translational speeds of yokes; four meshed rack-pinion sets then convert translational speeds of yokes to rotational speeds of four output gears. The output speed of the IVT is the maximum rotational speed of four output gears that are rectified by one-way bearings. The IVT was designed for the conversion of variable power from the prime mover to a constant output speed with a continuously variable speed ratio. The input rotational speed and the input torque that are loaded on the input shaft are denoted as wpand tp, respectively. The output rotation speed and the output torque of the output shaft of the IVT are denoted as wuand tu, respectively. The input-to-output speed ratio i of the IVT is defined as i=wp/wu. The input rotational speed wpis transmitted from the DC motor to the gear pair, as shown inFIG.5. The rotational speed wnof the driven gear (NG2) that is the modulated rotation speed of the ICM can be represented as wn=wpin(1) where inis the speed ratio of the gear pair, e.g., a noncircular gear pair. Based on the kinematic model of the IVT in [Li, 2021], the speed ratio of the IVT can be represented as i=wpwu=2prog4ℓcr(2) Since the pitch radius rogof the output gear is constant, the input-to-output speed ratio of the IVT is determined by the crank lengthcr. The crank lengthcris changed with the rotation angle θsgof control gears that can be obtained by θsg=∫ωsgdt. The IVT system includes a permanent magnetic DC motor that provides the power required to operate the IVT system, a magnetic brake that provides a variable load for the IVT system, and the IVT. There are two submodels in the dynamic model of the IVT system, i.e., a dynamic model of the magnetic DC motor and a dynamic model of the IVT. There are also some assumptions that all components of the IVT system are considered as rigid bodies and friction in the IVT system is neglected. In the experimental setup of the IVT system, the input speed wpand the input torque tpare provided by the permanent magnetic DC motor. A dynamic model of the permanent magnetic DC motor can be represented as {LaI˙a=-RaIa-kewp+VpJn1w.p=ktIa-bwp-tp(3) where Lais the armature inductance, Rais the armature resistance, Iais the armature current, keis the velocity constant, Vpis the supply (armature) voltage of the DC motor, Jn1is the moment of inertia of the driving gear (NG1), e.g., a noncircular gear, ktis the torque constant, b is the damping coefficient, and the overdot means time differentiation. Substituting Eq. (1) into Eq. (3), the input torque of the IVT system can be represented as tp=ktRaVp-ktkeRainwn-Jn1inw.n-Jn1wn2dindqn(4) where the partial derivative of inwith the respect to qncan be represented as dindqn=-p22sin(mod(qn+p4,p2)-p4)(5) in which mod(qn+p4,p2) means the remainder of the division of qn+p4byp2. Rotational speeds wrof ring gears of PGSs are proportional to the rotational speed wnof the driven gear (NG2), e.g., a noncircular gear. The rotational speed wrof crank gears and the rotational speed of the cranks wcrare also proportional to the rotational speed wnof the driven gear in the ICM. The kinetic energy of the ICM can be represented as T1=12Jawn2(6) where Jais the effective moment of inertia of the kinetic energy with respect to wn, i.e., Ja=0.0346 kg·m2. Translational speeds of yokes of two SYSs and rotational speeds of four output gears are proportional tocrwn. The kinetic energy of SYSs and output gears can be represented as T2=12Jbℓcr2wn2(7) where Jbis the effective mass of the kinetic energy with respect tocrwn, i.e., Jb=2.9 kg. Rotational speeds of the output shaft and the brake are proportional to incrwn. The kinetic energy of the output shaft and the brake can be represented as T3=12Jcin2ℓcr2wn2(8) where Jcis the effective mass of the kinetic energy with respect to incrwn, i.e., Jc=36 kg. The potential energy of the IVT is Vt=mrg[cos(qn)−sin(qn)]cr(9) where mris the mass of a roller, i.e., mr=1 kg, and g is the gravitational acceleration. The generalized force of the IVT system can be represented as Qt=intp-22progintu(10) The total kinetic energy of the IVT can be represented as Ttotal=T1+T2+T3−Vt(11) Based on Lagrange's equations, the system equation of the IVT system can be represented as ddt∂Ttotal∂wn-∂Ttotal∂qn=Qt(12) With Eqs. (4), (10), and (12), a dynamic equation of the IVT system can be represented as J(qn,ℓcr)q¨n=G(qn)ℓcr-12Jq(qn)q.n2-Vk(qn)q.n+Fp(qn,Vp)-Fu(qn,tu)ℓcr(13) where J(qn,cr) is the sum of moments of inertia of components in the IVT system that can be represented as J(qn,cr)=Ja+Jbin2+Jcin2cr2+Jn1cr2(14) G (qn) is the gravitational acceleration function of the potential energy of the IVT system that can be represented as G(qn)=g[sin(qn)+cos(qn)] (15) Jq(qn) is the derivative of the sum of moments of inertia of the IVT system with respect to, which can be represented as Jq(qn)=2(Jcℓcr2+Jn1)indindqn(16) Vk(qn) is the kinetic energy of the IVT system with respect tothat can be represented as Vk(qn)=ktkeRain2(17) Fp(qn,Vp) is the kinetic energy generated by the DC motor, which can be represented as Fp(qn,Vp)=ktRainVp(18) and Fu(qn,tu) is the kinetic energy generated by the brake, which can be represented as Fu(qn,tu)=22progintu(19) Based on Eq. (22), the input-to-output speed ratio i of the IVT is determined by the rotational angle qsg1of the first control gear which is equal to the rotational angle qsof the control shaft. The rotational angle qsof the control shaft is controlled by the stepper motor that can be represented as qs=qsg1=pVsnsprLsIs(20) where Vs, Ls, and Isare the applied voltage, the armature inductance, and the armature current of the stepper motor, respectively, and nspris the number of steps per revolution. Based on Eqs. (2) and (20), the crank lengthcrcan be also represented as ℓcr=pVs2nsprLsIs(21) Nonlinear Model-Based IVT Controllers FIG.6shows the block diagram of the control scheme of the IVT system. The control problem addressed herein is the feedback design for two IVT controllers, which are a crank length controller and a forward speed controller. The input-to-output speed ratio i of the IVT system is controlled by the forward speed controller and the crank length controller. The crank length controller is designed to adjust the speed ratio for any desired output speed of the IVT. The forwards speed controller is used to track a desired input speed for maximizing efficiency of the prime mover with time-delay feedback control that can reduce speed fluctuations of the output speed. Since the dynamic performance of the IVT system strongly depends on the rotational angle qnof the gear, e.g., a noncircular gear, and the crank lengthcraccording to Eq. (13), the control behavior and the input-to-output speed ratio change with the rotational speed wpof the DC motor and the rotational angle qsof the stepper motor. Hence, the goal of the control strategy of the IVT system is to make the average of the output speed wnof the IVT over 2 p in qnconverge to a desired output speed for any Vpand tuthat are input and output loads, respectively, by adjusting the crank lengthcr, while the DC motor operates on the rotational speed of the prime mover (e.g., automobile, hydro-turbine, etc.). Detailed control objectives include: the crank length controller generates a desired crank length*crthat depends on the speed ratio of the desired input speedand the output speedrequired in the IVT system; and the forward speed controller forces the modulated input speed wnof the ICM to approach the desired input speed. Additionally, the time-delay feedback controller can reduce speed fluctuations of the output speed. i. Crank Length Controller The crank length controller involves a crank length forward control and a crank length feedback control. Based on Eq. (2), the crank length forward control is designed to calculate the desired crank length that can be represented as ℓcr*=2progwu*4inwn*(22) A look-up table is developed for the shift schedule of the crank length controller based on the maximal crank lengthcrmax. If the calculated crank length is smaller than or equal to the maximal crank lengthcrmax, the crank lengthcris a function of the desired modulated input speedand the desired output speed, which is denoted as(;); if the calculated crank length is larger than the maximal crank lengthcrmax, the crank lengthcris set to the maximal crank lengthcrmax. In order to distinguish different cases in the look-up table based on the armature voltage Vpof the DC motor and the output torque tuof the output shaft, a boundary function of the crank length controller in working regions of the armature voltage Vpof the DC motor and the output torque tuof the output shaft can be defined by =(;)−cr max(23) which is shown inFIG.7. Hence the look-up table of the crank length controller of the IVT system can be represented as ℓcr(wu*;wn*)={ℛ(wu*;wn*),ifℏ≤0ℓcrmax,ifℏ>0(24) The crank length feedback control is designed to adjust the crank length of the IVT for the desired output speed. Since one has no access to the mean output speed wnof the IVT in real time, the average of the output speed of the IVT in a period of 2 p prior to the current rotation position is used as a feedback variable. The tracking error of the crank length controller can be represented as Δwu=wu*-2p∫qn(t)-2pqn(t)1wuds(25) The crank length controller can be represented as cr=lΔwu(26) where l is the integral gain that is used to control the changing rate of the crank length, which can be determined in control experiments. In order to achieve control of the output speed wuof the IVT, the average of the tracking error Δwuin a period of 2 p needs to asymptotically approach zero. The crank lengthcrthat is generated by the crank length controller is used in the forward speed controller. ii. Forward Speed Controller An input speed forward control was designed to obtain the corresponding armature voltage Vpof the DC motor to the desired modulated input speed. The modulated input speed wuof the ICM is a periodic variable and the rotation angle qnof the driven gear, e.g., a noncircular gear, can be represented as qn(t)=∫0twn(t)ds. Since the modulated input speed wnof the ICM is always positive, the dynamic equation of the IVT system can be represented as (27) J(qn,ℓcr)wnwn′=M-12Jq(qn)wn2-Vk(qn)wn(27) where a prime denotes the derivative of a function with respect to qn, wn{acute over (w)}nis equal to {dot over (w)}, Jq(qn) is the derivative of the sum of moments of inertia of the IVT system with respect to qn, Vk(qn) is the kinetic energy of the IVT system, and M=G(qn)cr+Fp(qn,Vp)−Fu(qn,tu)cr(28) where G(qn) is the gravitational acceleration function of the potential energy of the IVT system, Fp(qn,Vp) is the kinetic energy generated by the DC motor, and Fv(qn, tu) is the kinetic energy generated by the brake. A coordinate transform is defined as t(qn)=∫0qn1wnds based on the bijective map between qnandcr. The right-hand side of Eq. (27) is continuous with respect to wn, and existence of a periodic solution of Eq. (27) and its convergence have been proven [Wang, 2018]. As mentioned above, the control goal is to operate the rotation speed of the DC motor to force the modulated input speedwith qn=t+Δqn, wherein Δqnis a periodic variable with the zero mean. To quantify the control goal of the forward speed controller, the tracking error of the forward speed controller is defined as Δwn=−wn(29) wherewnis the average of the modulated input speed wnof NG2in a period of 2 p prior to the current rotation position. The time-delay variable can be represented as [Wang, 2018] w_n=2p∫qn(t)-2pqn(t)1wnds(30) In order to achieve control of the modulated input speed Δwnof the ICM, the average of the tracking error Δwnin a period of 2 p needs to asymptotically approach zero as the rotation angle qnof the driven gear increases; hence, Eq. (29) should approach zero. According to Eqs. (14), (16), and (28), J, Jq, and M are functions of qn,cr, Vp, and tu. The crank lengthcris generated by the crank length controller. The output torque tuof the output shaft can be measured by the torque meter, but cannot be controlled. The armature voltage Vpof the DC motor can serve as the control variable of the forward speed controller. The time-delay feedback control of the IVT system can be represented as {Jwn′=Mwn-12Jq(qn)wn-Vk(qn)Vp′=I1Δwn+I2(wn-wT)(31) where I is the integral gain, I2is the damping gain, and wT=wn(qn−2 p). The goal of the time-delay feedback control is to select I1and I2for fast convergence of Eq. (31) to the desired armature voltage Vpof the DC motor and the output torque tuof the output shaft in their working regions that are Vp∈[2, 12] V and tu∈[1.5, 9] Nm, respectively. IVT Experimental Setup The IVT system as it is during control tests is shown inFIG.8. This experimental setup of the IVT system consists of an IVT, a permanent DC motor, a magnetic brake, a stepper motor, two torque sensors, and three angular encoders. The control speed of control gears is provided by a stepper motor. The magnetic brake mounted on the output shaft is used to provide a constant torque for loading the gear system meshes while the DC motor provides the power required to operate the IVT system at any desired input rotational speed value. Three angular encoders are mounted on the input shaft, the secondary shaft, and the output shaft of the IVT to measure the corresponding rotational angles, respectively. Meshed gears, scotch yoke systems, and bearings of the IVT are lubricated by Gear Oil VG100 during control tests to provide favorable lubrication conditions to minimize friction and damping. All shafts of the IVT are supported by oversized bearings and a rigid housing to ensure that translational motions and torsional vibration of gear trains are small. The DC motor and the magnetic brake are both mounted on rigid pedestals and connected to the corresponding shafts by couplings to eliminate the eccentric effect. The complete implementation of the proposed control strategy for the IVT system was performed using LABVIEW. National Instruments devices are used to build the controllers for the IVT system. A data acquisition (DAQ) unit was used to sample signals from three angular encoders that were installed on the input shaft, the secondary shaft, and the output shaft of the IVT, and transfers these signals to a computer. A schematic diagram is shown to explain in detail the overall operation of the control system for the IVT system, as shown inFIG.9. According to the input data of three-day tidal speed data, an acceleration control test is performed based on averaging every four data points of tidal speeds to reduce the test time from 72 to 18 h. The proposed control strategy for controlling the modulated input speed wnof the input-control module and the crank lengthcrof the IVT system were implemented in the IVT system according to the following procedure: Step 1: The implementation used the same control strategy for the forward speed controller and the crank length controller described in “Crank length Controller.” The desired output speed for control tests was set to 300 rpm. Step 2: The input speed wp(t) of the input shaft of the IVT was determined by the desired modulated input speed(kT) of the ICM, and was converted to the voltage percentage of the DC motor. Step 3: The proposed control strategy of the IVT system was discretized with a sampling time of T=5 ms. The time interval for each control loop was set to 0.1 s. Step 4: With signals from the angular encoder on the input shaft, the forward speed controller built in the computer generates control signals for the modulated input speed wn(t) of the ICM, and the control signals were transferred to the DC motor by the time-delay feedback controller. The gains I1and I2in the time-delay feedback control are set as 0.015 and 0.021 mm/rad−1, respectively. Step 5: The DAQ generated a signal sequence with signals of the output speed wn(kT) from the angular encoder on the output shaft, and outputs it to the crank length controller. The expected input-to-output speed ratio was changed to the next value by changing the crank lengthcr, which is controlled by the rotation angle of the control shaft based on Eq. (2). The integral gain I in the crank-length controller is set as 0.0145 mm/rad−1. The rotation angle of the control shaft was driven by the stepper motor to reach the expected rotation angle. The stepper motor was controlled by the crank length controller through the motion control interface to finish the current control loop. System Identification To develop the control model that is applicable to a desired speed ratio of the IVT system, system parameters and continuous time signals of the DC motor and the IVT are identified and used to describe nominal behaviors of the IVT system. The pursued approach to obtain these system parameters of an approximation model of the true IVT system is to perform experiments on the closed-loop system in FIG.6. The DC motor of the IVT system is considered as one unit here. The manipulated variable is the armature voltage Vp(t) of the DC motor. Measured signals of the DC motor are the armature voltage {circumflex over (V)}p, the armature current Îa, the input torque {circumflex over (t)}p, and the angular velocity ŵp. System parameters of the DC motor are shown in Table. 1. It is understood by the person skilled in the art that these system parameters represent one embodiment of a DC motor and are not intended to limit the invention in any way. TABLE 1System Parameters of the DC MotorItemValueArmature inductance La(mH)1.476Armature resistance Ra(Ω)0.487Torque constant kt(Nm/A)0.0479Damping coefficient β0.43Moment of Inertia of NG1 Jn1(kg · m2)0.0214Velocity constant ke(V/rad/s)0.048 System parameters of the IVT that are the nonlinear part of the IVT system can be estimated based on the system parameters of the DC motor. Output signals of the output torque {circumflex over (t)}pof the IVT can be transformed to frequency domain via discrete Fourier transform (DFT) for a standard DFT grid Ωpthat is Ωp={0.05;0.10;0.20;0.30;0.40;0.50;0.60;0.70;0.80, . . . ,1.0;2.0;3.0;4.0;5.0;6.0;7.0;8.0;9.0;10.0, . . . ,14.0;18.0;22.0;26.0;30.0;34.0;38.0;42.0;46.0} (32) Based on Eqs. (27) and (28), the discretizing continuous-time model of the IVT system with k=t/t0. To avoid excessive amplitudes of input signals of the armature voltage {circumflex over (V)}pof the DC motor, the phases φiof input signals of the armature voltage {circumflex over (V)}pof the DC motor are chosen based on Schroeder phases [Isermann, 2011]. Estimated frequency response functions of the output rotation speed and the output torque of the IVT system are wˆu=-13.712+1.88×10790.551p2e-2(wi+189.03390.551)(33)t^u=-23.661+8.998×106104.761p2e-2(wi+203.45104.761)(34) respectively, where wi∈Ωp, and the subscript i denotes the ith frequency. Based on the least squares method, one has Γ=∑i=129❘"\[LeftBracketingBar]"wu(k)-wˆu(wi)❘"\[RightBracketingBar]"2+∑i=129❘"\[LeftBracketingBar]"tu(k)-t^u(wi)❘"\[RightBracketingBar]"2(35) System parameters Ja, Jb, and Jcof the IVT can be obtained by minimizing Eq. (35), as shown in Table2. Results of frequency response functions of the IVT system are based on multiple harmonics of the fundamental frequency of the IVT system, as shown inFIGS.10A and10B. TABLE 2System parameters of the IVTParameterValueEffective moment of inertia of the kinetic energy Ja(kg m2′)0.0346Effective mass of the kinetic energy Jb(kg)2.9Effective mass of the kinetic energy Jc(kg)36 Tidal Resource and Hydro-Turbine Assessment Chesapeake Bay, which is the largest bay in the US, is approximately 315 km long and 4.2 to 56 km wide and has a surface area of nearly 11,601 km2[Xiong, 2010]. In this experiment, tidal current speed measurement was deployed at the 20 m depth of water at the mouth of Chesapeake Bay, just east of the Bay Bridge tunnel, as shown inFIG.11. Three-day tidal current speed data of the deployed location in Chesapeake Bay was retrieved from the National Oceanic and AtmosphericAdministration [Earwaker, 1999], as shown inFIG.12. These three days inFIG.12are denoted as Day 1, Day 2, and Day 3 herein. The positive value of the tidal current speed means tidal flows from Chesapeake Bay to Atlantic Ocean, whilethe negative value means the tidal flows are in the opposite direction. Magnitudes of the positive and negative directions of tidal speed ranges are approximately 1.62 m/s and 0.71 m/s, respectively. The IVT was used in a TCEC which comprised two cross-flow turbines (CFTs), an IVT, and a doubly-fed induction generator, as shown inFIG.13. The CFT used in this example is a hybrid vertical axis wind (or water) turbine apparatus comprising a modified-Savonius (MS) rotor in the central region and a straight bladed H-type Darrieus rotor in the surrounding annular region, as described herein in aspects x-x. Each CFT is 2 m in diameter and 5 m long, with a 20 m mean depth. The TCEC can generate 35 kW at a tidal current speed of 1.5 m/s. In order to maintain high harvesting efficiency of CFTs at both low and high tidal currentspeeds, the TSR of CFTs are kept at its optimal value, which for the purposes of this experiment was 2 [Liu, 2019]. i. Experimental Control Results for Rotation Speeds of the CFT Control tests on the performance of the proposed control strategy of the IVTsystem were conducted on the test rig inFIG.8. The maximal crank lengthcrwas set to 12. Control tests for variable tidal speeds were performed to validate the control strategy with variable speed ratios. The input speed of the input shaft of the IVT and the calculated rotation speed of CFTs were obtained based on their TSR and the tidal current speed. The average output speedwuwas sampled over a duration of each rotation of the output shaft to obtain its average value. Experimental average speed ratios can be obtained by dividing the input speeds wpby the average output speedswu. The control performance of the proposed control strategy of the IVT system was evaluated in a control test using the variable calculated rotation speed of CFTs. The control test for a variable input speed was performed to validate the control strategy by keeping the output speed constant, which is 300 rpm, with the variable rotation angle θsof the control shaft. The variable input speed profiles of three-day tidal speed data that was applied in the control test is shown inFIGS.14A-14C.FIGS.14A-14Calso exhibits the tracking performance of the forward speed controller for the variable rotation speed of CFTs. Maximum errors between experimental results of input speeds and the calculated rotation speed of CFTs corresponding to tidal speed data of Day 1, Day 2, and Day 3 are 2.36%, 2.17%, and 2.04%, respectively. ii. Experimental Control Results for Variable Tidal Speeds The evolution in time of the output speed wuof the IVT with the variable calculated rotation speed of CFTs with three-day tidal speed data are shown inFIGS.15A-B,FIGS.16A-B, andFIGS.17A-Bfor Day 1, Day 2, and Day 3, respectively. The IVT reaches the stable desired output speedin around 0.8 s via the proposed control strategy. For the time exceeding 0.8 s, the proposed crank length controller keeps the speed ratio constant, which means that the crank lengthcris a constant and the stepper motor does not operate during this period. In the time period from 0 to 0.8 s, the crank length controller changes the crank length to its expected value and changes the rotation angle of the stepper motor to achieve the desired control angle. Maximum errors between the average output speedwuof the IVT and the desired output speed were within 1.43%, 1.58%, and 1.61%, respectively, which can arise from backlashes in gears and gaps in components in the IVT, lubrication and misalignment issues, and friction between gear tooth surfaces. Despite input speed variation, the proposed control strategy substantially ensures an almost constant output speed wnof the IVT system with variable tidal speeds. The average error between the experimental result of the output speeds without time-delay feed-back control and the desired output speed corresponding to tidal speed data of Day 1, Day 2, and Day 3 were 4.97%, 4.43%, and 5.04%, respectively. The proposed time-delay feedback control can effectively reduce fluctuations of the output speed of the IVT system with variable tidal speeds. In order to further verify the accuracy of experimental results, simulation results of the proposed control strategy of the IVT system are also provided here. The average error between the simulation results of the output speeds with time-delay feedback control and the desired output speed corresponding to tidal speed data of Day 1, Day 2, and Day 3 were 0.59%, 0.54%, and 0.64%, respectively. The deviation between average errors of experimental and simulation results of the output speed with time-delay feedback control corresponding to tidal speed data of Day 1, Day 2, and Day 3 were 1.74%, 1.62%, and 1.82%, respectively. The average error between the simulation result of the output speed without time-delay feedback control and the desired output speed corresponding to tidal speed data of Day 1, Day 2, and Day 3 were 4.21%, 4.16%, and 4.63%, respectively. The deviation between average errors of experimental and simulation results of the output speed without time-delay feedback control corresponding to tidal speed data were 4.14%, 3.68%, and 3.87%, respectively. The high control performance of the output speed of the IVT system was validated, wherein small deviations between the corresponding average errors of experimental and simulation results of the output speed with and without time-delay feedback control were achieved. Since the input speed jumps from one sinusoidal waveform to another, sudden changes of the speed ratio occur at each peak of the waveform and the speed ratio is adjusted back to the desired value in one or two control loops with the proposed control strategy of the IVT system. Experimental and simulation results of the speed ratios of the IVT corresponding to tidal speed data of Day 1, Day 2, and Day 3 are shown inFIGS.18A-b,FIGS.19A-B, andFIGS.20A-20B, respectively. The speed ratios were kept to their desired value with the variable input speeds of the IVT system. The deviation between average errors of experimental and simulation results of the speed ratios with time-delay feedback control corresponding to tidal speed data of Day 1, Day 2, and Day 3 were 2.24%, 2.19%, and 2.41%, respectively, as shown inFIGS.20A-20B. The deviation between average errors of experimental and simulation results of the speed ratio without time-delay feedback control corresponding to tidal speed data of Day 1, Day 2, and Day 3 were 4.67%, 4.31%, and 4.43%, respectively. Fluctuations of the speed ratios on these three days can be reduced by 2.39%, 2.12%, and 2.02% with the proposed time-delay feedback control. Comparison of the speed ratios of experimental and simulation results with time-delay feedback control shows that the proposed control strategy of the IVT system can achieve good control accuracy of the IVT system with the variable rotation speeds of CFTs. iii. Spectral Analysis of Experimental Control Results In order to analyze high-frequency components in experimental results of output speeds of the IVT, fast Fourier transform analysis of experimental results of the output speed of the IVT is performed here, as shown inFIG.21. According to the frequency analysis result, there is no high-frequency oscillations in output speed signals. Three components of the frequency analysis result are frequencies of rack-pinion sets in scotch-yoke systems, the noncircular gear pair, and planetary gear sets of the IVT, which are 0.04 Hz, 0.79 Hz, and 1.58 Hz, respectively, which are in good agreement with their theoretical results, which are 0.0416 Hz, 0.8148 Hz, and 1.6131 Hz, respectively. Conclusions A new control strategy that combines a closed-loop control and an integral time-delay feedback control was developed for high-performance nonlinear control of the IVT system. The forward speed controller and the crank length controller were developed based on the nonlinear dynamic model of the IVT system, whose equations are derived using Lagrange's equations. The primary merit of the forward speed controller and the crank length controller lies in the fact that an accurate and complete model-based approach can establish a tracking error model for desired control values in varying operating conditions of TCECs. The proposed control strategy with the tracking error model exhibits good control performance of the speed ratio of the IVT system with a variable input speed. The time-delay feedback control can reduce fluctuations of the output speed and the speed ratio of the IVT. Experimental results show that the control strategy can adjust and stabilize the speed ratio of the IVT system for the desired output speed. The control strategy of the IVT system can restrict fluctuations of the output speed and the speed ratio within 1.61% and 2.41% for the variable rotation speed of CFTs, respectively. The proposed control strategy can be used to promote commercialization of the IVT for TCECs. Although the invention has been variously disclosed herein with reference to illustrative embodiments and features, it will be appreciated that the embodiments and features described hereinabove are not intended to limit the invention, and that other variations, modifications and other embodiments will suggest themselves to those of ordinary skill in the art, based on the disclosure herein. The invention therefore is to be broadly construed, as encompassing all such variations, modifications and alternative embodiments within the spirit and scope of the claims hereafter set forth. REFERENCES J. Baker, Features to aid or enable self starting of fixed pitch low solidity vertical axis wind turbines, J. Wind Eng. Ind. Aerod., 15 (1) (1983), pp. 369-380Y. Bazilevs, A. Korobenko, X. Deng, J. Yan, M Kinzel, J.O. Dabiri, Fluid-structure interaction modeling of vertical-Axis wind turbines, J. Appl. Mech., 81 (8) (2014), 081006-081006-8A.-J. Buchner, M. Lohry, L. Martinelli, J. Soria, A. J. Smits, Dynamic stall in vertical axis wind turbines: comparing experiments and computations, J. Wind Eng. Ind. Aerod., 146 (2015), pp. 163-171M. Chowdhury, K. S. Rahman, V. Selvanathan, N. Nuthammachot, M. Suklueng, A. Mostafaeipour, A. Habib, M. Akhtaruzzaman, N. Amin, K. Techato, Current trends and prospects of tidal energy technology, Environment, Development and Sustainability (2020) 1-16.L. A. Danao, O. Eboibi, R. Howell, An experimental investigation into the influence of unsteady wind on the performance of a vertical axis wind turbine, Appl. Energy, 107 (2013), pp. 403-411L. A. Danao, J. Edwards, O. Eboibi, R. Howell, A numerical investigation into the influence of unsteady wind on the performance and aerodynamics of a vertical axis wind turbine, Appl. Energy, 116 (2014), pp. 111-124E. Denny, The economics of tidal energy, Energy Policy 37 (5) (2009) 1914-1924.R. Dominy, P. Lunt, A. Bickerdyke, J. Dominy, Self-starting capability of a Darrieus turbine, Proc. IME J. Power Energy, 221 (1) (2007)K. L. Earwaker, C. E. Zervas, Assessment of the National Ocean Service'sTidal Current Program, National Oceanic and Atmospheric Administration, 1999.O. Edenhofer, R. Pichs-Madruga, Y. Sokona, K. Seyboth, S. Kadner, T. Zwickel, P. Eickemeier, G. Hansen, S. Schlömer, C. von Stechow, et al., Renewable Energy Sources and Climate Change Mitigation: Special Report of the Intergovernmental Panel on Climate Change, Cambridge University Press, 2011.R. Everett, G. Boyle, S. Peake, J. Ramage, Energy Systems and Sustain-ability: Power for a Sustainable Future, Oxford University Press, 2012.C. Frid, E. Andonegi, J. Depestele, A. Judd, D. Rihan, S. I. Rogers, E. Kenchington, The environmental interactions of tidal and wave energy generation devices, Environmental Impact Assessment Review 32 (1) (2012) 133-139.S. W. Funke, S. C. Kramer, M. D. Piggott, Design optimisation and resource assessment for tidal-stream renewable energy farms using a new continuous turbine approach, Renewable Energy 99 (2016) 1046-1061.K. A. Haas, H. M. Fritz, S. P. French, B. T. Smith, V. Neary, Assessment of energy production potential from tidal streams in the United States, Tech. rep., Georgia Tech Research Corporation (2011).N. Hill, R. Dominy, G. Ingram, J. Dominy, Darrieus turbines: the physics of self-starting, Proc. IME J. Power Energy, 223 (1) (2009), pp. 21-29R. Isermann and M. Münchhof, 2011, Identification of Dynamic Systems: An Introduction with Applications, Vol. 1, Springer, Berlin Heidelberg.M. Islam, D. S.-K. Ting, A. Fartaj, Aerodynamic models for Darrieus-type straight-bladed vertical axis wind turbines, Renew. Sustain. Energy Rev., 12 (4) (2008), pp. 1087-1109C. Johnstone, D. Pratt, J. Clarke, A. Grant, A techno-economic analysis of tidal energy technology, Renew. Energy 49 (2013) 101-106.M. A. Kamoji, S. B. Kedare, S. V. Prabhu, Performance tests on helical Savonius rotors, Renew. Energy, 34 (3) (2009), pp. 521-529B. Kirkle, L. Lazauskas, Enhancing the performance of vertical axis wind turbine using a simple variable pitch system, Wind Eng., 15 (4) (1991), pp. 187-195N. D. Laws, B. P. Epps, Hydrokinetic energy conversion: Technology, re-search, and outlook, Renewable and Sustainable Energy Reviews 57 (2016) 1245-1259.M. Lewis, S. Neill, P. Robins, M. Hashemi, Resource assessment for future generations of tidal-stream energy arrays, Energy 83 (2015) 403-415.C. Li, S. Zhu, Y. Xu, Y. Xiao, 2.5D large eddy simulation of vertical axis wind turbine in consideration of high angle of attack flow, Renew. Energy, 51 (2013), pp. 317-330G. Li, W. Zhu, Design and power loss evaluation of a noncircular gear pair for an infinitely variable transmission, Mechanism and Machine Theory, 156, 2021, 104137.H. W. Liu, W. Li, Y. G. Lin, S. Ma, Tidal current turbine based on hydraulic transmission system, Journal of Zhejiang University-SCIENCE A 12 (7) (2011) 511-518.K. Liu, M. Yu, W. Zhu, Enhancing wind energy harvesting performance of vertical axis wind turbines with a new hybrid design: A fluid-structure interaction study, Renewable Energy 140 (2019) 912-927.A. C. Mahato, S. K. Ghoshal, Various power transmission strategies in wind turbine: An overview, International Journal of Dynamics and Control 7 (3) (2019) 1149-1156.J. F. Manwell, J. G. McGowan, and A. L. Rogers, 2010, Wind Energy Explained: Theory, Design and Application, John Wiley & Sons.M. Nakajima, S. Iio, T. Ikeda, Performance of double-step Savonius rotor for environmentally friendly hydraulic turbine, J. Fluid Sci. Technol., 3 (2008), pp. 410-419I. Paraschivoiu, Wind Turbine Design: with Emphasis on Darrieus Concept, Presses inter Polytechnique (2002)G. Payne, A. Kiprakis, M. Ehsan, W. H. S. Rampen, J. Chick, A. Wallace, Efficiency and dynamic performance of digital displacement™ hydraulic transmission in tidal current energy converters, Proceedings of the Institution of Mechanical Engineers, Part A: Journal of Power and Energy 221 (2) (2007) 207-218.A. M. Plagge, L. Jestings, B. P. Epps, Next-generation hydrokinetic power take-off via a novel variable-stroke hydraulic system, in: Proceedings of International Conference on Offshore Mechanics and Arctic Engineering, Vol. 45547, American Society of Mechanical Engineers, 2014, p. V09BT09A018.M. Ross, 1997, “Fuel Efficiency and the Physics of Automobiles,” Contemporary Physics, 38(6), pp. 381-394.O. Rourke, F. Boyle and A. Reynolds, “Tidal energy update 2009,” Applied Energy, vol. 87, pp. 398-409, 2010.S. J. Sangiuliano, Turning of the tides: Assessing the international implementation of tidal current turbines, Renewable and Sustainable Energy Reviews 80 (2017) 971-989.E. Segura, R. Morales, J. Somolinos, A. Lopez, Techno-economic challenges of tidal energy conversion systems: current status and trends, Renew. Sustain. Energy Rev. 77 (2017) 536-550.A. Sgobbi, S .G. Simoes, D. Magagna, W. Nijs, Assessing the impacts of technology improvements on the deployment of marine energy in europe with an energy system perspective, Renew. Energy 89 (2016) 515-525.K. Touimi, M. Benbouzid, P. Tavner, Tidal stream turbines: With or with-out a gearbox?, Ocean Engineering 170 (2018) 74-88.A. Uihlein and D. Magagna, “Wave and tidal current energy—A review of the current state of research beyond technology,” Renewable and Sustainable Energy Reviews, vol. 58, pp. 1070-1081,2016.X. F. Wang, and W. D. Zhu, 2016, “Design, Modeling, and Experimental Validation of a Novel Infinitely Variable Transmission Based on Scotch Yoke Systems,” ASME Journal of Mechanical Design, 138(1), p. 015001.X. F. Wang, and W. D. Zhu, 2018, “Design and Stability Analysis of an Integral Time-Delay Feedback Control Combined With an Open-Loop Control for an Infinitely Variable Transmission System,” ASME Journal of Dynamic Systems, Measurement, and Control, 140(1), p. 011007.D. W. Wekesa, C. Wang, Y. Wei, L. A. M. Danao, Influence of operating conditions on unsteady wind performance of vertical axis wind turbines operating within a fluctuating free-stream: a numerical study, J. Wind Eng. Ind. Aerod., 135 (2014), pp. 76-89D. W. Wekesa, C. Wang, Y. Wei, J. N. Kamau, L .A. M. Danao A numerical analysis of unsteady inflow wind for site specific vertical axis wind turbine: a case study for Marsabit and Garissa in Kenya, Renew. Energy, 76 (2015), pp. 648-661D. W. Wekesa, C. Wang, Y. Wei, W. Zhu, Experimental and numerical study of turbulence effect on aerodynamic performance of a small-scale vertical axis wind turbine, J. Wind Eng. Ind. Aerod., 157 (2016), pp. 1-14Y. Xiong, C. R. Berger, Chesapeake bay tidal characteristics, Journal of Water Resource and Protection 2 (7) (2010) 619. | 104,459 |
11859717 | DETAILED DESCRIPTION InFIG.1, an earth working machine according to the present invention is labeled generally with the number10. Earth working machine10, embodied in the present example as a large road milling machine, stands on substrate U that is to be worked by it. The large road milling machine has for this purpose front12and rear14drive units that can be embodied as wheels or as crawler track units, which are known per se and will not be further discussed here. Large road milling machine10comprises an operator's platform16from which large road milling machine10can be controlled and operated. Located in the region behind operator's platform16, i.e. between operator's platform16and the rear end of large road milling machine10, is an engine compartment18in which is arranged an internal combustion engine42explained in further detail in conjunction withFIG.2, which furnishes drive power for propelling and operating large road milling machine10. Located in the region below operator's platform16and between the front and rear drive units12and14in a longitudinal machine direction is a milling drum housing20in which a milling drum22constituting a working apparatus, rotatable around a milling drum axis A orthogonal to the drawing plane ofFIG.1, i.e. the transverse direction of large road milling machine10, is received. With milling drum22, substrate U can be removed to a removal depth predetermined by modifying the height of machine frame26relative to drive units12and14. Alternatively or additionally, milling drum22can be received in machine frame26vertically adjustably relative thereto. The milled material removed by milling drum22is wetted in milling drum housing20in order to decrease the environmental dust impact of large road milling machine10, and conveyed by discharge device24, indicated inFIG.1as being merely in the vicinity of the machine, in front of large road milling machine10. During operation, large road milling machine10therefore usually follows a truck whose loading device it fills with bulk material while being operated to remove substrate U. Numerous apparatuses on large road milling machine10, for example the vertical adjustment system for machine frame26relative to drive units12and14, or the steering system for drive units12and14and the propulsion system for drive units12and14, are implemented by way of hydraulic motors or hydraulic pumps. Milling drum22, conversely, can be mechanically driven to move by way of internal combustion engine42received in engine compartment18. Internal combustion engine42is a drive power source both for the mechanically driven milling drum22and for the hydraulically actuatable or drivable apparatuses of large road milling machine10. InFIG.2, the drive train of the working apparatus of earth working machine10ofFIG.1, in the form of a highly schematic block diagram, is labeled with the reference character40. Drive train40encompasses internal combustion engine42, for example in the form of a diesel internal combustion engine, as a source of drive power. The use of an Otto-cycle engine as a drive motor is, however, also not excluded. Drive shaft44of internal combustion engine42is coupled, with interposition of an elastic coupling46known per se, to input shaft48of a shiftable transmission50described in detail below in conjunction withFIG.3. With the use of shiftable transmission50it is possible to operate the internal combustion engine at an optimum steady-state rotation speed and nevertheless to allow working apparatus22, for example in the form of a milling drum or milling rotor, to operate at different rotation speeds and different torques. The steady-state operating rotation speed of internal combustion engine42can be selected for optimum performance, optimum emissions, and/or optimum consumption. An output shaft52of shiftable transmission50is coupled, via a belt drive54known per se, to the input side of a planetary gearset assemblage56that is connected on the output side to working apparatus22in torque-transferring fashion. Belt drive54comprises at least two belt pulleys, one of which can be embodied for temporary attachment of an auxiliary drive so that working apparatus22can be rotated at low speed for maintenance and/or repair purposes. As already noted above, what is depicted inFIG.2is merely a highly schematic block diagram. Planetary gearset assemblage56can in fact be arranged at least in part, or in fact entirely, in the interior of working apparatus22. In the exemplifying embodiment depicted, working apparatus22encompasses a hollow cylindrical milling drum on whose outer side milling bits are arranged, usually with interposition of bit holders or quick-change bit holders. The cavity radially inside the milling drum and surrounded by it offers space to at least partly accommodate planetary gearset assemblage56. As a rule, what takes place in drive train40is that the rotation speed of drive shaft44of internal combustion engine42is stepped down and the torque available at drive shaft44is stepped up. This means that working apparatus22rotates around its working apparatus axis more slowly than drive shaft44does around its rotation axis, but with a torque that, ignoring unavoidable losses, is reciprocally greater. Whereas, in the exemplifying embodiment presented, belt drive54steps torque down and rotation speed up from the input side to the output side, planetary gearset assemblage56steps torque up and steps speed down. In the example shown inFIG.2, the planetary gearset assemblage is in fact the only one of the three rotation speed- and torque-converting apparatuses50,54,56which steps rotation speed down and steps torque up. In the present exemplifying embodiment, for example, the torque transfer ratio of the belt drive from the input side to the output side can be selected to be between 0.78 and 0.8, and in the present exemplifying embodiment the torque transfer ratio of planetary gearset assemblage56from the input side to the output side can be equal to approximately 20.5 to 20.7. Input shaft48of shiftable transmission50constitutes, more precisely, a principal input drive of shiftable transmission50. Output shaft52, depicted inFIG.2, of shiftable transmission50likewise constitutes a principal output drive thereof. A first embodiment of shiftable transmission50is depicted highly schematically inFIG.3. As depicted inFIG.3, input shaft48and output shaft52of shiftable transmission50are selectably connectable to one another so as to rotate together at the same speed, or disconnectable from one another, by way of a direct-drive clutch60. The direct-drive clutch can be, for example, a multi-disc clutch. By way of direct-drive clutch60, input shaft48can be connected to output shaft52of the shiftable transmission to yield a shaft arrangement rotating together. Very high efficiency in terms of power transfer from internal combustion engine42to working apparatus22is thereby achieved. Direct-drive clutch60constitutes a first gearing stage for torque-transferring connection of input shaft48and output shaft52. With this first gearing stage, no transmission assemblage of any kind is involved in the transfer of drive power from input shaft48to output shaft52. A second gearing stage that can likewise be implemented on shiftable transmission50encompasses a transmission assemblage64that, upon activation of the second gearing stage and deactivation of the first gearing stage, transfers drive power from input shaft48to output shaft52of shiftable transmission50. Transmission assemblage64encompasses a first transmission sub-assemblage66located closer to the input side, and a second transmission sub-assemblage68located closer to the output side, of shiftable transmission50. In the exemplifying embodiment according to the present invention that is depicted, each of the two transmission sub-assemblages66and68encompasses exactly one gear pair. First transmission sub-assemblage66encompasses input drive pinion70, which meshes with an output drive pinion72of the first transmission sub-assemblage. In the example depicted, output drive pinion72is arranged on an intermediate shaft74so as to rotate together. The tooth count of input drive pinion is assumed to be z1and the tooth count of output drive pinion72is assumed to be z2; as shown inFIG.3, z1>z2. Intermediate shaft74furthermore carries input drive pinion76of the second transmission sub-assemblage, which meshes with output drive pinion78of the second transmission sub-assemblage on output shaft52. In the embodiment depicted, output drive pinion78is fixedly connected to output shaft52of shiftable transmission50so as to rotate together therewith at the same speed. In the example depicted, input drive pinion76of the second transmission sub-assemblage is selectably connectable to intermediate shaft74so as to rotate together, or disconnectable therefrom, via an intermediate clutch80. Intermediate clutch80can again be a multi-disc clutch. In a departure from what is depicted inFIG.3, intermediate shaft74can also be embodied as a split intermediate shaft, in which case input drive pinion76can then be fixedly coupled to the output drive side of intermediate shaft74, and the input drive side and output drive side of the (now split) intermediate shaft can be connectable to one another in order to rotate together, or disconnectable from one another, by way of intermediate clutch80. Input drive pinion76of the second transmission sub-assemblage has a tooth count z3that is greater than the tooth count z4of output drive pinion78of second transmission sub-assemblage68. The tooth counts z1, z2, z3, and z4are selected so that the tooth counts of pinions of similar size, i.e. for example the tooth counts z1and z3of the two input drive pinions70and76, likewise differ from one another by no more than two teeth, as also do the tooth counts z2and z4of the similarly sized output drive pinions72and78. It is then the case that the transfer ratios of the two transmission sub-assemblages66and68can differ by no more than 1%, so that for an assumed overall transfer ratio j of transmission assemblage64, it is approximately true that each transfer ratio of transmission sub-assemblages66and68is approximately the square root of j. The result is that at the meshing engagement points of the respective transmission sub-assemblages, i.e. between pinions70and72on the one hand and between pinions76and78on the other hand, the forces that are transferred between the pinions are approximately the same, which results in homogeneous loading of the two transmission sub-assemblages and thus uniform wear behavior for the entire transmission assemblage64. With the arrangement of direct-drive clutch60and intermediate clutch80as shown, shiftable transmission50can advantageously be shifted between its two gearing stages under load. It is therefore possible to switch, with no interruption in load, between direct drive and the transfer ratio furnished by transmission assemblage64. For reliable stoppage of the working apparatus when both clutches (direct-drive clutch60and intermediate clutch80) are released, shiftable transmission50preferably comprises a braking apparatus81that, in the present embodiment, interacts with the output drive side of intermediate clutch80. A brake disc81a, on which braking force can be exerted by a brake caliper81bof braking apparatus81, can be provided for this purpose on the output drive side of intermediate clutch80. Merely for the sake of completeness, be it noted that shiftable transmission50comprises four further power takeoffs82,84,86,88. Hydraulic pumps90,92,94,96are respectively coupled to power takeoffs82,84,86,88. Shiftable transmission50is thus, in the present case, a pump distributor transmission. In the example depicted, power takeoffs82and84are located on a common first power takeoff shaft85. Power takeoffs86and88are located on a common second power takeoff shaft87. First power takeoff shaft85is rotationally driven by a power takeoff pinion89that is connected to first power takeoff shaft85so as to rotate together, and meshes permanently with input drive pinion70of first transmission sub-assemblage66. Second power takeoff shaft87also has a second power takeoff pinion91connected nonrotatably to it so as to rotate together. Said pinion is rotationally driven indirectly, with interposition of an intermediate pinion93, by output drive pinion72of first transmission sub-assemblage66. This ensures that first and second power takeoff shafts85and87rotate in the same direction. It also ensures that, regardless of the engagement states of direct-drive clutch60and intermediate clutch80, torque is always transferred both to first power takeoff shaft85and to second power takeoff shaft87. A control apparatus of shiftable transmission50ensures exclusion of critical operating states, for example simultaneous torque transfer engagement of both direct-drive clutch60and intermediate clutch80, or braking engagement of braking apparatus81when direct-drive clutch60and intermediate clutch80are not both released. The control apparatus of shiftable transmission50can be implemented by a machine control apparatus of earth working machine10, or can be a control apparatus separate therefrom, for example using respective microprocessors and/or stored-program control systems as known in the existing art. In a departure from what is depicted inFIG.3, a part of intermediate shaft74which is constantly rotationally driven by the input shaft can also be guided out of a housing of shiftable transmission50as an additional or alternative power takeoff. Only one of the two clutches (direct-drive clutch60and intermediate clutch80) can be respectively activated for torque transfer, while the other must be deactivated. It is possible, however, to deactivate both clutches60and80simultaneously, for example if torque is required only at the power takeoffs but not at the principal output drive. FIG.4depicts a second embodiment of a shiftable transmission according to the present invention. Identical and functionally identical components and component portions are labeled inFIG.4with the same reference characters as inFIG.3, but incremented by 100. The second embodiment inFIG.4will be described below only to the extent that it differs from the first embodiment inFIG.3, the description of which is otherwise also to be referred to for an explanation of the second embodiment inFIG.4. Shiftable transmission150ofFIG.4comprises no power takeoffs, but only the principal input drive through input shaft148and principal output drive via output shaft152. Intermediate clutch180inFIG.4is also, merely as an illustration of design options, arranged not on intermediate shaft174but on output shaft152. Intermediate clutch180serves to selectably connect output drive pinion178of second transmission sub-assemblage164to output shaft152or disconnect it therefrom. Even though intermediate clutch180is arranged on output shaft152of shiftable transmission150, it is an intermediate clutch180for purposes of the present Application because it is arranged in the torque transfer path of transmission arrangement168and enables interruption or establishment of a transfer of torque from input shaft148to output shaft152via intermediate shaft174. In this second embodiment, braking apparatus181interacts with output shaft152, which supports a brake disc181so as to rotate together with it. | 15,499 |
11859718 | DETAILED DESCRIPTION As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and similarly a second element could be termed a first element without departing from the scope of the various described embodiments. The first element and the second element are both elements, but they are not the same element. WA The terminology used in the description of the various described embodiments is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including.” “comprises.” and/or “comprising.” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Referring toFIG.1, an example of an axle assembly10is shown. The axle assembly10may be provided with a motor vehicle like a truck, bus, farm equipment, mining equipment, military transport or weaponry vehicle, or cargo loading equipment for land, air, or marine vessels. The motor vehicle may include a trailer for transporting cargo in one or more embodiments. The axle assembly10is configured to provide torque to one or more traction wheel assemblies that may include a tire mounted on a wheel. The wheel may be mounted to a wheel hub that may be rotatable about a wheel axis. One or more axle assemblies may be provided with the vehicle. A single axle assembly is shown inFIGS.1and2. The axle assembly10may include a housing assembly20, a differential assembly22, at least one axle shaft24, an electric motor module26, and a transmission module28, a drive pinion30, a shift mechanism32, or combinations thereof. Housing Assembly Referring toFIG.1, the housing assembly20receives various components of the axle assembly10. In addition, the housing assembly20may facilitate mounting of the axle assembly10to the vehicle. In at least one configuration, the housing assembly20may include an axle housing40and a differential carrier42. The axle housing40may receive and may support the axle shafts24. In at least one configuration, the axle housing40may include a center portion50and at least one arm portion52. The center portion50may be disposed proximate the center of the axle housing40. As is best shown inFIG.2, the center portion50may define a cavity54that may at least partially receive the differential assembly22. A lower region of the center portion50may at least partially define a sump portion56that may contain or collect lubricant58. Lubricant58in the sump portion56may be splashed by a ring gear82of the differential assembly22and distributed to lubricate various components that may or may not be received in the housing assembly20. For instance, some splashed lubricant58may lubricate components that are received in the cavity54like the differential assembly22, bearing assemblies that rotatably support the differential assembly22, a drive pinion30, and so on, while some splashed lubricant58may be routed out of the cavity54to lubricate components located outside of the housing assembly20, such as components associated with the transmission module28, the shift mechanism32, or both. Referring toFIG.1, one or more arm portions52may extend from the center portion50. For instance, two arm portions52may extend in opposite directions from the center portion50and away from the differential assembly22. The arm portions52may have similar configurations. For example, the arm portions52may each have a hollow tubular configuration that may extend around and may receive a corresponding axle shaft24and may help separate or isolate the axle shaft24or a portion thereof from the surrounding environment. An arm portion52or a portion thereof may or may not be integrally formed with the center portion50. It is also contemplated that the arm portions52may be omitted. Referring primarily toFIG.2, the differential carrier42is configured to support the differential assembly22. For example, the differential carrier42may include one or more bearing supports that may support a bearing like a roller bearing assembly that may rotatably support the differential assembly22. The differential carrier42may be mounted to the center portion50of the axle housing40. The differential carrier42may also facilitate mounting of the electric motor module26. In at least one configuration, the differential carrier42may include a mounting flange60and/or a bearing support wall62. The mounting flange60may facilitate mounting of the electric motor module26. As an example, the mounting flange60may be configured as a ring that may extend around an axis70. In at least one configuration, the mounting flange60may include a set of fastener holes that may be configured to receive fasteners that may secure the electric motor module26to the mounting flange60. The bearing support wall62may support bearings that may rotatably support other components of the axle assembly10. For example, the bearing support wall62may support a bearing that may rotatably support the drive pinion30, a bearing that may rotatably support a rotor of the electric motor module26, or both. The bearing support wall62may extend in an axial direction away from the axle housing40and may extend around the axis70. The bearing support wall62may define a hole that may extend along or around the axis70and receive the drive pinion30and the bearings that rotatably support the drive pinion30. The bearing support wall62may be integrally formed with the differential carrier42or may be a separate component that is fastened to the differential carrier42. Differential Assembly, Drive Pinion, and Axle Shafts Referring toFIG.2, the differential assembly22is about a differential axis80and is configured to transmit torque to the axle shafts24and wheels. The differential assembly22is operatively connected to the axle shafts24and may permit the axle shafts24to rotate at different rotational speeds in a manner known by those skilled in the art. The differential assembly22may be at least partially received in the center portion50of the housing assembly20. The differential assembly22may have a ring gear82that may have teeth that mate or mesh with the teeth of a gear portion of the drive pinion30. Accordingly, the differential assembly22may receive torque from the drive pinion30via the ring gear82and transmit torque to the axle shafts24. The drive pinion30may operatively connect the transmission module28to the differential assembly22. As such, the drive pinion30may transmit torque between the differential assembly22and the transmission module28. In at least one configuration, the drive pinion30may be rotatable about the axis70and may be rotatably supported inside another component, such as the bearing support wall62. Referring primarily toFIGS.2and6, the drive pinion30may optionally include or may be coupled to a drive pinion extension90. The drive pinion extension90may effectively increase the axial length of the drive pinion30. In at least one configuration, the drive pinion extension90may be a separate component from the drive pinion30and may be coupled to the drive pinion30such that the drive pinion extension90is rotatable about the axis70with the drive pinion30. In addition, the drive pinion extension90may be fixedly positioned with respect to the drive pinion30such that the drive pinion extension90may not move along the axis70with respect to the drive pinion30. It is also contemplated that the drive pinion extension90may be integrally formed with the drive pinion30. For convenience in reference, the term “drive pinion30” is used herein to refer to the drive pinion30with or without the drive pinion extension90. In at least one configuration, the drive pinion extension90may extend from a first end92to a second end94and may include a socket96and the spline98. The socket96may extend from the first end92and may receive the drive pinion30. The second end94may be received inside and may be rotatably supported by a support bearing418. The spline98, if provided, may facilitate coupling of the drive pinion extension90to a shift collar310that may be moveable along the axis70as will be discussed in more detail below. Referring toFIG.1, the axle shafts24are configured to transmit torque between the differential assembly22and corresponding wheel hubs and wheels. Two axle shafts24may be provided such that each axle shaft24extends through a different arm portion52of axle housing40. The axle shafts24may extend along and may be rotatable about an axis, such as the differential axis80. Each axle shaft24may have a first end and a second end. The first end may be operatively connected to the differential assembly22. The second end may be disposed opposite the first end and may be operatively connected to a wheel. Optionally, gear reduction may be provided between an axle shaft24and a wheel. Electric Motor Module Referring toFIG.2, the electric motor module26, which may also be referred to as an electric motor, is configured to provide propulsion torque. The electric motor module26may be mounted to the differential carrier42and may be operatively connectable to the differential assembly22. For instance, the electric motor module26may configured to provide torque to the differential assembly22via the transmission module28and the drive pinion30as will be discussed in more detail below. The electric motor module26may be primarily or completely disposed outside the differential carrier42. In addition, the electric motor module26may be axially positioned between the axle housing40and the transmission module28. In at least one configuration, the electric motor module26may include a motor housing100, a coolant jacket102, a stator104, a rotor106, and at least one rotor bearing assembly108. The electric motor module26may also include a motor cover110. The motor housing100may extend between the differential carrier42and the motor cover110. The motor housing100may be mounted to the differential carrier42and the motor cover110. For example, the motor housing100may extend from the mounting flange60of the differential carrier42to the motor cover110. The motor housing100may extend around the axis70and may define a motor housing cavity120. The motor housing cavity120may be disposed inside the motor housing100and may have a generally cylindrical configuration. The bearing support wall62of the differential carrier42may be located inside the motor housing cavity120. Moreover, the motor housing100may extend continuously around and may be spaced apart from the bearing support wall62. In at least one configuration, the motor housing100may have an exterior side122, an interior side124, a first end surface126, and a second end surface128. The exterior side122faces away from the axis70and may define an exterior or outside surface of the motor housing100. The interior side124is disposed opposite the exterior side122and may face toward the axis70. The interior side124may be disposed at a substantially constant radial distance from the axis70in one or more configurations. The first end surface126is disposed at an end of the motor housing100that may face toward the differential carrier42. For instance, the first end surface126may be disposed adjacent to the mounting flange60of the differential carrier42and may engage or contact the mounting flange60. The first end surface126may extend between the exterior side122and the interior side124. The second end surface128may be disposed opposite the first end surface126. As such, the second end surface128may be disposed at an end of the motor housing100that may face toward the motor cover110and may engage or contact the motor cover110. The coolant jacket102facilitates cooling or heat removal, such cooling of the stator104. The coolant jacket102may be received in the motor housing cavity120of the motor housing100and may engage the interior side124of the motor housing100. The coolant jacket102may extend axially (e.g., in a direction along the axis70) between the differential carrier42and the motor cover110. For example, the coolant jacket102may extend axially from the differential carrier42to the motor cover110. In addition, the coolant jacket102may extend around the axis70and around the stator104. Accordingly, the stator104may be at least partially received in and may be encircled by the coolant jacket102. The coolant jacket102may extend in a radial direction from the stator104to the interior side124of the motor housing100. In at least one configuration, the coolant jacket102may include a plurality of channels through which coolant may flow. The stator104is received in the motor housing cavity120. The stator104may be fixedly positioned with respect to the coolant jacket102. For example, the stator104may extend around the axis70and may include stator windings that may be received inside and may be fixedly positioned with respect to the coolant jacket102. The rotor106extends around and is rotatable about an axis, such as axis70. In addition, the rotor106may extend around and may be supported by the bearing support wall62. The rotor106may be received inside the stator104, the coolant jacket102, and the motor housing cavity120of the motor housing100. The rotor106may be rotatable about the axis70with respect to the differential carrier42and the stator104. In addition, the rotor106may be spaced apart from the stator104but may be disposed in close proximity to the stator104. One or more rotor bearing assemblies108rotatably support the rotor106. For example, a rotor bearing assembly108may extend around and receive the bearing support wall62of the differential carrier42and may be received inside of the rotor106. The rotor106may be operatively connected to the drive pinion30. For instance, a coupling such as a rotor output flange130may operatively connect the rotor106to the transmission module28, which in turn may be operatively connectable to the drive pinion30. The motor cover110may be mounted to the motor housing100and may be disposed opposite the axle housing40and the differential carrier42. For example, the motor cover110may be mounted to the second end surface128of the motor housing100. The motor cover110may be spaced apart from and may not engage the differential carrier42. The motor cover110may be provided in various configurations. In at least one configuration, the motor cover110may include a first side140and a second side142. The first side140may face toward and may engage the motor housing100. The second side142may be disposed opposite the first side140. The second side142may face away from the motor housing100. The motor cover110may also include a motor cover opening through which the drive pinion30may extend. The motor cover110may be integrated with the transmission module28or may be a separate component. Transmission Module Referring toFIGS.2and4, the transmission module28is configured to transmit torque between the electric motor module26and the differential assembly22. As such, the transmission module28may be operatively connectable to the electric motor module26and the differential assembly22. In at least one configuration, the transmission module28may include a transmission housing. The transmission housing may include one or more individual housings, such as a first transmission housing200, a second transmission housing202. The transmission module28may also include a transmission204. The first transmission housing200and the second transmission housing202may cooperate to define a transmission housing cavity206that may receive the transmission204. The first transmission housing200may be mounted to the electric motor module26. For instance, the first transmission housing200may be mounted to the second side142of the motor cover110. As such, the motor cover110may separate the first transmission housing200from the motor housing100. The second transmission housing202may be mounted to the first transmission housing200. For instance, the second transmission housing202may be mounted to and may engage or contact a side of the first transmission housing200that may face away from the motor cover110. As such, the first transmission housing200may separate the second transmission housing202from the motor cover110. The transmission204may be operatively connected to the electric motor. In at least one configuration, the transmission204may be configured as a countershaft transmission that includes a set of drive pinion gears210, a first countershaft gear set212, and optionally a second countershaft gear set214. The set of drive pinion gears210is received in the transmission housing cavity206of the transmission housing and may be arranged along the axis70between the first transmission housing200and the second transmission housing202. The set of drive pinion gears210may include a plurality of gears, some or all of which may be selectively coupled to the drive pinion30. The set of drive pinion gears210is spaced apart from the drive pinion30and is rotatable about the axis70. The gears may be independently rotatable with respect to each other. In the configuration shown, the set of drive pinion gears210includes a first gear220, a second gear222, a third gear224, and a fourth gear226; however, it is to be understood that a greater or lesser number of gears may be provided. The first gear220extends around the axis70and may be disposed proximate the first transmission housing200. In at least one configuration, the first gear220may have a through hole that may receive the drive pinion30, an extension of the drive pinion30like the drive pinion extension90, or both. The first gear220may have a plurality of teeth that may be arranged around and may extend away from the axis70. The teeth of the first gear220may contact and may mate or mesh with teeth of a first countershaft gear that may be provided with the first countershaft gear set212and the second countershaft gear set214as will be discussed in more detail below. The first gear220may be operatively connected to the rotor106of the electric motor module26such that the rotor106and the first gear220are rotatable together about the axis70. For example, the first gear220may be fixedly positioned with respect to the rotor106or fixedly coupled to the rotor106such that the first gear220is not rotatable about the axis70with respect to the rotor106. It is contemplated that the first gear220may be fixedly mounted to or integrally formed with the rotor output flange130. As such, the first gear220may be continuously connected to the rotor106such that the first gear220and the rotor106may be rotatable together about the axis70but may not be rotatable with respect to each other. It is also contemplated that the first gear220may be selectively coupled to the drive pinion30or drive pinion extension90, such as with a shift collar. In addition, the first gear220may be decoupled from the drive pinion30and may be rotatable with respect to the drive pinion30. As such, a clutch or shift collar310may not connect the first gear220to the drive pinion30or the drive pinion extension90. The drive pinion extension90, if provided, may be received inside the first gear220and may be spaced apart from the first gear220. In at least one configuration, the first gear220may be axially positioned along the axis70between the second gear222and the electric motor module26. The second gear222extends around the axis70. In at least one configuration, the second gear222may have a through hole that may receive the drive pinion30, the drive pinion extension90, or both. The second gear222may have a plurality of teeth that may be arranged around and may extend away from the axis70. The teeth of the second gear222may contact and may mate or mesh with teeth of a second countershaft gear that may be provided with the first countershaft gear set212and the second countershaft gear set214as will be discussed in more detail below. As is best shown inFIG.7, the second gear222may also have inner gear teeth232that may extend toward the axis70and may be received in the through hole. The second gear222may have a different diameter than the first gear220. For example, the second gear222may have a larger diameter than the first gear220. In at least one configuration, the second gear222may be axially positioned along the axis70between the first gear220and the third gear224. The drive pinion30or drive pinion extension90, if provided, may be received inside the second gear222and may be spaced apart from the second gear222in one or more configurations. The third gear224extends around the axis70. In at least one configuration, the third gear224may have a through hole that may receive the drive pinion30, the drive pinion extension90, or both. The third gear224may have a plurality of teeth that may be arranged around and may extend away from the axis70. The teeth of the third gear224may contact and may mate or mesh with teeth of a third countershaft gear that may be provided with the first countershaft gear set212and the second countershaft gear set214as will be discussed in more detail below. As is best shown inFIG.7, the third gear224may also have inner gear teeth234that may extend toward the axis70and may be received in the through hole. The third gear224may have a different diameter than the first gear220and the second gear222. For example, the third gear224may have a larger diameter than the first gear220and the second gear222. In at least one configuration, the third gear224be axially positioned along the axis70between the second gear222and the fourth gear226. The drive pinion30or drive pinion extension90, if provided, may be received inside the third gear224and may be spaced apart from the third gear224in one or more configurations. The fourth gear226extends around the axis70. In at least one configuration, the fourth gear226may have a through hole that may receive the drive pinion30, the drive pinion extension90, or both. The fourth gear226may have a plurality of teeth that may be arranged around and may extend away from the axis70. The teeth of the fourth gear226may contact and may mate or mesh with teeth of a fourth countershaft gear that may be provided with the first countershaft gear set212and the second countershaft gear set214as will be discussed in more detail below. As is best shown inFIG.7, the fourth gear226may also have inner gear teeth236that may extend toward the axis70and may be received in the through hole. The fourth gear226may have a different diameter than the first gear220, the second gear222, and the third gear224, such as a larger diameter. In at least one configuration, the fourth gear226be axially positioned along the axis70further from the electric motor module26than the first gear220, the second gear222, and the third gear224. As such, the fourth gear226may be axially positioned proximate or adjacent to a side of the second transmission housing202that is disposed opposite the first transmission housing200. The drive pinion30or drive pinion extension90may be received inside the fourth gear226and may be spaced apart from the fourth gear226in one or more configurations. Referring toFIG.4, thrust bearings240may optionally be provided between members of the set of drive pinion gears210, between the first transmission housing200and the set of drive pinion gears210, between the second transmission housing202and the set of drive pinion gears210, or combinations thereof. The first countershaft gear set212is received in the transmission housing cavity206and may be in meshing engagement with the set of drive pinion gears210. The first countershaft gear set212may be rotatable about a first countershaft axis250. The first countershaft axis250may be disposed parallel or substantially parallel to the axis70in one or more embodiments. The term “substantially parallel” as used herein means the same as or very close to parallel and includes features or axes that are within ±3° of being parallel each other. The first countershaft gear set212may include a first countershaft260and a plurality of gears. In the configuration shown, the plurality of gears of the first countershaft gear set212include a first countershaft gear270, a second countershaft gear272, a third countershaft gear274, and a fourth countershaft gear276; however, it is contemplated that a greater number of countershaft gears or a lesser number of countershaft gears may be provided. The first countershaft260is rotatable about the first countershaft axis250. For instance, the first countershaft260may be rotatably supported on the first transmission housing200and the second transmission housing202by corresponding bearing assemblies280. For example, first and second bearing assemblies280may be located near opposing first and second ends the first countershaft260, respectively. The first countershaft260may support and be rotatable with the first countershaft gear270, the second countershaft gear272, the third countershaft gear274, and the fourth countershaft gear276. The first countershaft gear270is fixedly disposed on the first countershaft260or fixedly mounted to the first countershaft260. As such, the first countershaft gear270may rotate about the first countershaft axis250with the first countershaft260and may not be rotatable with respect to the first countershaft260. For example, the first countershaft gear270may have a hole that may receive the first countershaft260and may be fixedly coupled to the first countershaft260. The first countershaft gear270may extend around the first countershaft axis250and may have a plurality of teeth that may be arranged around and may extend away from the first countershaft axis250. The teeth of the first countershaft gear270may contact and may mate or mesh with the teeth of the first gear220. In at least one configuration, the first countershaft gear270may be axially positioned along the first countershaft axis250between the first transmission housing200and the second countershaft gear272of the first countershaft gear set212. The second countershaft gear272is fixedly disposed on the first countershaft260or fixedly mounted to the first countershaft260. As such, the second countershaft gear272may rotate about the first countershaft axis250with the first countershaft260and may not be rotatable with respect to the first countershaft260. For example, the second countershaft gear272may have a hole that may receive the first countershaft260and may be fixedly coupled to the first countershaft260. The second countershaft gear272may extend around the first countershaft axis250and may have a plurality of teeth that may be arranged around and may extend away from the first countershaft axis250. The teeth of the second countershaft gear272may contact and may mate or mesh with the teeth of the second gear222. The second countershaft gear272may have a different diameter than the first countershaft gear270and the third countershaft gear274. In at least one configuration, the second countershaft gear272may be axially positioned along the first countershaft axis250between the first countershaft gear270of the first countershaft gear set212and the third countershaft gear274of the first countershaft gear set212. The third countershaft gear274is fixedly disposed on the first countershaft260or fixedly mounted to the first countershaft260. As such, the third countershaft gear274may rotate about the first countershaft axis250with the first countershaft260and may not be rotatable with respect to the first countershaft260. For example, the third countershaft gear274may have a hole that may receive the first countershaft260and may be fixedly coupled to the first countershaft260. The third countershaft gear274may extend around the first countershaft axis250and may have a plurality of teeth that may be arranged around and may extend away from the first countershaft axis250. The teeth of the third countershaft gear274may contact and may mate or mesh with the teeth of the third gear224. The third countershaft gear274may have a different diameter than the first countershaft gear270and the second countershaft gear272. In at least one configuration, the third countershaft gear274may be axially positioned along the first countershaft axis250between the second countershaft gear272of the first countershaft gear set212and the fourth countershaft gear276of the first countershaft gear set212. The fourth countershaft gear276is fixedly disposed on the first countershaft260or fixedly mounted to the first countershaft260. As such, the fourth countershaft gear276may rotate about the first countershaft axis250with the first countershaft260and may not be rotatable with respect to the first countershaft260. For example, the fourth countershaft gear276may have a hole that may receive the first countershaft260and may be fixedly coupled to the first countershaft260or may be integrally formed with the first countershaft260. The fourth countershaft gear276may extend around the first countershaft axis250and may have a plurality of teeth that may be arranged around and may extend away from the first countershaft axis250. The teeth of the fourth countershaft gear276may contact and may mate or mesh with the teeth of the fourth gear226. The fourth countershaft gear276may have a different diameter than the first countershaft gear270, the second countershaft gear272, and the third countershaft gear274. In at least one configuration, the fourth countershaft gear276may be axially positioned along the first countershaft axis250further from the electric motor module26than the third countershaft gear274of the first countershaft gear set212. The second countershaft gear set214, if provided, is received in the transmission housing cavity206and may be rotatable about a second countershaft axis250′. The second countershaft axis250′ may be disposed parallel or substantially parallel to the axis70and the first countershaft axis250in one or more embodiments. The second countershaft gear set214may generally be disposed on an opposite side of the axis70from the first countershaft gear set212or may be disposed such that the first countershaft axis250and the second countershaft axis250′ may be disposed at a common radial distance from the axis70. The first and second countershaft gear sets212,214may be positioned at any suitable rotational angle or position about the axis70. The second countershaft gear set214may have the same or substantially the same configuration as the first countershaft gear set212. For example, the second countershaft gear set214may include a second countershaft260′ that may be analogous to or may have the same structure as the first countershaft260. In addition, the second countershaft gear set214may include a plurality of gears that are rotatable with the second countershaft260′. In the configuration shown, the plurality of gears of the second countershaft gear set214include a first countershaft gear270′, a second countershaft gear272′, a third countershaft gear274′, and a fourth countershaft gear276′; however, it is contemplated that a greater number of gears or a lesser number of gears may be provided. The first countershaft gear270′, second countershaft gear272′, third countershaft gear274′, and the fourth countershaft gear276′ of the second countershaft gear set214may be analogous to or may have the same structure as the first countershaft gear270, second countershaft gear272, third countershaft gear274, and the fourth countershaft gear276, respectively, of the first countershaft gear set212. The first countershaft gear270′, second countershaft gear272′, third countershaft gear274′, and the fourth countershaft gear276′ may be arranged along and may be rotatable about a second countershaft axis250′ rather than the first countershaft axis250and may be fixed to the second countershaft260′ rather than the first countershaft260. The first gear220and the first countershaft gears270,270′ may provide a different gear ratio than the second gear222and the second countershaft gears272,272′, the third gear224and the third countershaft gears274,274′, and the fourth gear226and the fourth countershaft gears276,276′. Gear ratios may be provided that are greater than 1:1, less than 1:1, equal (i.e., 1:1), or combinations thereof. The teeth of the drive pinion gears and the countershaft gears may be of any suitable type. As a non-limiting example, the meshing teeth of the members of the set of drive pinion gears210, the gears of the first countershaft gear set212, and the gears of the second countershaft gear set214may have a helical configuration. Shift Mechanism Referring primarily toFIGS.2,5and6, the shift mechanism32is configured to selectively connect a member of the set of drive pinion gears210to the drive pinion30. For example, the shift mechanism32may operatively connect a member of the set of drive pinion gears210to the drive pinion30to provide torque at a desired gear ratio, and hence may change the torque transmitted between the electric motor module26and the differential assembly22. The shift mechanism32may couple one member of the set of drive pinion gears210at a time to the drive pinion30. The member of the set of drive pinion gears210that is coupled to the drive pinion30may be rotatable about the axis70with the drive pinion30. The shift mechanism32may be received in or partially received in a shift mechanism cavity300, which is best shown inFIGS.2and3. The shift mechanism cavity300may be at least partially defined by the second transmission housing202may be disposed proximate an end of the axle assembly10. Referring toFIGS.1and2, a cover302may enclose an end of the axle assembly10and help define the shift mechanism cavity300. The cover302may be mounted on the end of the second transmission housing202to help enclose the shift mechanism cavity300. The cover302may be a single component or may be an assembly of multiple parts. A portion of the cover302is removed inFIG.3. The shift mechanism32may have any suitable configuration. In at least one configuration such as is shown inFIG.5, the shift mechanism32may include a shift collar310, an actuator312, a detent linkage314, a linkage316, a collar318, and a linkage retaining device320. The shift mechanism32may also include a biasing member322, a first pin324, and a second pin326. Referring primarily toFIGS.5-7, the shift collar310may be rotatable about the axis70with the drive pinion30. In addition, the shift collar310may be moveable along the axis70with respect to the drive pinion30. The shift collar310may selectively connect a member of the set of drive pinion gears210to the drive pinion30as will be discussed in more detail below. The shift collar310may be at least partially received in the shift mechanism cavity300and may be extendable through components of the transmission204, such as the set of drive pinion gears210. In at least one configuration, the shift collar310may include a first end330, a second end332, a shift collar hole334, and a shift collar spline336. The shift collar310may also include a first tubular shift collar portion340, a second tubular shift collar portion342, a shift collar gear344, a threaded portion348or combinations thereof. Referring primarily toFIG.6, the first end330may face toward the drive pinion30. In addition, the first end330may be disposed adjacent to the drive pinion30or the drive pinion extension90. The second end332may be disposed opposite the first end330. As such, the second end332may face away from the drive pinion30. The shift collar hole334may extend along the axis70between the first end330and the second end332. In at least one configuration, the shift collar hole334may be configured as a through hole that may extend from the first end330to the second end332. The drive pinion30or the drive pinion extension90may be received inside the shift collar hole334. Referring toFIGS.5and7, the shift collar spline336may couple the shift collar310to the drive pinion30or the drive pinion extension90. The shift collar spline336may be disposed in the shift collar hole334and may be axially positioned near the first end330. The shift collar spline336may extend toward the axis70and may mate with a spline of the drive pinion30or the spline98of the drive pinion extension90that may have spline teeth that may extend away from the axis70. The mating splines may allow the shift collar310to move in an axial direction or along the axis70while inhibiting rotation of the shift collar310about the axis70with respect to the drive pinion30. Thus, the shift collar310may be rotatable about the axis70with the drive pinion30when the shift collar spline336mates with the spline of the drive pinion30or the drive pinion extension90. The first tubular shift collar portion340may extend from the first end330toward the second end332. The first tubular shift collar portion340may have a hollow tubular configuration and may be at least partially received inside the set of drive pinion gears210of the transmission204. The first tubular shift collar portion340may have a larger outside diameter than the second tubular shift collar portion342. The second tubular shift collar portion342, if provided, may extend from the second end332toward the first tubular shift collar portion340or to the first tubular shift collar portion340. For instance, the second tubular shift collar portion342may have a hollow tubular configuration and may be at least partially disposed outside of the set of drive pinion gears210. The shift collar gear344may be disposed between the first end330and the second end332of the shift collar310. In at least one configuration, the shift collar gear344may be disposed opposite the shift collar hole334and may extend from the first tubular shift collar portion340. The shift collar gear344may have teeth that may be arranged around the axis70and that may extend away from the axis70and away from the shift collar hole334. The shift collar spline336may be disposed opposite the shift collar gear344. The shift collar gear344is engageable with different members of the set of drive pinion gears210as will be discussed in more detail below. The threaded portion348may be axially positioned between the first end330and the second end332. For instance, the threaded portion348may be provided with the second tubular shift collar portion342and may be axially positioned between the first tubular shift collar portion340and the second end332. The threaded portion348may be disposed on an exterior side of the second tubular shift collar portion342that may face away from the axis70. It is also contemplated that the threaded portion348may be omitted. Referring toFIG.5, the actuator312is configured to move the shift collar310along the axis70to selectively connect a member of the set of drive pinion gears210to the drive pinion30. The actuator312may be of any suitable type, such as an electrical, electromechanical, or mechanical actuator. In at least one configuration, the actuator312may be mounted to the second transmission housing202. A portion of the actuator312may be rotatable about an actuator axis350. For instance, the actuator312may have an actuator shaft352that may extend along the actuator axis350and may be rotatable about the actuator axis350. The actuator shaft352may be operatively connected to the detent linkage314. Referring toFIGS.5and7, the detent linkage314is coupled to the actuator312. For instance, the detent linkage314may be fixedly coupled to the actuator shaft352. As such, the detent linkage314may be rotatable about the actuator axis350with the actuator shaft352. The detent linkage314may define a plurality of recesses360. The recesses360may be configured to receive a detent feature362. The detent feature362may inhibit rotation of the detent linkage314about the actuator axis350when the detent feature362is received in a recess360. For example, rotation of the detent linkage314may be inhibited when the detent feature362is in a recess360and a sufficient actuation force is not provided by the actuator312to overcome the rotational resistance exerted by the detent feature362. The detent linkage314may be rotatable about the actuator axis350with respect to the linkage316. The linkage316may operatively connect the actuator312to the shift collar310. In at least one configuration, the linkage316may be positioned along the actuator axis350closer to the actuator312than the detent linkage314is positioned to the actuator312. The linkage316may be rotatable about the actuator axis350. In at least one configuration, the linkage316be rotatably disposed on the detent linkage314and may be rotatable about the actuator axis350. The linkage316may normally rotate with the detent linkage314but may rotate with respect to the detent linkage314when a blocked shift condition is present. The linkage316may define a plurality of gaps or recesses370. The gaps or recesses may be defined by at least one tooth that may be provided with the linkage316. For instance, the linkage316may have a set of teeth. In the configuration shown, a first tooth372and a second tooth374are shown; however, it is contemplated that a different number of teeth may be provided. The teeth may be arranged such that at least one gap or recess370is disposed adjacent to a tooth. For instance, a gap or recess370may be provided between adjacent teeth or on opposite sides of a tooth. The recesses370may be configured to receive an engagement feature462of the linkage retaining device320as will be discussed in more detail below. Referring toFIGS.5and6, the collar318may receive the shift collar310. The collar318may extend at least partially around the axis70in the shift collar310. For instance, the collar318may be configured as a ring that may extend around the axis70. The collar318may be coupled to the linkage316as will be discussed in more detail below. In at least one configuration and as is best shown inFIG.6, the collar318may include a first collar side440, a second collar side442, and a collar hole444. The collar318may also include a collar arm446and a shift block448. The first collar side440may face toward the transmission module28, the drive pinion30, or both. The second collar side442may be disposed opposite the first collar side440. As such, the second collar side442may face away from the transmission module28, the drive pinion30, or both. The collar hole444may extend between the first collar side440and the second collar side442. The collar hole444may be a through hole that may extend through the collar318. The shift collar310is received inside the collar hole444and may be rotatable about the axis70with respect to the collar318. For instance, the second tubular shift collar portion342may be received inside the collar hole444and may extend through the collar hole444. In at least one configuration, the collar hole444may receive a bearing assembly that may be positioned between the shift collar310and the collar318. For example, the bearing assembly may extend from an outside circumference of the second tubular shift collar portion342to the inside diameter of the collar318that defines the collar hole444. Referring primarily toFIGS.5-7, the collar arm446extends from the collar318. For instance, the collar arm446may extend from the collar318in a direction that extends away from the axis70. In the configuration shown, the collar arm446is shown extending at an oblique angle from the collar318and is angled away from the transmission204; however, it is contemplated that the collar arm446may be angled toward the transmission204or may be disposed substantially perpendicular to the axis70. The term “substantially perpendicular” is used herein to designate features or axes that are the same as or very close to perpendicular and includes features that are within ±3° of being perpendicular each other. The collar arm446may be integrally formed with the collar318or may be a separate component that is fastened to the collar318. In the configuration shown, the collar arm446is illustrated as being integrally formed with the collar318and is disposed below the axis70. The collar arm446is moveably disposed on an alignment rod450. The collar arm446and the alignment rod450may cooperate to limit or inhibit rotation of the collar318about the axis70. The alignment rod450is disposed on the shift mechanism cavity300. For instance, the alignment rod450may be received in the shift mechanism cavity300and may be mounted to the second transmission housing202, the cover302, or both. In the configuration shown, the alignment rod450is shown as being received in a pocket or recess in the cover302and in a pocket of the second transmission housing202. The alignment rod450may be fixedly disposed on the cover302or the second transmission housing202or may be disposed in a manner in which movement of the alignment rod450is limited. For example, the alignment rod450may slide along the axis70and/or rotate about the axis70but may remain its axial orientation. The alignment rod450may be disposed substantially parallel to the axis70. In at least one configuration, the alignment rod450may be disposed below the axis70, below the shift collar310, or both. In at least one configuration, the collar arm446has an opening in which the alignment rod450may be received. The opening may be a hole, recess, slot or the like inside which the alignment rod450may be received. It is also contemplated that the alignment rod450may define a recess or slot that extends along its axial length and a portion of the alignment rod450, such as the end of the alignment rod450, may be received in the recess or slot in the alignment rod450. Referring toFIG.6, the shift block448, if provided, may be fixedly positioned with respect to the collar318. The shift block448may be integrally formed with the collar318or may be provided as a separate component that is attached to the collar318. For instance, the shift block448may extend from an outside circumference of the collar318, the second collar side442, or combinations thereof. The shift block448, if provided, may facilitate mounting of a fastener452that may connect or couple the linkage316to the collar318. The first thrust bearing410may facilitate rotation of the shift collar310about the axis70with respect to the collar318. The first thrust bearing410may be axially positioned between the first collar side440and the shift collar310. Optionally, washers may be axially positioned adjacent to one or both sides of the first thrust bearing410. The second thrust bearing412may facilitate rotation of the shift collar310about the axis70with respect to the collar318. The second thrust bearing412may be positioned between the second collar side442and the retainer nut414. Optionally a washer may be axially positioned adjacent to one or both sides of the second thrust bearing412. For example, a washer may be provided between the second thrust bearing412and the retainer nut414. The retainer nut414may be mounted to the shift collar310. For instance, the retainer nut414may have a threaded hole that may receive the second tubular shift collar portion342and mate with the threaded portion348of the shift collar310. The retainer nut414may inhibit axial movement of the shift collar310with respect to the collar318and may help secure the first thrust bearing410and the second thrust bearing412. It is also contemplated that the retainer nut414may be omitted and a different fastener or fastening technique may be used. For instance, a fastener like a snap ring or a press-fit fastener may replace a threaded connection. An encoder disc416may optionally be mounted to the drive pinion30or the drive pinion extension90. In at least one configuration, the encoder disc416may be disposed adjacent to the retainer nut414. For instance, the encoder disc416may be axially positioned between the retainer nut414and a support bearing418that rotatably supports the drive pinion30or drive pinion extension90. For example, the support bearing418may be positioned between a shoulder of the drive pinion30or drive pinion extension90and the support bearing418, if provided. The encoder disc416may have detectable features such as protrusions and/or recesses that may be detectable by a sensor to detect rotation or the rotational speed of the drive pinion30. The support bearing418may rotatably support the drive pinion30or drive pinion extension90. For instance, the drive pinion30or drive pinion extension90may be received inside and may be rotatably supported by the support bearing418, which in turn may be supported by the second transmission housing202, the cover302, or both. The linkage retaining device320is selectively engageable with the linkage316to limit or inhibit rotation of the linkage316in at least one direction about the actuator axis350. The linkage retaining device320may have any suitable configuration. For instance, the linkage retaining device320may be configured as a solenoid or linear actuator that has a shaft that is movable along a linkage retaining device axis460. In at least one configuration, the linkage retaining device axis460may be disposed substantially parallel to the axis70; however, it is contemplated that other orientations may be provided. The linkage retaining device axis460may be offset from the axis70. It is also contemplated that the linkage retaining device axis460may be disposed substantially perpendicular to the actuator axis350. Referring primarily toFIG.7, the linkage retaining device320may be mounted to a portion of the housing, such as the cover302. The linkage retaining device320may include an engagement feature462. The engagement feature462may be movable along the linkage retaining device axis460. For instance, the engagement feature462may be disposed at an end of the shaft of the linkage retaining device320. The engagement feature462may be engageable with at least one member of the set of teeth of the linkage316to limit or inhibit rotation of the linkage316about the actuator axis350. The detent linkage314may be rotatable about the actuator axis350with respect to the linkage316when the engagement feature462is engaged with at least one member of the set of teeth. The linkage retaining device320is operable independent from the detent feature362. Referring toFIG.5, the biasing member322may operatively connect the detent linkage314to the linkage316. In addition, the biasing member322may control relative rotational movement between the detent linkage314and the linkage316(e.g., rotational movement of the linkage316with respect to the detent linkage314). For example, the biasing member322may permit the actuator shaft352and the detent linkage314to rotate about the actuator axis350with respect to the linkage316when the shift collar310is inhibited from moving along the axis70, such as during a blocked shift as will be discussed in more detail below. The biasing member322may be positioned along the actuator axis350between the detent linkage314and the linkage316. The biasing member322may have any suitable configuration. For instance, the biasing member322may be configured as a spring, such as a torsion spring. The first pin324may extend from the detent linkage314toward the linkage316. The first pin324may be spaced apart from the linkage316. The first pin324may engage an end or tab of the biasing member322. The second pin326may extend from the linkage316. The second pin326may be spaced apart from the first pin324and the detent linkage314. The second pin326may engage the same end or tab and/or a different end or tab of the biasing member322. Various components of the shift mechanism32may typically move together when the shift collar310is free to move along the axis70. For instance, components such as the actuator shaft352, detent linkage314, linkage316, and the biasing member322may rotate together about the actuator axis350when the actuator shaft352is rotated and the shift collar310is free to move along the axis70. However, some of these components may move respect to each other when the shift collar310is not free to move along the axis70. For example, the actuator shaft352and the detent linkage314may be rotatable with respect to the linkage316when the shift collar310is not free to move along the axis70. The shift collar310may not be free to move along the axis70when the rotational speed of the shift collar310about the axis70is not sufficiently synchronized with the rotational speed of a member of the set of drive pinion gears210. For instance, the shift collar310may be blocked from shifting or moving along the axis70when the teeth of the shift collar gear344are inhibited from entering the gaps between the inner gear teeth of a drive pinion gear or exiting the gaps between the inner gear teeth of a drive pinion gear. Relative rotational movement of the detent linkage314with respect to the linkage316is accommodated by the biasing member322when there is a blocked shift. For instance, the first pin324may remain in engagement with the second end or second tab of the biasing member322but may be rotated to disengage or move away from the first end or first tab of the biasing member322. The second pin326may remain in engagement with the first end but may be disengaged from the second end. This relative rotational movement may store potential energy in the biasing member322. The potential energy may be released when the blocked shift condition is no longer present, such as when the rotational speed of the shift collar310is sufficiently synchronized with the rotational speed of a member of the set of drive pinion gears210to permit axial movement of the shift collar310. As a result, the actuator312may complete its intended rotation of the actuator shaft352as if the shift collar310not blocked even when a blocked shift condition is present, thereby avoiding heating/overheating of the actuator312and the consumption of energy that would occur if the actuator312had to continuously work or exert force to attempt to complete shifting of the shift collar310. Moreover, sufficient potential energy may be stored in the biasing member322that may be released to complete a shift of the shift collar310when sufficient synchronization is obtained. Operation of the Shift Mechanism Referring toFIGS.7-11, the actuator312may move the shift collar310along the axis70between a plurality of positions to selectively couple the shift collar310to the transmission204or to decouple the shift collar310from the transmission204. For instance, the actuator312may move the shift collar310along the axis70between the first, second, and third positions. Examples of these positions are illustrated inFIGS.7,9, and11. The actuator312may also move the shift collar310along the axis70to first and second neutral positions, which are best shown inFIGS.8and10. It is noted that inFIGS.7-11only a portion of the transmission204is shown to better illustrate movement of the shift collar310. In the examples below, reference to connecting or disconnecting a member of the set of drive pinion gears210to/from the drive pinion30includes direct and indirect connections to and disconnections from the drive pinion30. For instance, a member of the set of drive pinion gears210may be directly coupled to the drive pinion30or indirectly connected to the drive pinion30such as via the drive pinion extension90. Referring toFIG.7, the shift collar310is shown in the first position. In the first position, the shift collar310may couple the fourth gear226to the drive pinion30. For example, the teeth of the shift collar gear344may mesh with the inner gear teeth236of the fourth gear226. Torque may be transmitted from the rotor106to the first gear220such as via the rotor output flange130, from the first gear220to the first countershaft gears270,270′, from the first countershaft gears270,270′ to the fourth countershaft gears276,276′ via the first and second countershafts260,260′, respectively, from the fourth countershaft gears276,276′ to the fourth gear226, and from the fourth gear226to the drive pinion30via the shift collar gear344of the shift collar310. The first gear220, the second gear222, and the third gear224may be rotatable about the axis70. Torque may be provided at the first gear ratio in the first position, such as a low-speed gear ratio. The engagement feature462may be disposed in a recess370and may engage the first member372of the set of teeth of the linkage316but not the second tooth374to inhibit movement of the shift collar310in a first direction along the axis70when the shift collar310is in the first position and the linkage316is in a first rotational position as shown. The first direction along the axis70may be to the right from the perspective shown. It is also contemplated that an additional tooth could be provided on the linkage316to inhibit movement of the shift collar310in the second direction along the axis70. Referring toFIG.8, the shift collar310is shown in the first neutral position. In the first neutral position, the shift collar310may not couple any member of the set of drive pinion gears210to the drive pinion30. As such, the teeth of the shift collar gear344may be spaced apart from the first gear220, the second gear222, the third gear224, and the fourth gear226. The teeth of the shift collar gear344may be axially positioned between the inner gear teeth234of the third gear224and the inner gear teeth236of the fourth gear226. As such, the first gear220, the second gear222, the third gear224, and the fourth gear226may be rotatable about the axis70with respect to the drive pinion30when the shift collar310is in the first neutral position and torque may not be transmitted between the transmission204and the drive pinion30. The first neutral position may be positioned between the first position shown inFIG.7and the second position shown inFIG.9. The engagement feature462may be retracted out of a recess370in the linkage316when the shift collar310is in the first neutral position. For example, the engagement feature462may be aligned with the first tooth372or first member of the set of teeth of the linkage316when the shift collar310is in the first neutral position. The engagement feature462may be spaced apart from the first tooth372or may contact a side of the first tooth372that faces away from the actuator axis350in this position. Referring toFIG.9, the shift collar310is shown in the second position. In the second position, the shift collar310may couple the third gear224to the drive pinion30. For example, the teeth of the shift collar gear344may mesh with the inner gear teeth234of the third gear224. Torque may be transmitted from the rotor106to the first gear220such as via the rotor output flange130, from the first gear220to the first countershaft gears270,270′, from the first countershaft gears270,270′ to the third countershaft gears274,274′ via the first and second countershafts260,260′, respectively, from the third countershaft gears274,274′ to the third gear224, and from the third gear224to the drive pinion30via the shift collar gear344of the shift collar310. As such, the first gear220, the second gear222, and the fourth gear226may be rotatable about the axis70with respect to the drive pinion30when the second gear ratio is provided. Torque may be provided at the second gear ratio in the second position, such as a mid-speed gear ratio. The engagement feature462may be engageable with one or more teeth of the linkage316when the shift collar310is in the second position. For instance, the engagement feature462may engage the second tooth374or a second member of the set of teeth of the linkage316to inhibit movement of the shift collar310in the first direction along the axis70when the shift collar310is in the second position and the linkage316is in a second rotational position as shown. The engagement feature462may engage the first tooth372to inhibit movement of the shift collar310in a second direction along the axis70when the shift collar310is in the second position and the linkage316is in a second rotational position as shown. The second direction along the axis70may be disposed opposite the first direction, such as to the left from the perspective shown. Referring toFIG.10, the shift collar310is shown in the second neutral position. In the second neutral position, the shift collar310may not couple any member of the set of drive pinion gears210to the drive pinion30. As such, the teeth of the shift collar gear344may be spaced apart from the first gear220, the second gear222, the third gear224, and the fourth gear226. The teeth of the shift collar gear344may be axially positioned between the inner gear teeth234of the third gear224and the inner gear teeth232of the second gear222. As such, the first gear220, the second gear222, the third gear224, and the fourth gear226may be rotatable about the axis70with respect to the drive pinion30when the shift collar310is in the second neutral position and torque may not be transmitted between the transmission204and the drive pinion30. The second neutral position may be positioned between the second position shown inFIG.9and the third position shown inFIG.11. The engagement feature462may be retracted out of a recess370in the linkage316when the shift collar310is in the second neutral position. For example, the engagement feature462may be aligned with the second tooth374of the linkage316when the shift collar310is in the second neutral position. The engagement feature462may be spaced apart from the second tooth374or may contact a side of the second tooth374that faces away from the actuator axis350in this position. Referring toFIG.11, the shift collar310is shown in the third position. In the third position, the shift collar310may couple the second gear222to the drive pinion30. For example, the teeth of the shift collar gear344may mesh with the inner gear teeth232of the second gear222. Torque may be transmitted from the rotor106to the first gear220such as via the rotor output flange130, from the first gear220to the first countershaft gears270,270′, from the first countershaft gears270,270′ to the second countershaft gears272,272′ via the first and second countershafts260,260′, respectively, from the second countershaft gears272,272′ to the second gear222, and from the second gear222to the drive pinion30via the shift collar gear344of the shift collar310. The shift collar gear344may not engage the inner gear teeth234of the third gear224or the inner gear teeth236of the fourth gear226. As such, the first gear220, the third gear224, and the fourth gear226may be rotatable about the axis70with respect to the drive pinion30when the third gear ratio is provided. Torque may be provided at the third gear ratio in the third position, such as a high-speed gear ratio. The engagement feature462may engage the second tooth374of the linkage316to inhibit movement of the shift collar310in the second direction along the axis70, or to the left from the perspective shown, when the shift collar310is in the third position and the linkage316is in a third rotational position as shown. It is also contemplated that an additional tooth could be provided on the linkage316to inhibit movement of the shift collar310in the first direction along the axis70. The present invention may provide an alignment shaft that limits or inhibits rotation of the collar about an axis. Such a configuration may help reduce load forces or torsional stress on components of a shift mechanism. In addition, such a configuration may help the collar aligned and in engagement with the linkage throughout the operating range or travel distance of components of the shift mechanism, thereby providing a more robust connection and reliable operation. The present invention may provide a linkage retaining device in addition to a detent mechanism to help reduce or prevent load forces from being transmitted to the actuator, such as when the shift collar is “kicked out” or experiences load forces in an axial direction or along the axis associated with meshing gear teeth rather than operation of the actuator. For example, teeth of the shift collar may mesh with teeth of a member of the set of drive pinion gears. The shape or curvature of the teeth, such as when a concave flank of one tooth meshes with a convex flank of another tooth, can result in an axial force vector that urges the shift collar teeth to self-center with respect to the drive pinion gear. Thus the axial force may urge the shift collar to move along the axis to a more centered position when there is some degree of misalignment. In the absence of the linkage retaining device, axial forces on the shift collar or axial movement of the shift collar may transmit load forces upstream toward the actuator, which may lead to increased stress on the actuator or other components and unintended rotation of the actuator shaft. The linkage retaining device absorbs or resists such load forces from being transmitted upstream past the linkage which may help improve durability of components such as the actuator. The linkage retaining device may act as a stop that prevents movement of the shift collar in at least one axial direction when the shift collar is in meshing engagement with the teeth of a member of the set of drive pinions, thereby permitting sufficient tooth meshing to provide reliable torque transmission while reducing or avoiding undesired axial movement of the shift collar and upstream force transmission in the shift mechanism past the linkage retaining device. While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention. | 67,471 |
11859719 | DETAILED DESCRIPTION FIG.1is a schematic view showing a transmission1for a vehicle. The transmission has an input shaft2and an output shaft3. The input shaft2and the output shaft3are connected to each other by gear wheels4. For example, a first gear wheel5of the input shaft2is engaged with a first gear wheel6of the output shaft3, and a second gear wheel7of the input shaft2is engaged with a second gear wheel8of the output shaft3. The gear wheels6,8of the output shaft3can be idle wheels, i.e. these gear wheels6,8are journaled on the output shaft3but can be rotationally locked to the output shaft by a synchronizer9. By movement of a synchronizer sleeve10in a first direction, the first gear wheel6of the output shaft3is rotationally locked to the output shaft3. By movement of the synchronizer sleeve10in a second opposite direction, the second gear wheel8of the output shaft3is rotationally locked to the output shaft3. Thus, one gear is represented by the first gear wheel5of the input shaft2and the first gear wheel6of the output shaft3. A further gear is represented by the second gear wheel7of the input shaft2and the second gear wheel8the output shaft3. The input shaft2can be driven by a motor11. The motor11can be any suitable motor, such an internal combustion engine, electric motor, etc. Between the motor11and the transmission1, a clutch12is suitably arranged for enabling the transmission1to be connected or disconnected to/from the motor11. In the example embodiment illustrated inFIG.1, the output shaft3has an output gear wheel13. The output gear wheel13is rotationally locked to the output shaft3and is engaged with a ring gear wheel14of a differential device15, thereby connecting the output shaft3to the ring gear wheel14. The differential device15is in turn suitably conventionally connected to the driven wheels of a vehicle (not shown). As schematically indicated inFIG.1, the transmission1comprises a parking lock device16. The parking lock device16has a wheel17, such as a gear wheel or ratchet wheel rotationally locked to a shaft3of the transmission1. In the example embodiment illustrated inFIG.1, the wheel17is arranged on the output shaft3. The transmission1further comprises a pawl18and an actuator unit (not shown inFIG.1) arranged for movement of the pawl18relative to the wheel17. The pawl18has a locked position where the pawl18and the wheel17are engaged and an unlocked position where the pawl18and the wheel17are disengaged from each other. When the pawl18and the wheel17are engaged with each other, the output shaft3is locked to a housing19of the transmission1. FIGS.2A and2Bshow a side view of the parking lock device16more in detail. InFIG.2Athe parking lock device locks the shaft3against rotation. The parking lock device16comprises the wheel17, the pawl18and the actuator unit20arranged for movement of the pawl18relative to the wheel17. InFIG.2Athe pawl18is in a locked position where the pawl18and the wheel17are engaged, thereby locking the shaft3against rotation. The pawl18and the actuator unit20are mechanically coupled to each other by a pin and slot mechanism21having a guide slot22and a guide pin23received by the guide slot22. In the example embodiment illustrated inFIG.2A, the guide pin23is attached to the actuator unit20and the guide slot22is arranged in the pawl18, though in another embodiment the guide pin could be attached to the pawl and the guide slot could be arranged in the actuator unit. The pawl18is suitably pivotally arranged for pivoting about a pivot axis24from the locked position to the unlocked position, and from the unlocked position to the locked position. In the example embodiment illustrated inFIGS.2A and2B, the pawl has a body28with a first end25pivotally arranged for pivoting about the pivot axis24and a second end26mechanically coupled to the actuator unit20by the pin and slot mechanism21. The first end25of the pawl18is pivotally connected to a fixed point, such as the housing19of the transmission1. The guide slot22is arranged at the second end26of the pawl18, opposite to the first end25of the pawl18. The body28is provided with a tooth29for engagement with the wheel17which tooth29is arranged between the first end25and the second end26of the pawl body28. The wheel17has suitably corresponding teeth30for receiving the tooth29between two teeth30. The wheel17(and the shaft3) is pivotable about a pivot axis27when the pawl18and the wheel17are disengaged. This wheel pivot axis27can be substantially in parallel with the pawl pivot axis24. The actuator unit20is arranged to move the pawl18from the unlocked position to the locked position by movement of the guide pin23along the guide slot22in a first direction, and from the locked position to the unlocked position by movement of the guide pin23along the guide slot22in a second direction. InFIGS.2A and2B, the first direction is from right to left, and the second direction is from left to right. InFIG.2Athe guide pin23is positioned in a leftmost position corresponding to the locked position of the pawl18where the pawl18and the wheel17are engaged. InFIG.2Bthe guide pin23is positioned furthest to the right in a position corresponding to the unlocked position of the pawl18where the pawl18and the wheel17are disengaged. The actuator unit20comprises a pushrod31for linear movement which pushrod31is mechanically coupled to the pawl18by the pin and slot mechanism21. At a free end32of the pushrod31, the guide pin23is attached to the pushrod31. For example, the actuator unit20may comprise a hydraulic cylinder60for movement of the pushrod31. In other words; the pushrod31is connected to a piston of the hydraulic cylinder60. InFIG.2Athe pushrod31has been moved by the hydraulic cylinder60to an extended position, whereas inFIG.2Bthe pushrod has been moved to a retracted position by the hydraulic cylinder60. Optionally, the hydraulic cylinder can be replaced by an electric motor and a ball screw, or a pneumatic cylinder, or by any another suitable drive unit. The actuator unit20can have a support portion33arranged to support and guide the pushrod31for counteracting deviation from the linear movement of the pushrod31. Such a support portion33may have one or more guiding surfaces34for guiding the pushrod31in the linear direction. In the example embodiment illustrated inFIGS.2A and2B, the actuator unit20comprises a spring35arranged to counteract movement of the pawl18from the locked position towards the unlocked position. The spring35can be a coil spring or any other suitable spring. The spring35will enable engagement of the pawl18and the wheel17even if initially there is a mismatch between the tooth29of the pawl18and the teeth30of the wheel17. As soon as the relative position between the pawl18and the wheel17is achieved the spring35will ensure engagement of the pawl18and the wheel17. The spring35can be arranged on the pushrod31. In the example embodiment illustrated inFIGS.2A and2B, the pushrod31has a first outer portion36to which the guide pin23is attached. The outer portion36is arranged to interact with the guiding surfaces34as described hereinabove. Further, the pushrod31has an inner portion37with a rod38receiving the spring35. The outer portion36and the inner portion37are axially displaceable relative to each other in the movement direction51of the pushrod31. The spring35is arranged between the outer portion36and a support part or spring seat39of the inner portion37of the pushrod31, for counteracting relative movement of the inner portion37and the outer portion36. This means that when the pushrod is being extended (moved from right to left inFIGS.2A and2B) the force will be transferred from the inner portion37to the outer portion36by means of the spring35. When the pushrod is being retracted (moved from left to right inFIGS.2A and2B), the spring will be unloaded, and the force will be directly transferred from the inner portion37to the outer portion36. FIGS.3A and3Bshow the parking lock device16inFIGS.2A and2Bin top views.FIG.3Acorresponds toFIG.2Awith respect to the guide pin position, andFIG.3Bcorresponds toFIG.2Bwith respect to the guide pin position. The outer portion36of the pushrod31has two legs40forming a fork and the pawl18is received between the legs40. The guide pin23is attached to the legs40and received by the guide slot22of the pawl18. The outer portion36has a through hole41for receiving the rod38of the inner portion37. At the end of the rod38a carrier or pusher unit42is arranged to transfer the force from the inner portion37to the outer portion36when the pushrod31is being retracted. FIG.4shows an example embodiment of a guide slot22of the pin and slot mechanism21. For at least a part55of the guide slot22, the main extension direction50of the guide slot22is angled relative to the linear movement direction51of the pushrod31, thereby causing the guide pin23to push against a surface52defining the guide slot22, when the pushrod31is moved. When the pushrod31is being retracted the guide pin23will push the pawl18away from the wheel17. The guide pin23will push against an upper portion52aof the guide slot defining surface52. In the example embodiment illustrated inFIGS.2A and2B, this means the pawl18is pivoted anti-clockwise about the pawl pivot axis24. When the pushrod31is being extended the guide pin23will push the pawl18towards the wheel17. The guide pin23will push against a lower portion52bof the guide slot defining surface52. In the example embodiment illustrated inFIGS.2A and2B, this means the pawl18is pivoted clockwise about the pawl pivot axis24. In other words; the main extension direction50of said guide slot part55has an extension direction component53perpendicular to the linear movement direction51of the pushrod31in a direction away from the wheel17when the guide pin23moves in the first direction from the unlocked position towards the locked position. Further, the main extension direction50of said guide slot part55has an extension direction component54in parallel with the linear movement direction51of the pushrod31in a direction towards the locked position when the guide pin23moves in the first direction. In addition to the inclined part55of the guide slot22, at an end56of the guide slot22, the guide slot22can have a different extension direction57, preferably an extension direction57substantially in parallel with the movement direction51of the pushrod31. Hereby, the position of the guide pin23at the end position (corresponding to the locked position of the pawl) can be more stable preventing accidental movement of the guide pin23and the pawl18from the locked position. Optionally, both ends56,58of the guide slot22can have such parts with a main extension direction substantially in parallel with the movement direction of the pushrod. Thus, the guide slot22can be Z-shaped for instance. It is to be understood that the present invention is not limited to the embodiments described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the appended claims. | 11,140 |
11859720 | DETAILED DESCRIPTION The following disclosure describes various illustrative embodiments and examples for implementing the features and functionality of the present disclosure. While particular components, arrangements, and/or features are described below in connection with various example embodiments, these are merely examples used to simplify the present disclosure and are not intended to be limiting. It will of course be appreciated that in the development of any actual embodiment, numerous implementation-specific decisions may be made to achieve the developer's specific goals, including compliance with system, business, and/or legal constraints, which may vary from one implementation to another. Moreover, it will be appreciated that, while such a development effort might be complex and time-consuming, it would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. While the making and using of various embodiments of the present disclosure are discussed in detail below, it should be appreciated that the present disclosure provides many applicable inventive concepts, which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative and do not delimit the scope of the present disclosure. In the interest of clarity, not all features of an actual implementation may be described in the present disclosure. In the Specification, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the present disclosure, the devices, components, members, apparatuses, etc. described herein may be positioned in any desired orientation. Thus, the use of terms such as “above”, “below”, “upper”, “lower”, “top”, “bottom” or other similar terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components, should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, as the components described herein may be oriented in any desired direction. When used to describe a range of dimensions or other characteristics (e.g., time, pressure, temperature) of an element, operations, and/or conditions, the phrase “between X and Y” represents a range that includes X and Y. Still further, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Example embodiments that may be used to implement the features and functionality of this disclosure will now be described with more particular reference to the accompanying FIGURES. FIGS.1A-Bare front views of an exterior of a tensioning apparatus101. In certain embodiments, the tensioning apparatus101is operable to supply tension, for example, for a belt or chain in a belt or chain-driven system, such as a system including a belt or chain linking a motor to another system element driven by such motor. The tensioning apparatus101includes a housing102, a trolley104, and a fastener106. The trolley104is adjustably positioned within the housing102about, or around, the fastener106. In general, the fastener106extends at least partially through the housing102in order to facilitate adjustment of the trolley104. In the embodiment and orientation shown inFIGS.1A-B, the fastener106is a bolt that extends vertically through an entirety of the housing102. However, it should be appreciated that the fastener106can be substituted with any other type of fastener, such as another suitable threaded member, with the fastener106being secured to the housing102in any suitable fashion. Still with reference toFIGS.1A-B, the trolley104includes an attachment point108for securing a pulley that engages, for example, a belt or chain for purposes of supplying tension. The attachment point108can be, for example, a threaded hole or other opening configured to receive a fastener, such as a bolt, that secures the pulley to the trolley104. The tensioning apparatus101is shown inFIGS.1A-Bwithout a pulley in order to better illustrate the trolley104. An example with a pulley will be described relative toFIGS.2A-B. Still with reference toFIGS.1A-B, the trolley104is adjustable within the housing102along an opening103in the housing102by applying force to the fastener106in either a tightening direction or a loosening direction. The opening103can be, for example, a slot that extends substantially parallel to the fastener106. In various embodiments, when a pulley is coupled to the trolley104via the attachment point108as described above, the fastener106can be tightened to a target torque (e.g., 8-12 inch-pounds) in order to supply configurable tension for a belt or chain via the pulley. In certain embodiments, once the target torque is reached, the fastener106can serve as a lockdown bolt, for example, that is secured to the housing102(e.g., via a nut) to prevent assembly loosening during operation. The pulley moves in unison with the trolley104along the opening103to supply the tension. In this manner, the opening103can be, or serve as, a slide along which the pulley moves for positional adjustment. Still with reference toFIGS.1A-B, in various embodiments, the trolley104can rise or lower in response to corresponding adjustment of the fastener106. For example, ifFIGS.1A and1Bare treated as depicting starting and adjusted positions, respectively, with reference toFIG.1A, force can be applied to the fastener106in a tightening direction to lift or raise the trolley104to the position shown inFIG.1B, with the raised position supplying increased tension. It should be appreciated that the fastener106can also be used in reverse fashion to decrease tension. For example, ifFIG.1Bis treated as representing a starting position andFIG.1Ais treated as representing an adjusted position, with reference toFIG.1B, force can be applied to the fastener106in a loosening direction to drop or lower the trolley104to the position shown inFIG.1A, with the lowered position supplying decreased tension. FIGS.2A-Bare front views of an exterior of a tensioning apparatus201with a pulley210coupled thereto. In general, the tensioning apparatus201corresponds to the tensioning apparatus101after the pulley210has been coupled to the attachment point108shown inFIG.1. As described above, the fastener106can be tightened to a target torque (e.g., 8-12 inch-pounds) in order to supply configurable tension for a belt or chain via the pulley210. The pulley210moves in unison with the trolley104along the opening103to supply the tension. The opening103can be, or serves as, a slide along which the pulley210moves for positional adjustment. Still with reference toFIGS.2A-B, in various embodiments, the pulley210can rise or lower in unison with the trolley104in response to corresponding adjustment of the fastener106. For example, ifFIGS.2A and2Bare treated as depicting starting and adjusted positions, respectively, with reference toFIG.2A, force can be applied to the fastener106in a tightening direction to lift or raise the pulley210to the position shown inFIG.2B, with the raised position supplying increased tension. As described previously, it should be appreciated that the fastener106can also be used in reverse fashion to decrease tension. For example, ifFIG.2Bis treated as representing a starting position andFIG.2Ais treated as representing an adjusted position, with reference toFIG.2B, force can be applied to the fastener106in a loosening direction to drop or lower the pulley210to the position shown inFIG.2A, with the lowered position supplying decreased tension. FIGS.3A-Bare rear views of an interior of a tensioning apparatus301. In some embodiments, the tensioning apparatus301can correspond to the tensioning apparatus101ofFIGS.1A-Band/or the tensioning apparatus201ofFIGS.2A-B. In particular, the tensioning apparatus301includes a housing302, a trolley304, and a fastener306that are generally arranged and configured to operate as described relative to the housing102, the trolley104, and the fastener106, respectively, ofFIGS.1A-Band2A-B. The trolley304includes an attachment point308similar to the attachment point108ofFIGS.1A-B, with the attachment point308being shown from a rear perspective inFIGS.3A-B. Still with reference toFIGS.3A-B, in various embodiments, the trolley304can rise or lower in response to corresponding adjustment of the fastener306. For example, ifFIGS.3A and3Bare treated as depicting starting and adjusted positions, respectively, with reference toFIG.3A, force can be applied to the fastener306in a tightening direction to lift or raise the trolley304to the position shown inFIG.1B, with the raised position supplying increased tension via a pulley coupled to the attachment point308in the fashion shown and described relative toFIGS.2A-B. It should be appreciated that the fastener306can also be used in reverse fashion to decrease tension. For example, ifFIG.3Bis treated as representing a starting position andFIG.3Ais treated as representing an adjusted position, with reference toFIG.3B, force can be applied to the fastener306in a loosening direction to drop or lower the trolley304(and a pulley coupled thereto) to the position shown inFIG.3A, with the lowered position supplying decreased tension. FIGS.4A-Bare rear views of an interior of a tensioning apparatus401. In some embodiments, the tensioning apparatus401can correspond to the tensioning apparatus101ofFIGS.1A-Band/or the tensioning apparatus201ofFIGS.2A-B. In particular, the tensioning apparatus401includes a housing402, a trolley404, and a fastener406that are generally arranged and configured to operate as described relative to the housing102, the trolley104, and the fastener106, respectively, ofFIGS.1A-Band2A-B. The trolley404includes an attachment point408similar to the attachment point108ofFIGS.1A-B, with the attachment point408being shown from a rear perspective inFIGS.4A-B. In contrast to the tensioning apparatus301ofFIGS.3A-B, the tensioning apparatus401includes a spring410and a plate412. The plate412is disposed about the fastener406inside the trolley404. The plate412can be, for example, a nut plate or threaded body with flanges. The spring410is disposed about the fastener406between the plate412and a top interior surface411of the trolley404. In a typical embodiment, the spring410compresses between the plate412and the top interior surface411in response to force applied to the fastener406in a tightening direction. In similar fashion, in a typical embodiment, the spring410decompresses in response to force applied to the fastener406in a loosening direction. In various embodiments, when the spring410is compressed between the plate412and the top interior surface411of the trolley404, the spring410preserves a position of the trolley404and the pulley coupled thereto against movement in a direction opposite the direction of compression of the spring410. In particular, in the example ofFIGS.4A-B, the spring410preserves the position of the trolley404and the pulley coupled thereto against downward movement, or slipping, by applying opposite upward force within an elasticity limit of the spring410. In this way, downward force or slipping of the trolley404and the pulley coupled thereto is typically prevented, or compensated for by counterforce from the spring410, until the spring410is fully decompressed. Tension applied via tightening of the fastener406is thereby preserved subject to the elasticity limit of the spring410. Advantageously, in certain embodiments, as a belt or chain to which tension is applied wears, the spring410, when compressed, provides consistent tension for the life of the belt or chain. Still with reference toFIGS.4A-B, in various embodiments, the trolley404can rise or lower in response to corresponding adjustment of the fastener406. Additionally, in various embodiments, the spring410can compress or decompress in response to corresponding adjustment of the fastener406. For example, ifFIGS.4A and4Bare treated as depicting starting and adjusted positions, respectively, with reference toFIG.4A, force can be applied to the fastener406in a tightening direction to both raise the trolley404to the position shown inFIG.1Band compress the spring410between the plate412and the top interior surface411of the trolley404. As described previously, the raised position can supply increased tension via a pulley coupled to the attachment point408in the fashion shown and described relative toFIGS.2A-B, and the compressed spring410can preserve such position. It should be appreciated that the fastener406can also be used in reverse fashion to decompress the spring410and thereafter decrease tension. For example, ifFIG.4Bis treated as representing a starting position andFIG.4Ais treated as representing an adjusted position, with reference toFIG.4B, force can be applied to the fastener406in a loosening direction to decompress the spring410such that, after the spring is fully decompressed, further force in the loosening direction causes the trolley404(and a pulley coupled thereto) to be dropped or lowered to the position shown inFIG.4A, with the lowered position supplying decreased tension. FIGS.5A-Billustrate an example of a tensioning system500. The tensioning system500includes a tensioning apparatus501having a tensioning pulley510, a motor514having a motor pulley516, a motor-driven system518having a drive pulley520, and a belt522. In various embodiments, the motor-driven system518can be, for example, a blower in a heating, ventilation, and air conditioning (HVAC) system). The belt522links the motor pulley516and the drive pulley520, for example, by being looped around each of the motor pulley516and the drive pulley520. The tensioning pulley510engages the belt522at a point between the motor pulley516and the drive pulley520and supplies tension for the belt522. AlthoughFIGS.5A-Bdescribe the belt522for purposes of illustration, it should be appreciated that the same principles are applicable to chains or other drive mechanisms. In general, the tensioning apparatus501can correspond to the tensioning apparatus101ofFIGS.1A-B, the tensioning apparatus201ofFIGS.2A-B, the tensioning apparatus301ofFIGS.3A-B, and/or the tensioning apparatus401ofFIGS.4A-B. For example, if the tensioning apparatus501corresponds to the tensioning apparatus301ofFIGS.3A-B, the tensioning apparatus501can be adjusted in the fashion described relative toFIGS.3A-Bto increase or decrease tension of the belt522. By way of further example, if the tensioning apparatus501corresponds to the tensioning apparatus401ofFIGS.4A-B, the tensioning apparatus501can further preserve a position of the pulley510, and the tension applied to the belt522, in the fashion described relative toFIGS.4A-B. Still with reference toFIGS.5A-B, in various embodiments, the pulley510can rise or lower in the fashion described relative toFIGS.1A-B,2A-B,3A-B, and/or4A-B.FIG.5Ashows the pulley510in a lowered position whileFIG.5Bshows the pulley510in a raised position. As shown, the raised position of the pulley510shown inFIG.5Bsupplies increased tension for the belt522as compared to the lowered position of the pulley510shown inFIG.5A. In various embodiments, the tensioning system500can provide a number of operational advantages. For example, in certain embodiments, the tensioning apparatus501is simple to adjust via a single fastener. In another example, the tensioning apparatus501, due to its design and adjustment simplicity, can prevent pulley misalignment due to improper tensioning. In general, the design and adjustment simplicity of the tensioning apparatus501also makes the apparatus more forgiving of minor pulley misalignment that can happen from improper installation in the factory, for example (e.g., misalignment of the motor514and the motor-driven system518). Further, in various embodiments, the tensioning apparatus501can serve as a drop-in replacement for an existing tensioning apparatus. Depending on the embodiment, certain acts, events, or functions of any of the algorithms described herein can be performed in a different sequence, can be added, merged, or left out altogether (e.g., not all described acts or events are necessary for the practice of the algorithms). Moreover, in certain embodiments, acts or events can be performed concurrently, e.g., through multi-threaded processing, interrupt processing, or multiple processors or processor cores or on other parallel architectures, rather than sequentially. Although certain computer-implemented tasks are described as being performed by a particular entity, other embodiments, are possible in which these tasks are performed by a different entity. Conditional language used herein, such as, among others, “can,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or states. Thus, such conditional language is not generally intended to imply that features, elements and/or states are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without author input or prompting, whether these features, elements and/or states are included or are to be performed in any particular embodiment. While the above detailed description has shown, described, and pointed out novel features as applied to various embodiments, it will be understood that various omissions, substitutions, and changes in the form and details of the devices or algorithms illustrated can be made without departing from the spirit of the disclosure. As will be recognized, the processes described herein can be embodied within a form that does not provide all of the features and benefits set forth herein, as some features can be used or practiced separately from others. The scope of protection is defined by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | 18,624 |
11859721 | DESCRIPTION OF PREFERRED EMBODIMENTS Referring to the drawings, in all the shown embodiments the mixing valve comprises a valve housing2defining a first inlet port4, a second inlet port6and an outlet port8. The two inlet ports4and6and the outlet port8are connected to a valve chamber10inside the valve housing2. This means the two inlet ports4and6open out into the valve chamber10and the outlet port8branches off this valve chamber10. Inside the valve chamber10there is arranged a movable valve element12, which in this embodiment is ball-shaped. The valve element12comprises an opening or cut out14enabling a flow path from the first inlet port4and/or the second inlet port6towards the outlet port8. In the shown position of the valve element both inlet ports4and6are open towards the outlet port8, such that two flows from the inlet ports4and6are mixed in the valve chamber. The ball-shaped valve element12in this embodiment is rotatable about a rotational axis R extending normal to the plane of the figures. The valve element12may be rotatable about the axis R by a drive motor16as schematically shown inFIG.7. Depending on the rotational position of the valve element12the first inlet port4can be fully closed or the second inlet port6can be fully closed. In intermediate positions the two inlet ports can be partly open with changing flow ratio depending on the rotational position of the valve element12. The mixing valve as shown inFIGS.1to6can for example be used in a heating circuit or system as shown inFIG.7. In this example the mixing valve18is connected to a heat source20, for example a boiler, and a heating circuit22, for example a floor heating circuit of a building. In the feed line towards the heating circuit22there is arranged a circulator pump24for providing a fluid flow through the heating circuit22. The outlet port8of the mixing valve18is connected to this feed line of the heating circuit22. The first inlet port4of the mixing valve18is connected to an outlet of the heat source20and the second inlet port6of the mixing valve18is connected to a return line26of the heating circuit22. The return line26is connected to the inlet of the heat source20. A connection to the second inlet port16branches off this return line26. The mixing valve18allows to admix a return flow from the return line26via the second inlet port6into a fluid flow of heating medium or fluid from the heat source20to adjust the temperature in the feed line of the heating circuit22. By admixing fluid from the return line the temperature can be reduced in known manner. A similar design can be used for a cooling circuit. In a cooling circuit the heat source20would be replaced by a cooling device. In case of a cooling system, thus, warm water from the return line26would be admixed to the flow of cool water to adjust the temperature. For the control of the mixing valve there is arranged at least one temperature sensor28at least inside the second inlet port6. Detecting the temperature inside the second inlet port6may be problematic in case that the fluid flow or pressure inside the first inlet port4is higher than in the second inlet port8. Under these circumstances there may occur the problem that a fluid flow from the first inlet port enters into the second inlet port6against or upstream the usual flow direction30inside the second inlet port6. This would influence the temperature detected by temperature sensor28. To reduce or eliminate this problem, there is arranged an obstruction32inside the second inlet port6. In the embodiments shown inFIGS.1and3to6the obstruction32is ring-shaped extending along the entire inner circumference of the second inlet port6about the longitudinal axis X in flow direction30. However, as explained with reference toFIG.2it would be sufficient to arrange the obstruction32on one side of the inner circumference of the second inlet port6only. The obstruction32should be arranged at least on the inner side which is distant from the first inlet port4, i.e. on the side of the inlet port6, which is closer to the outlet port8. In these preferred embodiments the first inlet port4and the outlet port8extend along the same longitudinal axis Y, with the second inlet port6extending transverse. This means, when seen inFIG.2the obstruction32is arranged on a diameter side, with reference to the longitudinal direction X, of the second inlet port6, which is away from the side on which the first inlet port4is located. The obstruction32is arranged on the side towards the outlet port8. Thus, the obstruction32is arranged on a inner side of the second inlet port6which is facing the first inlet port4. Thus, a fluid flow from the first inlet port4would primarily impinge on the side opposite, i.e. facing the first inlet port4which is the side with the obstruction32. Thus, the obstruction32can influence a fluid flow entering from the first inlet port4into the second inlet port6. Preferably, the obstruction32extends at least along an angle of 90° about the longitudinal axis X, preferably at least along an angle of 180° and further preferred along the entire circumference as shown in the other figures. The obstruction32as shown, is angled with respect to the longitudinal axis X such that it forms a pocket-like area34facing down-stream in flow direction30, i.e. facing towards the valve chamber10. By this, the obstruction32can deflect a fluid flow entering in a direction opposite to the flow direction30and/or block such fluid flow. By this, it is prevented that the fluid flows further upstream against the usual flow direction30, so that an influence on the temperature in the area, in which the temperature sensor38is located, can be reduced or eliminated. Concerning the size and position of the obstruction32there are some preferred parameters. For example the distance d between the inner free end of the obstruction32and the outer circumference of the ball-shaped valve element2should be larger than zero and smaller than the inner diameter D of the second inlet port6adjacent to the valve chamber10. The angle A between the obstruction32and the inner circumferential wall36of the second inlet port6, i.e. the angle A between the obstruction32and the longitudinal axis X should preferably be in a range between 15° and 90°. The angle A is the angle between a surface on the downstream side of the obstruction32, seen in usual flow direction, and the inner circumferential wall36of the second inlet port6adjacent to the valve chamber10. The radial extension r of the obstruction32is preferably larger than three percent of the diameter D and smaller than 25 percent of the diameter D described above. The radial extension r is the radial distance of the inner free end of the obstruction32from the inner circumferential wall36of the second inlet port6adjacent to the valve chamber10. The obstruction32extends from the inner circumferential wall36into the interior of the second inlet port6by the radial extension r. At the same time the obstruction32is angled or extends obliquely to the inner circumferential wall36by the angle A to form the pocket-like area or space34. Beside this general preferred structure of the obstruction32there are several possibilities to arrange or provide such an obstruction32inside the second inlet port6. As shown in the example inFIG.1the obstruction32is provided on an insert38inserted into the second inlet port6and at the same time forming a valve seat for the valve element12. Furthermore, in this design the obstruction32has the shape of a ring-shaped lip extending into the interior of the second inlet port6.FIG.3shows a similar embodiment with an insert38′. In this embodiment the valve seat is enlarged so that also the valve seat40comprises a portion extending into the interior of the second inlet port6. In the embodiment according toFIG.4the obstruction32is integrally formed with the valve housing2, i.e. with the portion of the valve housing2defining the second inlet port6. In this embodiment only the valve seat40′ is formed as an insert. Also in the further embodiment shown inFIG.5the obstruction32is integrally formed with the portion of the valve housing2defining the second inlet port6. However, in this embodiment the obstruction32is not lip-shaped but has a shape of a shoulder defining the pocket-like area34. In longitudinal direction, i.e. in direction of the longitudinal axis X the obstruction32forms a reduction in diameter inside the second inlet port6extending in upstream direction. Further upstream the diameter is enlarged. Also in the embodiment according toFIG.6the obstruction32is formed on an insert42. However, in this embodiment the insert42defining the obstruction32is independent from the insert40′ defining the valve seat. It has to be understood that all the dimensions explained with reference toFIG.1could be used in the same way for the embodiments shown inFIGS.3to6. Furthermore, other possibilities to arrange an obstruction32on the inner circumference of the second inlet port6can be used to achieve similar effects. While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. Reference characters2valve housing4first inlet port6second inlet port8outlet port10valve chamber12valve element14opening16drive motor18mixing valve20heat source22heating circuit24circulator pump26return line28temperature sensor30flow direction32obstruction34pocket-like area36inner circumferential wall38, 38′insert40, 40′valve seat, insert forming valve seat42insertRrotational axisx, ylongitudinal directionsddistanceDdiameterAanglerradial extension | 9,776 |
11859722 | DETAILED DESCRIPTION Both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the features, as claimed. As used herein, the terms “comprises,” “comprising,” “having,” including,” or other variations thereof, are intended to cover a non-exclusive inclusion such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such a process, method, article, or apparatus. Moreover, in this disclosure, relative terms, such as, for example, “about,” “substantially,” “generally,” and “approximately” are used to indicate a possible variation of ±10% in the stated value. FIG.1is a view of a piston check valve assembly10(e.g., showing a downstream end) according to aspects of the present disclosure. Piston check valve assembly or piston check valve system10may include a body12, a bonnet14, and a valve assembly or piston assembly50. Body12may include a pair of opposed ends formed by annular flanges or ports130. A hollow interior of body12may house piston assembly50. Bonnet14may be secured to an upper opening of body12to secure piston assembly50. Body12may define an upstream end110and a downstream end120(FIG.2). Annular flanges or ports130, formed at upstream and downstream ends110and120, respectively, may be sized and shaped for connection to upstream and downstream components, and may include a series of bolt holes to allow ports130to facilitate leak-free connections to these components. Bonnet14may be secured to a top surface of body12by a plurality of fasteners80and fixing members82. In the exemplary configuration shown inFIG.1, each fastener80may include a threaded bolt or stud having an end embedded within body12, while fixing members82may include respective nuts or other suitable tightening mechanism connected to the threading of the fasteners80. Bonnet14may have an annular shape, including a proximal face16formed with a series of holes through which fasteners80extend. Bonnet14may also include a bottom end or bottom face48, and a central recess18(FIG.2). Body12may be formed of a corrosion-resistant material, such as a metal material. Body12may be formed by carbon steel, for example. Bonnet14may be formed of a similar material as body12(e.g., a metal material such as carbon steel). With reference toFIG.2, which is a cross-sectional view of check valve system10along line II-II ofFIG.1, piston assembly50may form a one-way valve that permits flow of fluid in a flow direction from upstream end110toward downstream end120, and prohibits flow of fluid in a direction from downstream end120toward upstream end110. Piston assembly50may include a cage or retainer52, a removable valve seat90, a resilient member56, and a piston58. Retainer52of piston assembly50may have a substantially cylindrical body portion, such as a proximal portion51. A distal portion53extending from proximal portion51may form a cage that includes openings62separated by a series of bridges63, such that each bridge63is surrounded by a pair of openings. Proximal portion51may include a top surface that contacts bottom face48of bonnet14, either directly or via a gasket. A distal end of retainer52, formed at the bottom of distal portion53, may face valve seat90via a mechanism described below. An interior of retainer52may define an axially-extending opening within which piston58is moveably secured. Piston58may be positioned within the opening of retainer52so as to be moveable between a closed position in which piston58rests on valve seat90, as shown inFIG.2, and an open position in which piston58is spaced away from and does not contact valve seat90. A central pillar60of piston58may, when piston58is in a closed position illustrated inFIG.2, be surrounded by these openings62and bridges63of retainer52. A distal end face59, extending below central pillar60, may block an opening in body12when piston58rests on valve seat90. Piston58may be biased towards this closed position by resilient member56. A recess64, formed in a proximal end of piston58, may receive and secure a distal end of resilient member56, such as a spring. Recess64may be surrounded by a rim46defined by piston58. Rim46may define a circular surface (when viewed from above) that opposes the face48of bonnet14. A proximal end of resilient member56opposite rim46may be fixed to bonnet14and may extend within a central recess18defined by bonnet14. When bonnet14is secured to body12, recess18may face the interior of body12and piston58. Below resilient member56, a body of piston58itself may further include one or more ball check valves70(e.g., configured to relieve excess pressure), and an orifice fitting72, which may each be accessible via recess64. One or more piston rings68may be provided in an outer circumference of a proximal portion of piston58to facilitate sliding motion of piston58within retainer52. A distal end face59of piston58may include an outer circumference configured to sealingly contact seat90at a peripheral surface of end face59, while a central portion of face59faces downward toward a bottom of body12. The outer periphery of end face59may include a tapered surface or chamfer for contacting seat90, as described below. A vent fitting84may be secured so as to extend through a center of proximal face16of bonnet14. Vent fitting84may be configured to relieve excess pressure within retainer52. For example, vent fitting84may be in communication with the interior of retainer52and may relieve pressure within retainer52when piston58moves proximally and reduces the size of a chamber between piston58and bottom face48of bonnet14. A force of resilient member56, such as a spring force, may be sufficient to close piston assembly50and block reverse or upstream flow of fluid in a direction from downstream end120toward upstream end110. A sufficient flow in an opposite direction may be permitted. For example, when fluid (e.g., oil, other petroleum products, water, etc.) introduced from upstream end110applies sufficient force on end face59, piston58may move proximally (upwards inFIG.2) so as to allow fluid communication in a direction from upstream end110toward downstream end120. Resilient member56may have a resistive force (e.g., spring force) selected to allow piston58to move proximally such that rim46is brought into contact with face48of bonnet14. Piston assembly50may be configured to allow piston58to travel an entire length of piston assembly50that is defined by retainer52. For example, resilient member56may be configured to permit piston58to travel to a fully open position in which end face59contacts bottom face48of bonnet14, as described below. At each position of piston58, including a fully-open position where rim46contacts face48, piston58may be aligned within retainer52. In particular, when piston58abuts bonnet14, piston58may have no angular tilt or substantially no angular tilt with respect to an axial direction defined by retainer52(e.g., a proximal to distal direction corresponding to the vertical axis inFIG.2). When piston58abuts seat90, piston58may also have no angular tilt or substantially no angular tilt with respect to this axial direction. During movement of piston58, bridges63may guide an outer circumference of the distal end portion of piston58while cylindrical proximal portion51of retainer52guides the outer circumference of the proximal end portion of piston58. This may prevent vibration and chatter of piston58within retainer52. Thus, the proximal and distal portions of piston58may remain aligned and prevented from tilting when in the closed position, the fully-open position, and in each intermediate position therebetween. In at least some configurations, this alignment may tightly secure piston58within retainer52. Additionally, piston rings68may be formed of a low-friction material configured to slide along an inner peripheral surface of retainer52, so as to reduce friction and wear. Valve seat90may be a ring-shaped member inserted within a recess of body12. Valve seat90may be formed of a suitable corrosion and wear-resistant material that is suitable for repeated contact with the angled or chamfered surface of face59of piston58. Valve seat90may be formed of a suitable metal material, such as a material including carbon steel. In some aspects, valve seat90may include a polymeric material, such as polytetrafluoroethylene (PTFE), polyether ether ketone (PEEK), other polymers, and composites thereof. Valve seat90may be coaxially disposed with respect to retainer52and opening13. Retainer52may be configured to press upon and secure seat90within body12while remaining stationary during operation of piston assembly50. Retainer52may be secured by bottom face48of bonnet14, which presses upon retainer52and urges retainer52in a distal direction (e.g., by applying a pre-determined torque to fixing members82). Due to the force applied to the end of proximal portion51of retainer52, as best shown inFIG.4, an end of distal portion53may press upon a proximal-facing surface of seat90, securing seat90within a recess of body12. Thus, retainer52may form a containment device that secures seat90. The assembly of retainer52and seat90may further facilitate reduction in chatter and vibration, even when valve system10is in a partially or fully open state, and during transitions between closed and open states. In some aspects, by applying a pressing force to seat90, seat90may be firmly secured to body12, without the need to be permanently attached to body12(e.g., by welding). This may facilitate removal of seat90when necessary, as described below. Additionally, reducing or eliminating vibration in this manner may reduce noise and extend the life of piston assembly50by reducing wear on piston58, retainer52, and valve seat90. As shown inFIGS.2and3, bonnet14may be fixed to an upper surface of body12so as to protrude within opening13of body12. With reference toFIG.3, a gasket86and an O-ring88may be provided to seal the interface between body12and bonnet14. Gasket86may extend circumferentially along an interface between bonnet14and body12. Gasket86may form a seal between a distally-facing surface of bonnet14and a proximally-facing surface of body12. One or more additional sealing members, such as O-rings88, may be placed within respective recesses of bonnet14. Additionally or alternatively, one or more O-rings88may be placed within one or more recesses of body12. Resilient sealing members, such as O-rings88, may form a seal between a radially-inwardly facing surface of body12and a corresponding surface of bonnet14. FIG.4is a cross-sectional view of piston assembly50when in the closed position, showing exemplary positions of piston58, retainer52, and seat90. When piston assembly50is closed, retainer52and seat90may each surround part of the distal end portion of piston58. In particular, seat90may extend distally of retainer52so as to surround the distal end of piston58, including end face59. A sealing surface95of valve seat90may be shaped to receive a mating surface of piston58. Sealing surface95may include a surface having a substantially circular shape when viewed from above. Sealing surface95may be an inclined or chamfered surface formed at an inner periphery of seat90. Piston58may be brought into contact with sealing surface95of valve seat90when piston58blocks the flow of fluid in an upstream direction. Thus, each time piston assembly50transitions from an open position to a closed position, piston58may impact sealing surface95. A clearance or gap96may be present at one or more locations between piston58and retainer52. Gap96may be formed between one or more areas where piston58is out of contact, or in discontinuous contact, with retainer52. While not shown inFIG.4, piston58may also contact retainer52at one or more locations of distal portion53, such as bridges63. Distal portion53of retainer52may be sized so as to prevent significant inclination of piston58with respect to a vertical direction (as represented by the vertical axis extending through piston58FIG.2). As discussed above, bonnet14may apply a force to retainer52that presses retainer52against valve seat90. This force may be transferred from retainer52to seat90at an interface between these two components, as shown inFIG.4. For example, retainer52may include an outer retainer recess76and an inner retainer protrusion78at the interface between retainer52and seat90. Seat90may include an inner seat recess55and an outer seat protrusion57, such that seat recess55faces and receives retainer protrusion78, while seat protrusion57faces and is received by retainer recess76. Seat protrusion57may be formed by a lip or ridge on a radially peripheral portion of seat90. Retainer protrusion78may press upon the surface of recess55. While a gap may be present between recess76and protrusion57as shown inFIG.4, protrusion57and recess76may be sized so as to contact each other. Additionally or alternatively, the locations of protrusions57and78(and recesses55and76) may be reversed, such that retainer52includes a protrusion at the radially-outer portion thereof and seat90includes a recess at a corresponding outer portion. Valve seat90may include an outer circumferential surface102that extends about an outer periphery of the ring-shaped seat90. Circumferential surface102may face body12so as to form an interface92, as shown inFIG.4. Interface92between seat90and body12may be free of welding, or other mechanisms for permanently fixing seat90to body12. In some aspects, seat90may be secured at interface92by the force applied by retainer52. Thus, valve seat90may be secured so as to abut body12in a manner that allows removal of valve seat90without the need to use cutting tools to separate seat90from body12. A distal or bottom end of valve seat90may include an annular surface104. Annular surface104and body12may form an interface94at which annular surface104of seat90contacts a supporting surface formed within a recess of body12. Like interface92, interface94may be free of welding or other mechanisms for permanently fixing seat90to body12. Thus, an entirety of seat90may be free of welds. If desired, a sealing member88may be placed below circumferential surface102and between seat90and body12. An exemplary process for assembling valve system10may include assembling valve seat90within body12in a manner that facilitates subsequent removal. Valve seat90may be positioned within body12by inserting valve seat90through opening13(FIG.2). Valve seat90may be placed within a recess of body12, such that valve seat90contacts body12as shown at interfaces92and94(FIG.4). If desired, an O-ring88may be sandwiched between body12and valve seat90to prevent the occurrence of leaks. With valve seat90positioned within body12, piston assembly50may be inserted into body12. For example, retainer52, piston58, and resilient member56of piston assembly50may be inserted through opening13. Bonnet14may be brought into tension via one or more fasteners80and fixing members82, such that a portion of retainer52, such as protrusion78, tightly secures valve seat90to body12. During operation of valve system10, and with reference toFIG.2, a flow of fluid from upstream end110toward downstream end120may apply an upward force to end face59of piston58. This force may urge piston58against the force of resilient member56, such that piston58moves upwards in a manner that compresses resilient member56. In some aspects, the pressure of fluid may be sufficient to cause piston58to move a full length of the cage or retainer52. This may bring, for example, rim46into contact with face48. When the force of fluid entering via upstream end110drops below the amount of force exerted by resilient member56, including when flow stops or reverses, piston58descends onto seat90, blocking the reverse flow of fluid. Over time, repeated openings and closings of piston assembly50may cause seat90to accumulate wear (e.g., on a sealing surface95). A method or process for removing and/or replacing valve seat90from check valve system10may be performed while valve system10remains connected to upstream and downstream components of a pipeline, such as one or more components secured to ports130. Once a supply of fluid to upstream end110has been discontinued, fasteners80and fixing members82may be removed, after which bonnet14may be separated from body12so as to release the force retaining valve seat90. With fasteners80and fixing members82removed, components of piston assembly50may be separated from body12and withdrawn through opening13, including resilient member56, piston58, and retainer52. Valve seat90may then be removed through opening13without the need to separate a bond, such as a weld, between body12and seat90. A replacement valve seat90may then be inserted through the upper opening of body12, and the remaining components of piston assembly50may be assembled within body12, as described above. In an alternative configuration, valve seat90may be removable, together with retainer52, through opening13. Regardless of whether valve seat90is removed separately or together with retainer52, the process for removing and/or replacing valve seat90may be performed inline (e.g., without removing valve system10from a series of connected pipeline components). It will be apparent to those skilled in the art that modifications may be made in the disclosed systems and methods without departing from the scope of the disclosure. Other aspects of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the features disclosed herein. It is intended that the specification and embodiments be considered as exemplary only. | 17,849 |
11859723 | DETAILED DESCRIPTION As part of the present invention we recognized that valve assemblies often use a valve guide that can be prone to sticking and thereby block the movement of the valve post of the valve assembly. In particular, we discovered that particles in the flowing proppant can get lodged in conventional tubular-shaped valve guide bushings surrounding the valve post, such that the valve cannot close. Additionally, we realized that such conventional valve guides can have smaller than desirable openings for proppant flow. This can cause higher proppant flow rates and greater flow resistance with subsequent greater rates of erosion, which in turn, can cause failure of the valve assembly. As further disclosed below for various embodiments of the disclosure, we have developed a valve guide which have a central space to contain the valve post valve post therein. One or more blades of the valve guide are used to form the central space and the valve post is only partially surrounded to thereby mitigate proppant particles becoming stuck between the valve post and the value guide. Additionally, embodiments of the disclosed valve guide are configured to providing a larger cross-sectional area for hydraulic fracturing slurry flow through the valve assembly. Having a larger cross-sectional flow area reduces slurry flow rates, decreases flow resistance and increases valve reliability by decreasing the onset of erosion-caused valve failure. In the drawings and descriptions that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals, respectively. The drawn figures are not necessarily to scale. Certain features of this disclosure may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. Specific embodiments are described in detail and are shown in the drawings, with the understanding that they serve as examples and that they do not limit the disclosure to only the illustrated embodiments. Moreover, it is fully recognized that the different teachings of the embodiments discussed, infra, may be employed separately or in any suitable combination to produce desired results. Unless otherwise specified, any use of any form of the terms “connect,” “engage,” “couple,” “attach,” or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to”. Unless otherwise indicated, as used throughout this document, “or” does not require mutual exclusivity. FIG.1presents a schematic, perspective view, with a portion in cross-section, of an illustrative embodiment of a well system, together with a hydraulic fracturing (fracing) system100for controlling the proppant flow by a hydraulic fracturing fluid pump (frac pump) that includes a valve assembly102and valve guide embodiments of the disclosure. The wellbore104can include a casing106that is cemented or otherwise secured to a wall of the wellbore104, although the wellbore104can be uncased or include uncased sections. A frac plug tool108can be positioned in the wellbore104to isolate discrete subterranean formation intervals110,112for different fracture stages that have been identified or reached and a hydraulic fracturing operation may be used to create fractures115in the intervals110,112to increase formation porosity for increasing the fluid conductivity of flow paths117between the formation intervals110,112and the wellbore104to increase oil or gas production. Perforations can be formed in the casing106to allow fracturing fluids or slurries to flow into formation intervals110,112. The fracturing system100can include, among other things, an operation control unit120, a manifold unit125, a frac pump130(e.g., a truck-mounted frac pump), with one or more valve assemblies102of the disclosure being part of the pump130. A wellhead tree135is present as part of the system100to cap the wellbore104. The system100can include one or more of the following: proppant storage tank140, fracturing fluid tank145, other fracking component storage tank150, and blender155(e.g. one or more blending trucks) and hydration apparatus160(e.g., coupled to the fluid tank145). One skilled in the pertinent art would understand how fracturing slurry fluid, pumped via the pump130into the wellbore104at a high a flow rate and pressure, through the valve102, to increase the pressure in the wellbore104, could be used as part of the system100to create or increase fractures115in the formation intervals110,112. For instance, the fracturing slurry fluid, including a hydrated gel, and/or resins (e.g., epoxy or other polymer resins) or composites thereof, can be pumped into the fractures115to prop the fractures in the formation open, to thereby, effectively increase the formation's porosity. One skilled in the pertinent art would understand how it would be desirable, to optimize the oil and gas extraction, to alter the composition of fracturing slurry fluids including proportion of proppants in slurry mixtures at different stages of hydraulic fracturing treatment using the system100. In some embodiments, the operation control unit120can be configured to coordinate the hydraulic fracturing operation, including controlling the flow though the valve assembly102, and the frac pump130, to deliver the fracturing slurry fluid to the wellbore104(e.g., via flow conduits170,172). The operation control unit120can be communication with the other system components and the frac pump130to monitor flow rates and pressures of the frac pump130, the manifold unit125and the wellhead tree135and control the delivery rates of proppant at least in part by controlling the of fracturing slurry fluid through the valve assembly102. A blender control unit165of the operation control unit120can be configured to control the delivery rates of proppants or other optional fracking components from corresponding tanks140,145,150to the blenders155by controlling flow through coupled to flow conduits (e.g., conduits174,176,178) configured to deliver the corresponding components to the blender155. The term “proppant” as used herein refers to particulate solids which, during fracturing treatment of a reservoir formation, are blended with a fracturing fluid and transported downhole in a wellbore for placement within a fracture flow path to retain conductive channels in subterranean fractures through which fluids may travel. Suitable materials for proppants, can include but are not limited to, sand, bauxite, ceramic materials, glass materials, polymer materials, polytetrafluoroethylene materials, nut shell pieces, cured resinous particulates comprising nut shell pieces, seed shell pieces, cured resinous particulates comprising seed shell pieces, fruit pit pieces, cured resinous particulates comprising fruit pit pieces, wood, composite particulates, and combinations thereof. Suitable composite proppants may comprise a binder and a filler material wherein suitable filler materials include silica, alumina, fumed carbon, carbon black, graphite, mica, titanium dioxide, meta-silicate, calcium silicate, kaolin, talc, zirconia, boron, fly ash, hollow glass microspheres, solid glass, and combinations thereof. The term “fracturing fluid” as used herein refers to a base fluid and one or more optional additives. Such additives include, but are not limited to salts, weighting agents, inert solids, fluid loss control agents, emulsifiers, dispersion aids, corrosion inhibitors, emulsion thinners, emulsion thickeners, viscosifying agents, gelling agents, surfactants, particulates (such as proppant or gravel), lost circulation materials, foaming agents, gases, pH control additives, breakers, biocides, crosslinkers, stabilizers, chelating agents, scale inhibitors, gas hydrate inhibitors, mutual solvents, oxidizers, reducers, friction reducers, clay stabilizing agents, and the like, and any combination thereof. Suitable base fluids of the fracturing fluids include, but art not limited to, oil-based fluids, aqueous-based fluids, aqueous-miscible fluids, water-in-oil emulsions, or oil-in-water emulsions. The fracturing fluid may include dispersants to control agglomeration of the particulate solids, viscosity-enhancing additives to inhibit settling and modify flow behavior, and iron control agents to prevent the precipitation of metal oxides. Other chemicals and substances may be incorporated into the fracturing fluid in order to enhance fracture treatment of the reservoir formation. The term hydraulic fracturing slurry fluid or “fracturing slurry” as used herein refers to a suspension of any the disclosed embodiments of proppants with any the disclosed embodiments of the fracturing fluid. One embodiment is valve guide for a fracturing pump valve assembly. FIGS.2A and2Bpresent perspective and plan views, respectively, of an embodiment of the valve guide200of the disclosure.FIG.2Cpresents a perspective view of the valve guide embodiment, similar to that shown inFIGS.2A-2B, as part of a valve assembly102embodiment of the disclosure.FIGS.2D and2Epresent exploded views of the valve guide200and valve assembly102embodiments similar to that shown inFIG.2C. With continuing reference toFIGS.2A-2Ethroughout, embodiments of the value guide200include a ring member202having one or more blades204. The one or more blades204project inward from an annular ring206of the ring member202. A first side208of the one or more blades204defines a central space210of the ring member202, the central space210configured to contain a cross-sectional portion of a valve post (e.g., cross-section of post212shown inFIG.2B) of the valve assembly102therein. The first side208of each of the one or more blades204facing the central space210is configured to extend parallel to a long axis length214of the valve post212. As further explained below, previously unrecognized result-effective variables corresponding to the blade's shape, position, and orientation can be adjusted to optimize the cross-sectional flow area and decrease flow resistance while balancing the need to provide a valve guide structure capable of containing the valve post and still mitigate valve sticking. In some embodiments, a planar surface216of the annular ring206is configured to rest adjacent to a planar surface218of a seat ring member220of the valve assembly102. In some such embodiments, a second side222of each of the blades204facing an intake fracturing slurry flow direction224through the valve assembly102is located above the planar surface216(e.g., on a side of the surface216closest to the slurry intake) of the annular ring206. In some such embodiments, a third side226of each of the blades204trailing the intake fracturing slurry flow direction224through the valve assembly102is located below the planar surface216(e.g., on a side of the surface216farthest from the slurry intake) of the annular ring206. In some embodiments, a fourth side230of each of the blades204is a major surface of the blade and the major surface is oriented parallel to an intake fracturing slurry intake flow direction224through the valve assembly102, to thereby help reduce flow resistance and facilitate directing flow in the intake direction224. Alternatively or additionally in some embodiments, a fifth side232, corresponding to the opposite side of the blade204is also a major surface oriented parallel to the intake fracturing slurry intake flow direction224. As illustrated, in some embodiments, the major surfaces of the fourth and/or fifth sides230,232can include or be planar surfaces, although in other embodiments the fourth and/or fifth sides230,232can include or be non-planar surfaces. In some embodiments, the sides of each of the blades can be shaped to help reduce flow resistance. For instance, as illustrated inFIGS.2A-2B, the second side222and/or the third side226of the blades204facing/trailing the intake fracturing slurry flow direction224through the valve assembly can be tapered such that a width (e.g., width236) of the second and/or third side and/or sides222,226nearer the first side208is less (e.g., about 50%, 75%, or 90% less) than a width of the side or sides222,226nearer the annular ring206. As illustrated, in some embodiments, the width236of the side or sides222,226can uniformly taper from the annular ring206to the first side208, although in other embodiments, the tapering can be non-uniform. For instance,FIGS.3A,3B and3Cillustrate perspective view and plan views of another embodiment of the valve guide200of the disclosure with the blades204configured with additional aerodynamic features.FIG.3Dshows this other valve guide200embodiment as part of the valve assembly102. As illustrated, the second and/or third side and/or sides222,226facing/trailing the intake fracturing slurry flow direction224can be configured to have beveled edges such that a width at an edge of the side (e.g., width310) is less (e.g., about 50%, 75%, 90%, or 99% less) than a width of a central portion of the blade204(e.g., width315). As further illustrated inFIG.3C, in some embodiments, the second and/or third side and/or sides222,226facing/trailing the intake fracturing slurry flow direction224can be configured to have a first portion320(e.g., a portion of the blade204nearest the ring206) with a uniform width236and a second portion322(e.g., a portion of the blade204nearest the central space210with a tapering width236, analogous to that described in the context ofFIGS.2A-2B. As illustrated inFIG.3A, the major surface or surfaces of the fourth and/or fifth sides230,232of the blades204can include a chamfered, shaved or angled portion330to minimize amount of the side in the slurry flow direction224. FIGS.4A-4Dshow plan views, similar to the views shown inFIGS.2B and3C, of other valve guide200embodiments. As illustrated inFIGS.4A and4Bthe one or more blades204of the valve guide200can be configured as a pair of blades. The first sides208of the pair of blades204are configured to, in combination, partially surround the cross-sectional portion of the valve post212and thereby define the central space210. For instance, the first sides208of opposing blades can be configured to have V-shaped (FIG.4A) or arc-shaped (FIG.4B) structures to define the central space210. As illustrated inFIG.4C, and also shown inFIGS.2A-2E and3A-3D, the one or more blades204of the valve guide200can be configured as three blades204, with the first sides208of the three blades configured, in combination, to partially surround the cross-sectional portion of the valve post212and thereby define the central space210. For instance, in some embodiments, such as shown inFIGS.2A-2E and3A-3D, the tips of blades can be the first sides define the central space210. However, as shown inFIG.4C, in some embodiments, one or more of the other non-tip sides (e.g., a blade side208ahaving a major surface analogous to sides230,232depicted inFIGS.2A-2E and3A-3D) of one or more of the blades204can be one of the sides that helps define the central space210. In some embodiments, as illustrated inFIGS.2A-2E and3A-3D, and4A-4Bthe two or three blades204can be equally distributed around the annular ring206, e.g., to provide a balanced blade structure. However, as shown inFIG.4C, in some embodiments, the blades204can be asymmetrically distributed around the ring206. As illustrated inFIG.4D, the one or more blades204of the valve guide200can be configured as a single blade where the first side208of the blade is configured to partially surround the cross-sectional portion of the valve post212to define the central space210. For instance the side208of the blade can be configured as a partially enclosing bushing having a gap410is small enough to prevent the value post212from getting out of the central space210but large enough to allow the egress of slurry particles out of the central space210. While some two or one blade valve guide embodiments may beneficially provide a greater cross-section flow area as compared to three or greater blade embodiments, some three or greater blade embodiments may advantageously provide a more stable central space210with a lower chance of valve sticking as compared to one or two blade embodiments. Based on the disclosed embodiments, one skilled in the pertinent arts would appreciate how embodiments of the valve guide200could be configured with one, two, three or greater blades, with the each of the blades having the same or different combinations of any of the blade configuration described in the context ofFIGS.2A-4D. Some embodiments of the valve guide can be manufactured as cast or sintered monolithic structure composed of carbide or stainless steel to provide a structure that is resistance to erosion from the flow of high pressure slurries. However, other embodiments of the valve guide can be constructed by machining a block of material via computer numerical controlled (CNC) milling, additive machine processes (e.g., 3D printing) or similar procedures familiar to those skilled in the art. In still other embodiments, individual parts of the valve guide can be separately constructed and then welded or otherwise bonded together to form the valve guide. Another embodiment is a valve assembly102for a fracturing pump. With continuing reference toFIGS.2C,2D and3D, the valve assembly102can include a seat ring member220and a poppet250. A plug-side252of the poppet250is configured to fit in an opening254of the seat ring member220, e.g., when the valve assembly102is in a closed state to block slurry flow, and, the plug-side252of the poppet250is configured to be outside of the seat ring opening254when the valve assembly102is in an open state, to allow slurry flow through the valve assembly102. The assembly102also includes the valve post212and the valve guide200. One section212aof the valve post212extends through the plug-side252and an opposite section212bof the valve post extends through a seat-side256of the poppet250. The valve guide of the assembly102can be any of the embodiments of the valve guide200described herein. For instance, the valve guide200can include a ring member202having one or more blades204, wherein the one or more blades204project inward from an annular ring206of the ring member202with a first side208of the one or more blades204defining a central space210of the ring member202. The central space210is configured to contain a cross-sectional portion of the valve post212and the first side208extends parallel to a long axis length214of the valve post212(e.g., extending 20, 40, 60, 80 or 100 percent of the length214). For instance, a planar surface216of the annular ring can be configured to rest adjacent to a planar surface218of the seat ring member220. As illustrated, in some embodiments, the valve guide200is located on a side of the valve assembly102configured to receive the intake of fracturing slurry flow224through the valve assembly102. E.g., the central space210can be configured to contain a cross-sectional portion corresponding to the section212aof the valve post212that extends through the plug-side252of the poppet250. As further illustrated, embodiments of the valve assembly102can further include a ring gasket260(e.g., an elastomeric or other flexible gasket), a spring265, and a second valve guide270located on a located on a discharge side of the assembly. The ring gasket260can be configured to be positioned between the seat ring member220and the poppet250such that a portion of the gasket260fits inside of the ring seat opening254and another portion is seated on the plug-side252of the poppet250when the assembly102is in a closed state, e.g., to facilitate forming a fluid seal to block slurry fluid flow through the assembly102. The spring265can be configured to positioned between the poppet250and the second valve guide270such that the spring265rests against the seat ring opening254of the poppet250and against an annular ring272or spokes274of the second valve guide270. One skilled in the art would understand how to provide sufficient tension on the spring265to keep the assembly in a closed state until pressure from the slurry flow224pushes on the poppet250and spring265to put the assembly in an open state. As illustrated inFIGS.2C,2D and3D, for some embodiments of the assembly102, the second valve guide270can be configured to have a bushing276(and some embodiments, an inner bushing278) configured to hold a section of the valve post212therein (e.g., section212bof the valve post extending through the seat-side256of the poppet250). However, as illustrated inFIG.2E, in other embodiments, to further mitigate valve sticking, the assembly102can alternatively further include a second one of the valve guides200alocated on a discharge side of the valve assembly102. For instance, the one or more blades204of the second valve guide200acan be configured to define a central space210configured to hold a cross-sectional portion of the opposite section212bof the valve post212therein. Based on the present disclosure, one skilled in the art would understand how to adjust the size of the spring265and/or the size of the annular ring206and/or the position of the blades204relative to the ring206in the second valve guide200asuch that the spring265could rest against a planar surface280of the annular ring206. Another embodiment is a hydraulic fracturing well system. Returning toFIG.1, embodiments of the system100can include a frac pump130coupled via flow conduits170,172to a wellhead tree135capping a wellbore104. The frac pump can be configured to deliver a fracturing slurry to the wellhead tree135and the frac pump can include one or more embodiments the valve assemblies102as disclosure herein. For instance, each valve assembly102can be include any of the embodiments of the seat ring member220, poppet250, valve post212, or valve guide200and can further include any other components of the assembly102(e.g., gasket260, spring265, second valve guide270,200a) such as described in the context ofFIGS.2A-4D. Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments. | 22,596 |
11859724 | DETAILED DESCRIPTION There is now described a check valve which comprises an obturator (or flap) which is moveable from an open condition to a closed condition and vice versa, and a pressure-activated actuator (which may be termed a secondary activation mechanism) which causes the obturator to be selectively held in an open condition, and in use overriding the biasing mechanism and its tendency to urge or move the flap element to a close d condition. The embodiment described below is in relation to the check valve provided at or connected to an outlet of an air compressor. Reference is made toFIGS.1and2. The main body or carcass of the check valve1is similar to a traditional check valve: it comprises a flap2, which closes under its own weight (or by/in addition to a spring force, which could be a coil spring or an air spring). The check valve could also be of the butterfly valve type. The check valve1comprises a fluid inlet1aand a fluid outlet1b. The flap2is mounted on a pivot shaft3. The pivot shaft3allows the flap to rotate about an axis from an opened condition to a closed condition and vice versa. In the illustrated example, the secondary activation mechanism referred to above comprises a piston5which is moveable in a cylinder6. The piston is connected to an articulated linkage which comprises a piston rod7aand an arm7b, and the parts7aand7bpivotably connected. The arm7bis fixedly connected to the shaft3, such that activation of the actuator assembly drives/causes movement of the piston to cause the flap2to open. The piston5divides the cylinder space into two sub-chambers. One side of the piston5(shown as the upper part in the Figures, although orientation is not important) is always connected to atmosphere or atmospheric pressure through a vent10. The other side of the piston5, i.e. the lower sub-chamber as illustrated, can be selectively connected to either atmospheric pressure or the pressurised fluid (i.e. compressed air) in the pipe to which the valve1is connected. The pipe is connected to a fluid outlet of a compressor, and the valve located downstream of the compressor. The piston5is sealed to the cylinder6to prevent leakage of the compressed air to atmosphere. The connection to the pipe is provided on the inlet side of the flap2, to allow the flap to function initially if the pipeline starts off at atmospheric pressure. The check valve1further comprises a control signal port or terminal12which is arranged to receive a signal (directly or indirectly) from a compressor. The input to the port12controls the function of a solenoid switching valve, illustrated schematically at13. The valve contains a solenoid which is configured to switch the source of pressure to which the lower sub-chamber of the chamber6is connected. The switching valve13is connected to atmospheric pressure by way of a conduit or inlet13a, and is also connected to the pressure of air within the pipe which has been output by the compressor by way of a conduit13b. The conduit13bconnects an aperture in the body of the check valve located upstream of the flap2, as best seen inFIG.3, to the switching valve13. The switching valve13further comprises an outlet13c, which fluidically connects to the lower sub-chamber of the cylinder6. The vent10and the inlet13abeing connected to atmospheric pressure may be thought of more generally as being connected to a reference pressure, which allows a pressure differential to be achieved, as is described in more detail below. Moreover, the vent10and13amay be connected to an inlet of the compressor. This is advantageous in the case of the use of a toxic gas, which would otherwise be vented to atmosphere can instead be contained with the fluid system. Specifically, the terminal12is arranged to receive a signal which is indicative of whether a power supply to the compressor changes from an ON state to an OFF state, or the compressor otherwise ceases operation (at least as far as delivering compressing air). Receipt of a signal indicative of a state transition causes the secondary activation mechanism to be energised. In practice, this control of the check valve1may be achieved by the actuator causing the flap3to remain in an open condition as long as a signal is received which is indicative of the compressor's compression function being in operation/running so as to deliver/output compressed air. In the absence of receipt of such a signal at the terminal12, the solenoid of the switching valve is configured to cause the pressure source to the lower sub-chamber to be connected to atmospheric pressure. Alternatively, a predetermined signal may be output to the terminal12which is indicative of a change of operational status of the compressor to a powered down or OFF condition, in relation to its compression delivery functionality. Therefore, the input terminal12is connected, directly or indirectly, to the compressor so as to effect the control of the actuator. Thereby, the operational mode of the valve is dependent on the operational status of the compressor. The switching valve13comprises a single 3-port solenoid activated valve. It will be appreciated that the switching valve could also be a valve(s) operated by means other than electrical activation, such as mechanical, hydraulic or pneumatic means. For example, the respective sub-chamber of the actuator assembly could be connected by a conduit to the fluid displacement device and then to a pressure sensor which outputs a signal to the controller. The switching valve13may alternatively comprises two solenoid-operated air control valves which change the medium to which the lower side of the cylinder6is connected to. One of the valves is normally open; the other is (normally) closed. When no electrical signal is applied, the valves default to these positions. When electrical signal is applied, they assume the opposite state. When no electrical signal is applied via the input terminal12, the check valve1operates as a conventional check valve: it opens when pressure at the inlet is greater than at the outlet, and closes when the opposite is true. The movement is caused by the pipeline pressure acting across the flap, causing it to lift open when the pump starts, begins dropping under its own weight and/or the action of a spring when the flow is reversing, and closes fully due to reversal of pressure across it. Since the lower portion of the cylinder6is connected by the valve13to atmosphere (the top sub-chamber is always connected to atmosphere), there is no significant force acting on the piston5, apart from some damping due to the small air passages of the secondary activation system. The piston5(which is mechanically linked to the flap of the check valve) is moved by the flap, and applies only a small damping force on the flap2. When an electrical signal is applied in response to a signal being received at the terminal12, the solenoid causes the air valves to disconnect the air below the piston5from the atmosphere and instead connect it to the air in the pipe which is just upstream of the flap in the main pipe. This means that so long as the pressure in the pipe is higher than atmospheric pressure, there will be an upward force on the piston at all positions of the flap2, causing the flap to be open (and remain open). The piston5and its linkage7aand7bto the flap are dimensioned (by way of respective surface areas) so that the expected pipeline pressure during all operating conditions is sufficient to keep the flap fully open (to counteract the closing force of its weight and/or any attached spring). Since the flap2is fully open, it does not cause a pressure drop to the fluid flowing in the main pipe. Conversely, the flow in the pipe applies very little force to the flap, and its position is controlled primarily by the piston5. The piston area can be smaller than the flap2area. Thus when the electrical signal is applied, the check valve1will not function as a normal or regular check valve, because it will not partially close when a low-pressure rarefaction passes through it (as long as the lowest pressure in the pulse is still above atmospheric, and sufficient to keep the piston at the top of its stroke by resisting the closing force of the flap). The flap will also not close in case of a flow reversal, as the pressure in the pipe will likely still be above atmospheric even if the flow reverses (this will be the case until the pipe network has fully drained to come down to atmospheric pressure). This means that by applying the electrical signal, the non-return nature of the valve is overridden or bypassed, and in almost all circumstances (while the electrical signal is applied) it becomes a manually or forced opened valve (with no capability to manually close it). To satisfy the non-return criteria of a check valve to protect the pipeline and compressor, the electrical signal is disconnected when any issues arise. This can be achieved by using a range of sensors on the compressor and/or the pipeline, as well as by connecting the valve to the same electrical supply as the compressor. These serve as protective measures (which cause the check valve to adopt its passive mode) and may include determining that when power is lost, for example. Reference is made toFIG.6which shows the check valve1connected to a fluid outlet of a rotary piston and cylinder device50. It will be appreciated that the obturator2inFIGS.2,3and4is in a closed condition. InFIG.5, the obturator2is shown in a partially open condition as a result of the pressure applied by the fluid flow, but without the assistance of activation of the actuator. | 9,656 |
11859725 | DETAILED DESCRIPTION The isolation valve of the present invention may be a ball valve or a diverter valve.FIG.1shows an embodiment of a gas purged ball valve according to the present invention. The ball valve100has a housing102with an inlet104aand an outlet104b. The valve100further includes a rotatable ball108seated between a pair of valve seats110a,110b. The valve seats110a,110bare positioned in the inlet104aand the outlet104bof the valve100, respectively. The ball108has a bore114through it, and the ball108may rotate between first and second positions. The bore114aligns with the inlet104aand outlet104bin the first position (SeeFIG.2a) and misaligns or is perpendicular to the inlet104aand outlet104bin the second position (SeeFIG.2b-2c). The aligning of the bore114with the inlet104aand the outlet104bforms the “open” process flow path through the valve100. The ball108is spaced apart from the interior surface of the housing102to form a cavity112therein as shown inFIG.1and more particularly shown inFIGS.2a-2c. The cavity112, or “void” between the valve seats110a,110band the housing102, is purged with an inert gas as will be discussed in further detail below. As shown inFIG.2b, the ball108further includes a key slot123that engages with the drive dog119of the valve100. A small opening125in the ball108proximate the key slot123enables the bore114to be in fluid communication with the cavity112. Close coupled to the housing102is a manifold116having a flow path118with an inlet120aand an outlet120b. A pressurized source of inert gas124, for example nitrogen, argon or helium, is connected to the manifold inlet120a. The outlet120bof the manifold116is in fluid communication with a port122in the housing102as shown inFIG.2b. The port122passes through the housing102and into the cavity112thus connecting the flow path118with the cavity112. Thus, the manifold116enables the cavity112to fill with the inert purge gas. While the manifold116can be constructed of a variety of solid materials, it is preferably constructed of a material having a high thermal conductivity such as aluminum alloy or copper. A one-way (non-return) valve128is positioned in the port122so that inert gas can flow from the manifold116into the cavity112, but not in the reverse direction. In one embodiment, a spring (not shown) is positioned in the port122between the ball (not shown) of the non-return valve128and the ball108of the isolation valve100. The spring establishes a minimum pressure at which the purge gas must enter the port122and cavity112. Certain process steps require heat to prevent the formation of solid by-products in the pipework and components (e.g. valves, vacuum pumps, etc.) downstream from the process tool. For example, the condensable solid, aluminum chloride (Al2Cl6) is a by-product of an aluminum etch process. In another example, ammonium hexaflurosilicate ((NH4)2SiF6)) is a condensable by-product of a silicon nitride chemical vapor deposition process using a fluorine-based chamber clean. Accordingly, the purge gas supplied to the cavity112is preferably heated in order to minimize condensation within the ball108and housing102of the valve100. As shown inFIGS.2band2c, the manifold116includes a heater126, for example a cartridge heater, that is sized to maintain the temperature of the purge gas so as to minimize condensation within the ball108and housing102of the valve100. The heater126should maintain the temperature of the purge gas at or above about 90° C., and preferably at or above about 120° C. If the manifold116is constructed of a material having a high thermal conductivity, such as aluminum alloy or copper, then the heater126can be positioned at any convenient location within the manifold116. However, preferably the heater126is positioned closer to the manifold outlet120bthan to the manifold inlet120a. As shown inFIGS.2band2c, the heater126is positioned within the manifold116proximate the flow path118and the manifold outlet120b. In addition, the flow path118preferably optimizes heat transfer from the heater126to the purge gas flowing through the manifold116. Thus, in one embodiment the flow path118is tortuous, where the purge gas must flow back-and-forth through the manifold116before it exits into port122. In another embodiment the flow path118may include baffles to increase turbulence or may be a packed bed to enhance heat transfer. As discussed above, the isolation ball valve100has a first position and a second position.FIG.2ashows the valve100in the first “open” position andFIGS.2band2cshow the valve100in the second “closed” position. When the valve100is “open,” process gas flows into the valve100through the valve inlet104a, through the bore114of the ball108and out through the valve outlet104b. SeeFIG.2a. While the process gas flows through the “open” valve100, heated purge gas flows from the manifold's116flow path118and into the cavity112, thus heating the ball108and housing102. From the cavity112, the heated purge gas flows through the opening125into the bore114of the ball108where the heated purge gas combines with the process gas before exiting the valve100. Preferably, the pressure of the heated inert gas supplied to the cavity112is higher than the normal maximum pressure of the process gas stream so that the inert gas can flow into the process gas stream. When the ball valve100is “closed,” as shown inFIGS.2band2c, and there are no leaks in the valve100, the heated purge gas continues to flow into the cavity112and bore114until the pressure of the purge gas inside the valve100reaches the pressure of the inert gas source124. Thus, under normal circumstances, the purge gas is “dead-headed” by the “closed” valve100. However, if the isolation valve100is damaged, for example from a scratch on the ball or a corroded valve seat and/or o-ring, harmless inert gas rather than the harmful process gas will leak from the cavity112and through the damaged area. To detect a leak or damage in the isolation valve100, pressure decay of the heated inert purge gas can be monitored. In one embodiment, a solenoid valve130is installed in the inert gas source line135upstream from the manifold inlet120atogether with a pressure regulator132to regulate the pressure to the manifold116as shown inFIG.3a. A pressure transducer134is also positioned in the inert gas source line between the manifold inlet120aand the solenoid valve130to monitor the pressure in the manifold116. A heater126is positioned within the manifold116, upstream of a check valve138. Under normal operating conditions, the pressure of the inert gas should remain at a constant, pre-determined value. As discussed above, the pressure of the heated inert gas in the cavity112should be higher than the maximum operating pressure of the process gas stream. The maximum pressure of the process gas stream is in turn determined by the characteristics of equipment, such as an abatement system, located downstream from the process chamber. For example, if the abatement system is a burner (e.g., See U.S. Pat. No. 7,494,633 issued to Stanton et al. and assigned to Edwards Limited) or a wet scrubber, then the pressure of the process gas stream may be about ±5 in H2O (or about ±0.181 psi, or 0.012 Bar). If, however, the abatement system is a gas reactor column (e.g., See U.S. Pat. No. 5,538,702 issued to Smith et al. and U.S. Publication No. 2005/0217732 A1 by Martin Ernst Tollner), then the pressure of the process gas stream may be as high as about 3.5 psi (i.e. about 0.24 Bar). Thus, in the former example, the pressure of the purge gas supplied to the valve100should be about 1 to about 5 psi (i.e. about 0.07 to 0.34 Bar). In the latter example, the pressure of the purge gas supplied to the valve100should be about 5 to about 15 psi (i.e. about 0.34 to 1.03 Bar). During operation, shortly after the isolation (ball) valve100is rotated to the second “closed” position and the pressure of the heated inert gas in the valve100has had a chance to dead-head, then the solenoid valve130is also “closed.” Thus, the cavity112becomes charged with the inert gas at a certain pressure as discussed in the preceding paragraph. Thus, if there are no leaks in the valve the pressure of the inert gas measured by the pressure transducer134will remain constant. If, however, the pressure transducer134measures a decay (or a decrease) in the pressure of the inert gas, then such decay is an indication that there is a leak in the isolation valve100. In another embodiment, a flow transducer136is positioned in the purge gas line135to monitor the flow rate of the purge gas as shown inFIG.3b. A pressure regulator132is also positioned in the purge gas line135, upstream of the flow transducer136. A heater126is positioned within the manifold116upstream of a check valve138. Under normal circumstances, the purge gas is dead-headed within the cavity112as discussed above with respect to measuring pressure decay. However, if the flow transducer136detects flow of the purge gas, then such flow is an indication that there is a leak in the isolation valve100. Notably, both flow and pressure decay of the purge gas line135can be monitored in order to detect failure of the isolation valve100. To accomplish this, the flow transducer136could be installed between the pressure transducer134and the manifold inlet120a. In another embodiment, the isolation valve is a diverter valve200as shown inFIG.4a. In this embodiment, the diverter valve200has a housing202with an inlet204a(shown inFIG.5) and two outlets204band204c. The diverter valve200also has a rotatable ball208seated between valve seats210a,210b,210c,210d. The valve seats210a,210b,210c,210dare positioned about the ball208as shown inFIG.4. The ball208has a bore with two limbs214a,214bthat are arranged to form a single “L” configuration as illustrated inFIG.5. Notably, the bores214a,214bare positioned within the plane represented by the horizontal dashed line inFIG.4a. However, the axis of rotation of the ball208, represented by the vertical dashed line inFIG.4a, is perpendicular to this plane. This perpendicular configuration is necessary to isolate the cavity212(described below) from the process fluid flow path through the bores214a,214bof the valve200. The ball208is rotatable between a first position and a second position. In the first position, bore214aaligns with the inlet204aand bore214baligns with the outlet204b. In this first position, the process gas flows from inlet204aand through outlet204b. In the second position, as shown inFIG.4a, the ball208is rotated so that bore214baligns with inlet204aand bore214aaligns with outlet204c. In this second position, process gas flows from inlet204aand through outlet204c. The ball208is spaced apart from the interior surface of the housing to form a cavity212therein as shown inFIG.4a. The cavity212is purged with an inert gas as will be described in detail below. As shown inFIG.4a, the ball208includes a key slot223that engages with the drive dog219of the valve200. A small opening225in the ball208proximate the key slot223enables the cavity212to be in fluid communication with the bores214a,214b. The small opening225must be sized so as to provide the necessary pressure drop thus allowing the cavity212to operate at a higher pressure than the process fluid flow. As shown inFIGS.4aand4b, close coupled to the housing202is a manifold216having a flow path218with an inlet220aand an outlet220b. A pressurized source of inert gas224, for example nitrogen, argon or helium, is connected to the manifold inlet220a. The outlet220bof the manifold216is in fluid communication with a port222in the housing202as shown inFIG.4. The port222passes through the valve housing202and into the cavity212thus connecting the flow path218with the cavity212. Thus, the manifold216enables the cavity212to fill with pressurized inert purge gas. While the manifold216can be constructed of a variety of solid materials, it is preferably constructed of a material having a high thermal conductivity such as aluminum alloy or copper. A one-way (non-return) valve228is positioned in the port222so that inert gas can flow from the manifold216into the cavity212, but not in the reverse direction. In one embodiment, a spring (not shown) is positioned in the port222between the ball229of the non-return valve228and the ball208of the isolation valve200. The spring establishes a minimum pressure at which the purge gas must enter the port222and cavity212. As shown inFIG.4b, the manifold216preferably includes a heater226, for example a cartridge heater, which is sized to maintain the temperature of the purge gas so as to minimize condensation within the ball208and housing202of the valve200. The heater226should maintain the temperature of the purge gas at or about 90° C., and preferably above about 120° C. If the manifold216is constructed of a material having a high thermal conductivity, such as aluminum alloy or copper, then the heater226can be positioned at any convenient location within the manifold216. However, preferably the heater226is positioned closer to the manifold outlet220bthan to the manifold inlet220a. As shown inFIG.4b, the heater226is positioned within the manifold216proximate the flow path218and the manifold outlet220b. In addition, the flow path218preferably optimizes heat transfer from the heater226to the purge gas flowing through the manifold216. Thus, in one embodiment the flow path218is tortuous as shown inFIG.4a, where the purge gas must flow back-and-forth through the manifold216before it exits into port222. In another embodiment the flow path218may include baffles to increase turbulence or may be a packed bed to enhance heat transfer. As discussed above, the isolation diverter valve200has a first position and a second position. When bores214aand214bare aligned with inlet204aand outlet204b, respectively, process gas flows into the valve200through the inlet204a, through the bores214a,214bof the ball208and out through outlet204b. While the process gas flows through the bores214a,214b, heated purge gas flows from the manifold's216flow path218and into the cavity212, thus heating the ball208and housing202. From the cavity212, the heated purge gas flows through the opening225into the bores214a,214bof the ball208where the heated purge gas combines with the process fluid before exiting the valve200. Preferably, the pressure of the heated inert gas supplied to the cavity212is higher than the normal maximum pressure of the process gas stream so that the inert gas can flow into the process gas stream. Similarly, when bores214aand214bare aligned with outlet204cand inlet204a, respectively, process gas flows into inlet204aand through outlet204c. SeeFIG.4a. As in the first position, heated inert purge gas flows into the bores214a,214bto combine with the process fluid. Moreover, the pressure of the inert purge gas is preferably higher than the operating pressure of the process gas. Thus, during operation, when the valve200is in either the first or second position, the heated inert purge gas flows constantly into the cavity and bores214a,214b. As discussed above, the port222is sized to ensure that the pressure of the purge gas exceeds the pressure of the process gas and to control the flow of the purge gas into the bores214a,214b. Should the valve200fail, for example, from corrosion of a valve seat, the flow rate of the inert purge gas will increase. Thus, using the same configuration shown inFIG.3b, a flow transducer can be positioned in the purge gas line to monitor the flow rate of the purge gas. If the flow transducer detects a relative increase in flow rate, then this would be an indication of a valve failure. The wetted components of the isolation valve100,200, such as the housing, ball108,208, and valve seats110a,110b, must be compatible with gases such as fluorine, chlorine, hydrogen bromide and other gases used in semiconductor, flat panel display and solar panel manufacturing processes. Similarly, the wetted components of the non-return valve128,228, such as the ball229, spring (not shown), washer (not shown) and sealing rings (not shown), must also be compatible with the aforementioned gases. Ball108,208, and ball229are preferably constructed of stainless steels (for example, 304L, 316L, etc.) that are corrosion resistant to the aforementioned gases. The spring (not shown) should be constructed out of an alloy having a high nickel content, or a Mnemonic material, such as those manufactured by Inco Alloys. The washer and sealing rings (not shown) should be constructed of stainless steels (e.g. 304L, 316L, etc.), Hastelloy, Viton® or Kalrez®. The manifold116can be constructed of a relatively inexpensive material such as aluminum. Also provided is a system300having an isolation valve100,200according to the present invention.FIG.6ashows a system300according to the present invention. The system300has redundant abatement systems302a,302bto receive an exhaust304from one or more vacuum pumps306connected to the outlet307of a process chamber308. The exhaust line304tees into each abatement system302a,302band in the embodiment shown inFIG.6a, an isolation valve100is installed in each line of the tee. In another embodiment301shown inFIG.6b, a diverter valve200according to the present invention is installed at the tee upstream from the abatement systems302a,302b. In both embodiments300,301, the isolation valves100,200are constructed and function as described above. The present invention as described above and shown in the embodiments ofFIGS.1-6bprovides cost-effective redundancy and enhanced safety in semiconductor, solar panel and flat panel display processes. It is anticipated that other embodiments and variations of the present invention will become readily apparent to the skilled artisan in light of the foregoing description, and it is intended that such embodiments and variations likewise be included within the scope of the invention as set forth in the following claims. Although elements have been shown or described as separate embodiments above, portions of each embodiment may be combined with all or part of other embodiments described above. Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are described as example forms of implementing the claims. | 18,592 |
11859726 | FIG.1depicts a variable-opening valve10intended to be used for controlling the flow rate of a mixture of solids and of fluids such as that present in petrochemical processing equipment. The valve10comprises a tubular pipe section12of axis X intended to be connected to a pipeline1in which the valve is to be placed. For this purpose it has, for example, two flanges12a,12bat its ends and which can be assembled with similar flanges belonging to the pipeline1. Alternatively, the tubular pipe section12may be butt-welded to the main pipeline in which the valve is to be placed. The fluids circulate through the valve10in a direction parallel to the axis X of the pipe section12, generally from the top downward as depicted symbolically by the arrow F inFIG.1. Generally, this type of tubular pipe section12is cylindrical in shape. The valve10also comprises a first flat plate14and a second flat plate16which extend transversely to the pipe section12, namely perpendicular to the axis X of the pipe section12, inside same. The second plate16is mounted with the ability to rotate about the axis X of the pipe section12. Usually, these two plates have the same shape and size. Each plate14,16is pierced with a respective central orifice141,161, and with a respective plurality of peripheral orifices143,163, which are arranged circumferentially around the central orifice141,161. The various orifices of each of the first and second plates correspond to one another at least in terms of shape and spacing, preferably in terms of size, shape and spacing, so that when the two plates14,16are positioned one above the other, the centers of their central orifice coincide, and a rotation of the two plates with respect to an axis passing through these centers allows greater or lesser super positioning of the peripheral orifices, as depicted inFIG.2. In other words, the positions and shapes, and advantageously also the size, of the various orifices of each of the first and second plates are such that these orifices correspond with one another, namely are aligned in a position perpendicular to the plates, in at least one relative position of these plates. Thus, adjusting the relative position of the two plates by rotation about the axis X passing through the centers of the central orifices141,161allows the cross section for the passage of the fluids through the peripheral orifices143,163to be modified and regulated. In the example, the peripheral orifices are smaller in size than the central orifices. The peripheral orifices are preferably arranged equidistantly from one another and from the central orifice that they surround. At least one support element supports the second plate16such that it can pivot with respect to the first plate14. Thus it is possible to provide a support element17secured to the internal wall of the pipe section12and extending over the entire periphery thereof, this support element17defining an annular surface on which the second plate16can rest (FIG.1). Note that several support elements17secured to the internal wall of the pipe section12may be provided. It is also possible to provide, in addition to the support element or elements17, or in place thereof, a support element of tubular shape18, secured to the first plate14and which connects, in a fluidtight manner, the central orifice141of the first plate to the central orifice161of the second plate, as depicted in the example, so as to prevent solid particles contained in the fluid passing through the valve from gaining access via the central orifice to the gap between the two plates. This tubular support18may be fixed in fluidtight manner to the first plate14by any suitable means, for example by welding if the two components are made of metal, or by riveting, screw-fastening, etc. In the example, the tubular support18has an upper flange18aresting on the face14aof the first plate14and welded thereto (FIG.1). The tubular support18at its other end has a lower flange18bholding the second plate16which is thus mounted with the ability to pivot on the tubular support18. Of course the invention is not restricted to this arrangement, it being possible for example for the tubular support18to be fixed to the face14bof the first plate around the central orifice thereof. The tubular support18may even be produced as one piece with the first plate, for example in the continuation of the central orifice thereof and may pass through the second plate. The second plate may be mounted on the tubular support by means of any other means or support that allows rotation (bearing, support lug, etc.). The valve10further comprises an adjusting system20engaging with the second plate16in order to adjust the relative positions of the peripheral orifices143,163of the first and second plates by rotating the second plate, in this instance about the axis X of the pipe section12. In the example depicted inFIGS.1,2and6, this adjusting system20comprises a toothed sector201secured to the periphery of the second plate16and engaging with the teeth of a rack202mounted with the ability to slide in translation in the direction of the arrow F1ofFIG.2. The movement of this rack may be instigated by a movement member203such as a stepping motor, a system of hydraulic rams, or any other suitable member. In the example ofFIGS.2and6, the toothed sector201projects from the periphery of the second plate16. It is possible for this toothed sector not to project from the periphery of the second plate16, as in the example ofFIG.4, where the toothed sectors201are secured to the face16bof the second plate. In the variants depicted inFIGS.3and4, one or two toothed sectors201are secured to the face16bof the second plate. The two toothed sectors201may therefore be positioned at diametrically opposing locations of the second plate, as depicted inFIG.4. The invention is not restricted to any one particular form of adjusting system, provided that it allows the second plate to be pivoted with respect to the first plate. According to the invention, each peripheral orifice143of the first plate14is surrounded by a collar145secured to the first plate14and projecting from a face14athereof that is situated on the opposite side to the second plate16. In the example, each collar145is produced as a single piece with the plate14. It will be noted that, in addition, each collar145is formed of a wall which has an internal cross section the same shape and size as the shape and size of the internal cross section of the peripheral orifice143that it surrounds. These internal cross sections are, in this instance, cross sections of planes perpendicular to the axis X of the pipe section. In other words, the internal surface145aof each collar145extends in the continuation (as a continuous extension) of an internal surface of the peripheral orifice143. This makes it possible to avoid inducing additional disturbance in the flow of fluid passing through the valve and to avoid erosion by the solid particles contained in the fluid at the junction between the orifice and the associated collar. Each collar145here extends in a direction perpendicular to the first plate14, or in other words parallel to the axis X of the pipe section12, over a predetermined height. This height is, for example, at least three times the inside passage diameter of the peripheral orifices and advantageously at most equal to the distance separating one end of the pipe section12(corresponding in the example to the flange12a) from the face14aof the first plate14. When these orifices are not cylindrical, the height of the collars may be determined from an imaginary inside diameter calculated for an imaginary circular internal passage section having the same cross-sectional area as the inside passage cross section of the orifice. The invention is not restricted to the example depicted, and in particular each collar145could be fixed to the first plate by any appropriate means, for example by welding, screw-fastening, rivets. Furthermore, the internal surface145aof each collar here extends parallel to the axis X of the pipe section12. Although this configuration is preferable, notably so as not to disrupt the flow passing through the peripheral orifices, configurations in which the collars have a flared, for example conical, shape are conceivable. Collars having a parallelepipedal internal cross section are also acceptable, although non-preferred. In the example depicted, each peripheral orifice163of the second orifice plate16is also surrounded by a collar165secured to the second orifice plate and projecting from a face16bthereof that is situated on the opposite side to the first orifice plate14. As with the first plate14, in the example, each collar165is produced as a single piece with the plate16. Each collar165also has an internal cross section that is the same shape and the same size as the shape and size of the internal cross section of the peripheral orifice163that it surrounds. In other words, the internal surface165aof each collar165extends in the continuation (as a continuous extension) of the internal surface of the peripheral orifice163. Each collar165here also extends in a direction perpendicular to the second plate16, or in other words parallel to the axis X of the pipe section12, over a predetermined height. This height is, for example, at least three times the inside passage diameter of the peripheral orifices, preferably at least five times the passage diameter of the peripheral orifices, and advantageously at most equal to the distance separating one end of the pipe section12(corresponding in the example to the flange12b) from the face16bof the second plate16. When these orifices are not cylindrical, the height of the collars may be determined from an imaginary inside diameter as defined hereinabove. Similarly, the invention is not restricted to the example depicted, and in particular each collar165could be fixed to the second plate by any appropriate means, for example by welding, screw-fastening, rivets. Furthermore, the internal wall165aof each collar here extends parallel to the axis X of the pipe section12. Although this configuration is preferable, notably so as not to disrupt the flow passing through the peripheral orifices, configurations in which the collars have a flared, for example conical, shape are conceivable. However, it is preferable for the internal wall165aof the collars165to be oriented in such a way as to direct a flow passing through these collars parallel to the axis X, possibly with a tolerance of at most 5% on the deviation from this axis. In the example depicted, the first plate14is furthermore provided, on the side of its face14bthat faces toward the second plate16, with a plurality of sealing elements22-25surrounding each one of the peripheral orifices143of the first plate14. These sealing elements22-25ensure sealing between the two plates, at the site of the peripheral orifices of the valve. These sealing elements22-25are advantageously made of metal. One or more sealing elements may surround each peripheral orifice. In the example, a single sealing element22(FIGS.1,7) or three sealing elements23,24,25(FIG.8) may be provided. Each sealing element22,23,24,25has a first edge22a,23a,24a,25asecured to the first plate14(to the face14bthereof) and an opposite free second edge22b,23b,24b,25bin sliding contact with the second plate16. Such sliding contact is defined in such a way as not to allow any particles that might be present in the fluid to enter the inter-plate space and to allow the sealing element or elements to slide over the second plate. Thus, when the second plate pivots with respect to the first plate, these sealing elements22-25scrape the face16aof the second plate which is situated facing the first plate14thereby preventing particles that may have fallen onto this face16a, for example when the peripheral orifices of the two plates do not exactly coincide, from slipping in between the plates14,16. When just a single sealing element22is provided, the internal surface22cthereof extends in the continuation (as a continuous extension) of the internal surface of the orifice143surrounded, and preferably perpendicular to the plates. Here, this internal surface22chas an internal cross section the same shape and size as the internal cross section of the peripheral orifice around which the sealing element is placed. The external surface22dis then preferably of a flared, in this instance frustoconical, shape widening toward the second plate. When several sealing elements23,24,25are provided, the sealing element23closest to the peripheral orifice surrounded has an internal surface23cextending in the continuation (as a continuous extension) of the internal surface of the orifice surrounded, preferably perpendicular to the plates. Here, this internal surface23chas an internal cross section the same shape and size as the internal cross section of the peripheral orifice around which the sealing element is placed. The external surface23dof the sealing element23may then have a shape similar to that of the internal surface23c. The sealing element25furthest from the peripheral orifice may then have an external surface25dof flared shape widening toward the second plate. Its internal surface25chere is of a shape similar to that of the internal surface23cand of the external surface23d. It is possible to provide only the two sealing elements23and25described hereinabove or to provide one or more intermediate sealing elements (just one,24, in the example) of similar shape to the sealing element closest to the peripheral orifice. However, the geometry of the sealing element or elements22-25is not restricted to these examples. In particular, the sealing-element external surface furthest from the peripheral orifice may be perpendicular to the first plate. It will be noted that, in the example depicted, the peripheral orifices of the first and second plates are all of cylindrical shape. However, the invention is not restricted to one particular shape of peripheral orifices, which may have an oblong shape, a polygonal, for example quadrilateral (rectangular, trapezoidal) shape, a circular arc shape, or some other shape. Similarly, the shape of the central orifices may be a shape other than cylindrical. The valve according to the invention is particularly well suited to use in a refinery unit such as a catalytic cracking unit. This type of valve is therefore placed in pipelines of appreciable (of the order of 1 meter) diameter. The various elements of the valve are therefore made of steel, preferably stainless steel, and possibly covered with a coating protecting them against erosion. The number of peripheral orifices is dependent on the dimensions of the valve and on the fluid flow rate considered. For the above-mentioned use, up to 10 or 12 orifices may be envisioned. The valve according to the invention could also be used in any application in which debris carried by the fluid is liable to plug the variable-section orifices (the peripheral orifices). | 15,108 |
11859727 | Elements of identical design or function are provided with the same reference designations across all figures. Reference is made firstly toFIG.1, which shows a schematic view of an adjusting device10according to the invention for adjusting a contour12of a seat contact face14of a vehicle seat16. Here, the vehicle seat16has a first fluid chamber or a first fluid bladder18and a second fluid chamber or a second fluid bladder20, which, by filling and/or emptying, serve for the adjustment of the contour12of the seat contact face14of the vehicle seat16. The adjusting device10furthermore has a valve22which is fluidically connected to the fluid bladders18,20and to a fluid source24. The valve22has a base element26, an intermediate element28connected to the base element26via webs, and a cover element30connected to the intermediate element28. A first chamber32, which is fluidically connected to the fluid source24, is situated between the base element26and a central section of the intermediate element28. The first chamber32is pressurized with the pressure medium, for example compressed air, provided by the fluid source24. The intermediate element28is designed such that a first fluid passage34, which is fluidically connected to the first chamber32, and a second fluid passage36, which is fluidically connected to the first fluid passage34, are created. The intermediate element28furthermore has webs38which extend to the cover element30and which delimit an upwardly open region40. The region40is covered from above by a shut-off element42such that the shut-off element42, the webs38and the intermediate element28form a second fluid chamber44, which is fluidically connected to the first chamber32via the first fluid passage34and is fluidically connected to a third fluid chamber46via the second fluid passage36. The third fluid chamber46forms a fluid connection which is fluidically connected to the first fluid bladder18. The shut-off element42furthermore has a third fluid passage47, which fluidically connects a fourth fluid chamber48, which is situated between the intermediate element28and the cover element30, to the second fluid chamber44. The cover element30furthermore has an opening50which fluidically connects the fourth fluid chamber48to the surroundings of the valve22. The shut-off element42has a sealing element52, for example in the form of a diaphragm element, which is movable between a first position and a second position. In a first position, the sealing element52closes the third fluid passage47and opens the first fluid passage34, whereby pressure medium can flow from the fluid source24via the first fluid passage34and the second fluid passage36into the first fluid bladder18for the purposes of filling the fluid bladder18, as indicated by the arrow inFIG.1. In a second position, the sealing element52closes the first fluid passage34and opens the third fluid passage47, as will be described in more detail in conjunction withFIG.2. Since the sealing element52closes the third fluid passage47in the first position, no pressure medium can flow into the fourth valve chamber48, such that the fourth valve chamber48is not pressurized. In order to move the sealing element52between the first and second positions, an actuator unit54is situated in the fourth valve chamber48of the valve22. The actuator unit54has a circuit board56with a top side58. The top side58extends in a circuit board plane, which is indicated by dashed lines with the reference designation60. The actuator unit54furthermore has an actuating element62which has an actuating section64and a bending section66connected to the actuating section64. The bending section66makes it possible for the actuating section64to be movable by means of bending in the bending section66. For this purpose, the bending section66has a (virtual) center of rotation about which the actuating section64can rotate. The actuator unit54furthermore has an actuator element68, the first end70of which is mechanically (and optionally electrically) connected to the actuating section64of the actuating element62and the second end72of which is mechanically (and optionally electrically) connected to the circuit board56. In the specific example ofFIG.1, the actuator element68is designed in the form of a shape memory alloy element681, in particular in the form of a shape memory alloy wire. The shape memory alloy element681can deform, in particular become shorter, when electrical power is applied thereto. In this specific example, the first end70of the shape memory alloy element681is mechanically and electrically connected to the actuating section64and the second end72of the shape memory alloy element681is mechanically and electrically connected to the circuit board56. Since the first end70of the shape memory alloy element681is mechanically and electrically connected to the actuating section64, the actuating section64can move or rotate about the bending section66, or about the virtual center of rotation thereof, when electrical power is applied to the shape memory alloy element681, owing to the shortening of the shape memory alloy element681. In the specific example ofFIG.1, the actuating section64rotates clockwise about the virtual center of rotation of the bending section66when, for example, electrical power is applied to the shape memory alloy element681. The use of a shape memory alloy element681as an actuator element68is merely an example. It is self-evidently conceivable that actuator elements of variable length other than the described shape memory alloy element681may be used for moving the actuating section. For example, the actuator element68could also be designed as a hot wire or as an electroactive polymer. When the actuator element68is actuated, or when electrical power is applied to the shape memory alloy element681, the actuating element lifts off from the sealing element52such that the sealing element52(for example owing to its inherent prestress) can open up the first fluid passage34, and pressure medium can flow from the fluid source24into the first fluid bladder18for the purposes of filling the fluid bladder18. The particular design embodiment of the actuator unit54now consists in that the actuating element62is arranged partially below and partially above the circuit board56. More specifically, the actuating section64and the bending section66are arranged on two opposite sides with respect to the circuit board plane60. As can be seen in the specific example ofFIG.1, it is for example the case that the actuating section64is arranged above the circuit board56or on a first side601with respect to the circuit board plane60, and the bending section66, which has the virtual center of rotation, is arranged below the circuit board56or on a second side602, situated opposite to the first side601, with respect to the circuit board plane60. By virtue of the fact that the actuating section64and the bending section66are arranged on opposite sides601,602with respect to the circuit board plane60, a relatively large lever H can be realized for a given structural height of the actuator unit54. As a result, in the case of a specified actuator force exerted on the actuating section64by the actuator element68or the shape memory alloy element681, a relatively high actuating force can be exerted on the sealing element52by the actuating section64. The actuator unit54can thus, whilst having a relatively small structural height, provide a relatively high actuating force, for example for moving the sealing element52. Likewise, a large lever H also makes it possible to realize the required stroke at the actuating section64or at the plunger element80with as small as possible an angle of rotation of the actuating element62. A small angle of rotation prevents damage to the actuator element68at both ends70and72as a result of excessive bending movement at the connection points to the actuating element62and to the circuit board56. The actuator element68or the shape memory alloy element681is in this case situated exclusively on the first side with respect to the circuit board plane60. In other words, the actuator element68is situated exclusively on that side on which the actuating section64is also situated. In this way, a force flow which is as linear as possible, and which is furthermore substantially perpendicular to the movement direction of the actuating section64, is exerted on the actuating section64by the actuator element68. As can also be seen inFIG.1, the actuating element62furthermore has a circuit board fastening section74, which is electrically and mechanically connected to the circuit board56. The circuit board fastening section74is in this case situated on the same side as the bending section66. This has the advantage that, during the assembly of the actuator unit54or during the assembly of the valve22, the actuating element62can first be installed, and the circuit board56is subsequently installed on the actuating element62. The actuating element62furthermore has an end position contacting section76which indicates an end position of the actuating section64. As shown by way of example inFIG.1, the end position contacting section76makes contact with the circuit board56in the end position of the actuating section64. As soon as the end position contacting section76makes contact with the circuit board56, an actuation of the actuator element68or a supply of electrical power to the shape memory alloy element681is interrupted. In this way, in particular if a shape memory alloy element681is used as the actuator element68, the shape memory alloy element681is prevented from being excessively heated and, under certain circumstances, damaged. As can be seen inFIG.1, the end position contacting section76is likewise situated below the circuit board or on the same side as the bending section66. This in turn has assembly advantages, since during assembly first the actuating element62and then the circuit board56can each be installed on the intermediate element28by way of a simple rectilinear joining movement. As can also be seen inFIG.1, the actuating section64projects beyond a lateral edge of the circuit board56. The lateral edge of the circuit board56is illustrated inFIG.1with the reference designation78and marks that edge of the circuit board56which marks the end of the circuit board56in the extent direction of the circuit board plane60. Since the actuating section64projects beyond the lateral edge78of the circuit board56, the actuating section64and the circuit board56are arranged adjacent to one another (in the longitudinal extent direction of the circuit board plane60). On the one hand, this has the advantage that the actuator unit54has an even more compact design. On the other hand, installation space and material for the circuit board56can be saved in this way. In an embodiment of the actuator unit54according to the invention which is not shown inFIG.1, the circuit board56may for example also have a cutout in the region of the actuating section54. As already mentioned, the sealing element52can be actuated by means of the actuating section64, such that selectively either the first fluid passage34or the third fluid passage47is open or closed. In order now to be able to actuate the sealing element52by means of the actuating section64, the actuator unit54has a plunger element80that is couplable to the actuating section64. The plunger element may be couplable, for example in the form of a floating bearing, to the sealing element52at one side and to the actuating section64at the other side. The plunger element80produces a mechanical connection between the actuating element64and the sealing element52. Here, the plunger element80extends in a longitudinal extent direction82that runs substantially perpendicular to the circuit board plane60. In other words, the longitudinal extent direction82extends through the circuit board plane60or intersects the circuit board plane60, in particular perpendicularly. This achieves a substantially 90° diversion between the substantially horizontally acting actuator force, which is exerted by the actuator element68or the shape memory alloy element681, and the substantially vertically acting actuating force, which acts on the sealing element52through the plunger element80. The 90° diversion has the advantage that a relatively high actuating force can be exerted on the sealing element52despite the relatively small structural height. It is self-evidently also possible for the sealing element52to be integrated into the plunger element80, such that the plunger element80is designed to bear sealingly against a valve seat of the first fluid passage34. As can also be seen inFIG.1, the adjusting device10has a further valve220, which is structurally identical to the valve22already mentioned. In the specific example ofFIG.1, the valve220is used to fill or empty the second fluid bladder20. It is self-evidently also possible for the valve220and also the valve22to be used for purposes other than the filling or emptying of the fluid bladders18,20. For example, the valves22and220may be connected pneumatically in series with a modified intermediate element28by virtue of the first fluid passage340of the valve220being connected to the pressure supply (fluid source24), the first fluid passage34of the valve22being connected to the third fluid chamber46, and the two second fluid passages36and360being connected to one another. In this way, a 3/3 valve is created from the two valves22and220. Reference is now made toFIG.2, which shows again the valve22fromFIG.1. By contrast toFIG.1, however, the actuator unit54is shown inFIG.2in a second switching state. In this second switching state, the sealing element52seals the first fluid passage34and the sealing element52opens up the third fluid passage47. In the second switching position of the actuator unit54, a pressure medium situated in the fluid bladder18can consequently flow via the third fluid chamber46, the second fluid passage36and the third fluid passage47from the fluid bladder18into the fourth valve chamber48and from there via the opening50to the surroundings of the valve22. In other words, in the second position of the actuator unit54, the bladder18can be emptied, which is indicated schematically by the flow arrows. Since, in the second position of the actuator unit54, the first fluid passage34is closed by means of the sealing element52, no pressure medium flows into the fourth fluid chamber48in the second switching state of the actuator unit54either. The actuator unit54is not acted upon with pressure medium, as is also the case in the second switching state. Since the actuator unit54is not acted upon with pressure medium either in the first switching state or in the second switching state, it is not necessary to provide an air-tight leadthrough of electrical lines or conductor tracks. This has considerable advantages in terms of the structural design and production of the valve22. As is also shown inFIG.2, the bending section66is formed such that the actuating section64is preloaded in the direction of the second switching state of the actuator unit54. As a result, the actuating section64can move the plunger element80in the direction of the first fluid passage34, whereby the sealing element52closes the first fluid passage34and opens the third fluid passage47. The third fluid passage47can generally also be regarded as a valve opening of the valve22, wherein the valve opening divides a valve chamber formed by the intermediate element28and the cover element30into a first region (fourth fluid chamber48) and a second region (second fluid chamber44). In this general formulation, the bending section66is thus formed such that the actuating section64is preloaded by the bending section66in a first position for opening the valve opening47. In order to now switch the actuator unit54from the first switching state (seeFIG.1) into the second switching state (seeFIG.2), it is merely necessary for an actuation of the actuator element68or a supply of electrical power to the shape memory alloy element681to be interrupted. This interruption reverses the previously caused shortening of the shape memory alloy element681, such that the shape memory alloy element681resumes its original shape. The preloaded actuating section64can now, in the absence of actuation by the shape memory alloy element681, move in the direction of the plunger element80, which in turn moves the sealing element52toward the first fluid passage34, whereby the first fluid passage34is closed and the third fluid passage47is opened. If another actuator element68is used instead of the shape memory alloy element681, the movement of the plunger element80occurs accordingly (owing to the preload of the actuating section64). Reference is now made toFIG.3, which shows a schematic detail view of a further embodiment of the actuator unit54fromFIGS.1and2. In the embodiment according toFIG.3, the actuating section64has a flow guide section84. The flow guide section84has the task, in the second position of the actuator unit54, that is to say in the position of the actuator unit54in which the fluid bladder18is being emptied, of conducting a flow flowing out of the third fluid passage47away from the actuator element68or from the shape memory alloy element681. This is indicated schematically by flow arrows. The flow guide section84may for example be a flow edge in the form of a beveled side edge of the actuating section64. The advantage of the flow guide section84is that, in particular if the shape memory alloy element681is used as actuator element68, the flow flowing out of the third fluid passage47does not cause any undesired cooling in the shape memory alloy element681. In other embodiments of the actuator unit54that are not shown, it is self-evidently possible for the flow guiding section84to have other expedient design embodiments that conduct a flow, which under certain circumstances flows out of the third fluid passage47, away from the actuator element68. Reference is finally made toFIG.4, which shows a schematic plan view of a valve assembly86for the adjusting device10. The valve assembly86is composed of multiple valves, each of which opens and closes a corresponding valve opening. In the specific example ofFIG.4, the valve assembly86has a first valve22, a second valve220, a third valve320and a fourth valve420, all of which are structurally identical. The valve assembly86is distinguished by the fact that the actuating element62of the valve22and a corresponding actuating element620of the valve220are formed in one piece in the form of a one-piece actuating element assembly500. As a result, the respective actuating elements of the respective valves22,220,320,420can be produced in a common processing step, whereby time and costs can be saved. In particular, it is thereby also possible for valve assemblies with different numbers of valves to be produced inexpensively and efficiently. As can also be seen inFIG.1, the respective actuating sections64,640project beyond the lateral edge78of the circuit board58. This once again illustrates the compact and material-saving design embodiment of the valve assembly86. Although the actuator unit54and the valves22,220,320,420have been described in conjunction withFIGS.1to4in the context of the filling and emptying of fluid bladders18,20, it is also conceivable for the actuator unit54according to the invention and the valves22,220,320,420according to the invention (and also the valve assembly86) to be able to be used for other purposes, such as the above-described interconnection of in each case two valves to form a 3/3 valve. | 19,731 |
11859728 | Reference numerals inFIGS.2to13are as follows: 1 control component;11/11′ motor,111/111′ rotating shaft;112/112′ input gear;1120/1120′ sun gear;1121 large-diameter portion;1122 small-diameter portion;1123 groove of large-diameter portion;1124 groove wall portion,1125 protruding ring;113 stator;114 rotor;115 upper bearing;116 lower bearing;117 transmission rod;1171 side wall portion;12 lead wire;13 mounting plate;130 gap;2 gear reduction mechanism;21 planetary gear,22 planetary gear carrier;221 first-stage planetary gear carrier;2210 center through hole;23 positioning rod;24 separator;240 communication flow path;241 center hole;242 through hole;243 radial through groove;244 annular groove;25 gear ring;250 inner chamber of gear ring;251 limiting groove;26 output gear carrier,261 disc-shaped body portion;262 hole portion;263 protruding portion of disc-shaped body portion;27/27A/27B bearing member;271/271A cylindrical portion;272/272A radially extending portion;273A axially extending portion;274/274A axial through groove;275 notch portion;3/3A valve body component,30 inner chamber of valve body component,31/31A valve body;311/311A body portion,312/312A extending portion;313 limiting boss;314 recess portion;3120A axial through hole;32 valve core;321 groove of valve core;33/33A first valve seat;33′ second valve seat;34 transmission shaft;341 first key portion;342 second key portion;343 blind hole;36 first connecting pipe;37 second connecting pipe;4 housing component,40 inner chamber of housing component,401 upper chamber;41 upper housing;411 protruding portion of upper housing;42 lower housing;421 second stepped portion;422 reduced-diameter portion;5 plug-in component;51 plug-in socket;511 upper portion;5110 plug-in chamber;512 middle portion;513 lower portion;5130 sealing chamber;514 first stepped portion;52 sealing glass;53 pin. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS In the electric, valve according to the present application, the housing component is fixedly connected to the valve body component, the control component includes the motor, and the control component is arranged in the inner chamber of the housing component. A control component includes a motor, and the control component is arranged in the inner chamber of the housing component. Compared with the conventional technology, the influence of moisture on the motor can be reduced. In order to enable those skilled in the art to better understand the technical solutions of the present application, the present application will be further described in detail with reference to the drawings and specific embodiments. It should be noted that, the orientation terms, such as upper and lower, involved in this application are defined with reference to the positions of the components in the figures and the relative positions of the components as shown inFIGS.2to13, which are only for clarity and ease of describing the technical solutions. It will be appreciated that, those orientation terms used herein should not limit the protection scope of the present application. It should be further noted that, the “rotation” referred to herein refers to movement in a circumferential direction, which includes not only rotation by one circle (360 degrees) or more, but also rotation by one circle (360 degrees) of less. FIG.2is a schematic sectional view of an electric valve according to the present application;FIG.3is a schematic structural view of a plug-in component inFIG.2;FIG.4ais a schematic structural view of a separator inFIG.2;FIG.4bis a schematic structural view of a gear ring inFIG.2;FIG.5is a schematic structural view of an output gear carrier inFIG.2;FIG.6is a schematic structural view of a bearing member inFIG.2;FIG.7is a schematic view showing the cooperation of the gear ring, the output gear carrier and the bearing member inFIG.2;FIG.8is a schematic sectional view of a transmission shaft inFIG.2. The electric valve includes a control component1, a gear reduction mechanism2, a valve body component3and a housing component4. A valve chamber of the electric valve includes an inner chamber30of the valve body component and an inner chamber40of the housing component, and the inner chamber the housing component. The control component1and the gear reduction mechanism2are arranged in the inner chamber40of the housing component. The control component1includes a motor11, a lead wire12and a mounting plate13. The motor11includes a stator113, a rotor114, a rotating shaft111, an input gear112, an upper bearing115and a lower bearing116which are both configured to position the rotating shaft111. The stator113and the rotor114are located above the gear reduction mechanism2. The lower bearing116is close to the input gear112, and the rotating shaft111penetrates through the lower bearing116. By energizing the lead wire12, the stator113is energized to drive the rotor114to rotate circumferentially, and the rotor114is fixedly connected to the rotating shaft111. The rotating shaft111is made by processing a stainless steel bar and is rotatable connected to the input gear112. The “rotatably connected” herein includes that the rotating shaft111is fixedly connected to the input gear112, and also includes that the rotating shaft111is connected to the input gear112by circumferentially as long as the rotating shaft111can drive the rotating shaft112to rotate. Specifically, the rotating shaft111may be fixed to the input gear112by interference fit. Besides, the rotating shaft111may be connected to the input gear112by key-groove cooperation. The motor11is fixedly connected to the mounting plate13by welding, the mounting plate13is fixedly connected to the housing component4by welding, or the mounting plate13may be integrally formed with the motor11. In this way, the motor11is fixed by the mounting plate13, which ensures the smooth operation of the rotating shaft111. The gear reduction mechanism2is provided in the inner chamber40of the housing component. The gear reduction mechanism2is a planetary gear mechanism, which includes a planetary gear21, a planetary gear carrier22and an output gear carrier26. The planetary gear21is mounted on the planetary gear carrier22, the planetary gear21meshes with the input gear112, the input gear112is configured to drive the planetary gear21to rotate circumferentially, and the planetary gear21is configured to drive the output gear carrier26to rotate circumferentially. The valve body component3includes a valve body31, a valve core32, a first valve seat33, a second valve seat33′ and a transmission shaft34. The valve body31is substantially tubular and made by stretching a stainless steel material. The first valve seat33is fixed to one end of the valve body31by welding, and the second valve seat33′ is fixed to another end of the valve body31by welding. The first valve seat33is fixed to a first connecting pipe36by welding, and the second valve seat33′ is fixed to a second connecting pipe37by welding. One of the first connecting pipe36and the second connecting pipe37serves as a flow path inlet, and the other serves as a flow path outlet. The valve core32is substantially spherical, and is arranged in the inner chamber30of the valve body component, and is located between the first valve seat33and the second valve seat33′. The valve body31includes a body portion311and an extending portion312extending outward from a circumferential outer wall of the body portion311, and the extending portion312is substantially tubular. In this embodiment, the output gear carrier26is rotatably connected to the transmission shaft34, and the transmission shaft34is rotatably connected to the valve core32. Specifically, the transmission shaft34is substantially cylindrical rod-shaped, the transmission shaft34penetrates through the extending portion312. One end of the transmission shaft34extends into the inner chamber40of the housing component and is connected to a hole portion262of the output gear carrier26by key-groove cooperation. The output gear carrier26is configured to drive the transmission shaft34to rotate circumferentially. Another end of the transmission shaft34extends into the inner chamber30of the valve body component and is connected to a groove321of the valve core32by key-groove cooperation. The transmission shaft34is configured to drive the valve core32to rotate circumferentially. The housing component4includes an upper housing41and a lower housing42, and the upper housing41and the lower housing42are respectively formed by stamping a stainless steel plate. A wall thickness of the lower housing42is larger than a wall thickness of the upper housing41. An upper end of the lower housing42includes a second stepped portion421with a stepped surface facing upward, the upper housing41is placed on the second stepped portion421, and the upper housing41is fixed to the lower housing42by welding. A lower end of the lower housing42includes a reduced-diameter portion422, at least part of the reduced-diameter portion422is located inside the extending portion312of the valve body31, and an outer wall of the reduced-diameter portion422is fixed to an inner wall of the extending portion312by welding. In this embodiment, the valve body31is fixedly connected to the housing component4, and the motor11is arranged in the inner chamber40of the housing component. The beneficial effect is that the influence of moisture on the motor11can be reduced, and the risk of short-circuit of the motor11can be reduced. Further, as shown inFIG.2, in this embodiment, the rotating shaft111is fixedly connected to the input gear112, and a circumferential outer wall of the input gear112includes a sun gear1120. The gear reduction mechanism2further includes a gear ring25and a partition plate24, and the gear ring25is fixedly connected to the partition plate24by welding. Apparently, the gear ring25may be connected to the partition plate24by circumferentially limiting, as long as the partition plate24does not rotate circumferentially relative to the gear ring25. The partition plate24includes a center hole241, at least part of the lower bearing116is located in the center hole241, and the lower bearing116is in clearance fit with the center hole241. With this arrangement, the motor11can be positioned. In the specific assembly, after the motor11is positioned, the mounting plate13is welded to an inner wall of the lower housing42for fixation. The gear ring25is substantially cylindrical, the sun gear1120is located in an inner chamber250of the gear ring25, the planetary gear21is located in the inner chamber250of the gear ring25, and the sun gear1120meshes with the planetary gear21. As shown inFIGS.2and4a, the mounting plate13is placed on the partition plate24, and the mounting plate13includes a gap130located on an outer circumference of the mounting plate13. The inner chamber40of the housing component includes an upper chamber401located above the mounting plate13and the inner chamber250of the gear ring, and the upper chamber401is in communication with the gap130. The stator113and the rotor114are located in the upper chamber401. The partition plate24includes a communication flow path240which communicates the gap130with the inner chamber250of the gear ring. The communication flow path240includes a through hole242axially penetrating through the partition plate24and a radial through groove243radially extending from the through hole242to a circumferential outer wall of the partition plate24. By providing the communication flow path240and the gap130, the upper chamber401is communicated with the inner chamber250of the gear ring, and fluid in the electric valve is introduced into the upper chamber401, which is beneficial to the heat dissipation of the motor11, and the upper chamber401may not form a liquid-sealing chamber, which improves the safety of the electric valve. Further, as shown inFIG.4a, the communication flow path240further includes an annular groove244, at least two through holes242are defined and are arranged symmetrically about the center hole241, and the annular groove244communicates with each of the through holes242. With this arrangement, the flow capacity of the communication flow path240is improved. The planetary gear carrier22includes a first-stage planetary gear carrier221, the first-stage planetary gear carrier221includes a center through hole2210, and a lower end of the rotating shaft111is located in the center through hole2210. The gear reduction mechanism2further includes a positioning rod23, which is processed by turning a metal bar. An upper end of the transmission shaft34includes a blind hole343, an upper end of the positioning rod23is located in the center through hole2210, and a lower end of the positioning rod23is located in the blind hole343. With this arrangement, the planetary gear carrier22can be positioned, the operation stability of the gear reduction mechanism2can be improved, and the risking of getting stuck can be reduced. FIG.10ais a schematic partial sectional view of a second electric valve according to the present application;FIG.10bis a schematic view showing the cooperation of a rotating shaft, a transmission rod, and an input gear inFIG.10a. The difference between this embodiment and the above-mentioned embodiments lies in the structure of the control component and the connection relationship between the control component and the gear reduction mechanism. As shown inFIGS.10aand10b, the motor11′ includes a rotating shaft111′ and a transmission rod117fixedly connected to the rotating shaft111′, the transmission rod117is substantially plate-shaped and includes a side wall portion1171. An input gear112′ includes a large-diameter portion1121and a small-diameter portion1122. A groove1123is defined at an upper end of the large-diameter portion1121, at least part of the transmission rod117is located in the groove1123, the groove1123includes a groove wall portion1124configured to abut against the side wall portion1171, and a circumferential movement gap is present between the groove wall portion1124and the side wall portion1171. A circumferential outer wall of the small-diameter portion1122includes a sun gear1120′, at least part of the sun gear1120′ is located in the inner chamber250of the gear ring, the sun gear1120′ meshes with the planetary gear21, and the small-diameter portion1122penetrates through the center hole241of the partition plate24. Further, as shown inFIG.10a, a protruding ring1125is provided at a lower end of the large-diameter portion1121, a longitudinal sectional profile of the lower end of the protruding ring1125is substantially arc-shaped, and the protruding ring1125abuts against the partition plate24. By providing the protruding ring1125, it is beneficial to reducing the frictional force when the input gear112′ rotates circumferentially, and prolonging the service life of the input gear112′. Further, as shown inFIGS.2and3, the electric valve further includes a plug-in component5, and the plug-in component5includes a plug-in socket51, a sealing glass52and a pin53. The sealing glass52is fixed in the plug-in socket51by sintering. Specifically, the plug-in socket51is made of stainless steel and has a substantially hollow structure, which includes an upper portion511, a middle portion512and a lower portion513. The upper portion511includes a plug-in chamber5110, the lower portion513includes a sealing chamber5130, the sealing chamber5130is in communication with the inner chamber40of the housing component, and the middle portion512is fixed and sealed to the sealing glass52by sintering, which separates the plug-in chamber5110from the sealing chamber5130. The pin53penetrates through the sealing glass52. An upper end of the pin53extends into the plug-in chamber5110and is configured to electrically connect with an external plug-in component, and a lower end of the pin53extends into the sealing chamber5130and is configured to electrically connect with the lead wire12of the control component1. The pin53is fixed to the sealing glass52by sintering. Further, the upper housing41includes a protruding portion411protruding upward. A lower end of the plug-in socket51includes a first stepped portion514with a stepped surface facing downward, and the protruding portion411is fixed to the first stepped portion514by welding. As shown inFIG.2, the transmission shaft34penetrates through the reduced-diameter portion422of the lower housing42, and a bearing member27is provided between the reduced-diameter portion422and the transmission shaft34. The second bearing member27is made by wear-resistant metal material powder metallurgy. The beneficial effect of this arrangement lies in that the wear of the transmission shaft34during the circumferential rotation is reduced and the service life of the transmission shaft34is prolonged. It is conceivable that the method of fixing the lower housing42to the valve body31may be fixing an inner wall of the reduced-diameter portion422to an outer wall of the extending portion312of the valve body31by welding. The transmission shaft34penetrates through the extending portion312, and a bearing member27is provided between extending portion312and the transmission shaft34. This embodiment has the same technical effect as the above embodiment. With reference toFIG.2,FIG.5, andFIG.7, one end of the transmission shaft34facing the control component1includes a first key portion341which is connected to the hole portion262of the output gear carrier26by key-groove cooperation, and the first key portion341is located in the inner chamber40of the housing component. The first key portion341has a non-circular cross section and extends into the hole portion262of the output gear carrier26. Another end of the transmission shaft34includes a second key portion342which is connected to the valve core32by key-groove cooperation, and the second key portion342is located in the inner chamber30of the valve body component. A lower end of the second key portion342extends into the groove321of the valve core32, and the second key portion342is in key-groove fit with the valve core32. As shown inFIG.4b,FIG.5,FIG.6andFIG.7, in this embodiment, a limiting groove251is provided at a lower end of the gear ring25. The output gear carrier26includes a disc-shaped body portion261. A hole portion262is provided in the disc-shaped body portion261, and the cross section of the hole portion262is non-circular. A protruding portion263is provided on one side of the disc-shaped body portion261facing the valve core32. In this embodiment, the bearing member27includes a cylindrical portion271and a radially extending portion272extending radially outward from a circumferential outer wall of the cylindrical portion271, the cylindrical portion271includes an axial through groove274, and the axial through groove274communicates the inner chamber40of the housing component with the inner chamber30of the valve body component. An outer edge of the radially extending portion272is fixed to the inner wall of the lower housing42by welding, one end of the radially extending portion272away from the cylindrical portion271is in key-groove fit with the limiting groove251, and another end of the radially extending portion272is in cooperation with the protruding portion263to limit a circumferential rotation stroke of the output gear carrier26. In the above embodiment, since the radially extending portion272of the bearing member27is fixed to the lower housing42by welding, on the one hand, the gear ring25is circumferentially limited due to the key-groove fit between the radially extending portion272and the limiting groove251of the gear ring25, and on the other hand, the protruding portion263is limited by the radially extending portion272, thus limiting the circumferential rotation stroke of the output gear carrier26, that is, limiting a circumferential rotation stroke of the transmission shaft34. This arrangement can limit the fully open position and the fully closed position of the valve core32, and realize the fully open, fully close and flow regulating functions of the electric valve. FIG.9is a schematic structural view of another bearing member. As shown inFIG.9, a bearing member27A includes a cylindrical portion271A, a radially extending portion272A extending radially outward from a circumferential outer wall of the cylindrical portion271A, and an axially extending portion273A extending axially upward from the radially extending portion272A. The cylindrical portion271A includes an axial through groove274A, and the axial through groove274A communicates the inner chamber40of the housing component with the inner chamber30of the valve body component. An outer wall of the axially extending portion273A is fixed to the inner wall of the lower housing42by welding, the axially extending portion273A is located in the limiting groove251and is in key-groove fit with the limiting groove251, and the radially extending portion272cooperates with the protruding portion263to limit the circumferential rotation stroke of the output gear carrier26. Further, as shown inFIG.5, two protruding portions263are provided, and the two protruding portions are arranged symmetrically relative to the central axis of the hole portion262. Such arrangement is beneficial to smooth rotation and reliable positioning of the output gear carrier in the circumferential direction. In addition, the protruding portions263and the disc-shaped body portion261are integrally formed by plastic injection molding or metal powder metallurgy, which is beneficial to enhancing the strength of the output gear carrier and making the limiting more reliable. FIG.11is a schematic partial sectional view of a third electric valve according to the present application;FIG.12is a schematic structural view of the valve body inFIG.11; andFIG.13is a schematic structural view of the bearing member inFIG.11. The difference between this embodiment and the above-mentioned embodiments lies in the structure and the stopping method of the valve body component and the bearing member. As shown inFIGS.10to12, in this embodiment, the valve body component3A includes a valve body31A, a transmission shaft34, a first valve seat33A, and a valve core32. The valve body31A is made of metal material by forging or casting, and the first valve seat33A is made of metal material by turning, forging or casting. The valve body31A includes a substantially cylindrical body portion311A and a protruding portion312A extending from an outer wall of the body portion311A toward the control component1. The protruding portion312A is provided with an axial through hole3120A, the cross section of the axial through hole3120A is circular, and the transmission shaft34penetrates through the axial through hole3120A. In this embodiment, an inner wall of the reduced-diameter portion422of the lower housing42is fixed to an outer wall of the extending portion312A by welding, a bearing member27B is provided between the extending portion312A and the transmission shaft34, the bearing member27B is formed by bending a metal sheet, and the bearing member27B has a notch portion275which communicates the inner chamber40of the housing component with the inner chamber30of the valve body component. In this embodiment, an upper end of the extending portion312A includes a limiting boss313, and two limiting bosses313are provided and are arranged symmetrically relative to a center axis of the axial through hole3120A. A recess portion314is formed between the two limiting bosses313, the recess portion314is located in a circumferential space between the two limiting bosses313, the protruding portion263of the output gear carrier26is placed in the recess portion314, and the protruding portion263is configured to abut against the limiting bosses313to limit the circumferential rotation stroke of the output gear carrier26. In this embodiment, the limiting bosses313are integrated with the valve body31A, no special machining for the bearing member is required, and the bearing member is easy to process. The principle and the embodiments of the present application are illustrated herein by specific examples. The above description of examples is only intended to facilitate the understanding of the method and spirit of the present application. It should be noted that, for those skilled in the art, many modifications and improvements may be made to the present disclosure without departing from the principle of the present disclosure, and these modifications and improvements are also deemed to fall into the protection scope of the present disclosure defined by the claims. | 24,678 |
11859729 | Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. DETAILED DESCRIPTION Example embodiments will now be described more fully with reference to the accompanying drawings. Firstly, it should be understood that the example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Further, when an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. In addition, although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments. Moreover, spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. FIGS.1-6illustrate a proportional solenoid valve apparatus10according to a first aspect of the present disclosure. Valve apparatus10is configured to proportionally control a flow of fluid, including liquids and gases. Valve apparatus10includes a housing or ported cavity block12. Cavity block12is generally a cubic or rectangular cubic structure having a plurality of sides14a,14b,14c,14d,14e, and14f. Side14aincludes a threaded inlet port16and an opposite side14bincludes a threaded outlet port18. As best shown inFIG.5, inlet port16is not axially aligned with outlet port18. Side14fincludes an opening20that leads to an interior cavity22formed within cavity block12. Cavity22communicates with each of inlet port16and outlet port18. Side14eincludes an elongated recess23having a central vent port25. Recess23may be used to mount cavity block12to a system that uses valve apparatus10. While inlet port16is illustrated as being formed on side14athat is opposite to the side14bthat includes outlet port18, it should be understood that the inlet port16and outlet port18can be formed on adjacent sides of the cavity block12, if desired. Moreover, while inlet port16and outlet port18are described as being threaded, which permits an adapter or some other type of device that provides and/or receives a flow of fluid to be attached to cavity block12, it should be understood that other attachment methods are contemplated. It should also be understood that the inlet port16and the outlet port18may have their functions reversed (i.e., inlet port16may function as an outlet port, and outlet port18may function as an inlet port). In either configuration, the valve apparatus10will function in the same manner. Cavity block12is preferably formed of a rigid material such as a metal (e.g., brass, steel, aluminum, etc.), but may be formed of other materials (e.g., polymeric materials) dependent on the application in which valve assembly10is intended to be used. As best shown inFIGS.3-6, valve apparatus10includes a valve assembly24that is located within cavity22. Valve assembly24includes a valve retainer body26, a poppet28, and an adjustable valve seat30. Valve retainer body26is preferably formed of a rigid material such as a metal or polymeric material, and is a generally cylindrical hollow structure including a first end32that is closed and configured to be located proximate an end wall34of cavity22, and an opposite second end36that is open and configured to be located proximate opening20of cavity22. First end32includes a first radially inwardly extending recess38that is configured for receipt of a first valve retainer body O-ring40. Second end36includes a second radially inwardly extending recess42that is configured for receipt of a second valve retainer body O-ring44. A third radially inwardly extending recess46is located between the first and second radially inwardly extending recesses38and42, which is configured for receipt of a third valve retainer body O-ring48. Each of the valve retainer body O-rings40,44, and48are configured to provide a fluid-tight seal between valve retainer body26and an interior surface50of cavity22. Valve retainer body26includes a first pair of apertures52or fluid ports that are located between first radially inwardly extending recess38and third radially inwardly extending recess46. A second pair of apertures54or fluid ports are located between second radially inwardly extending recess42and third radially inwardly extending recess46. First apertures52are configured to be aligned with inlet port16, while second apertures54are configured to be aligned with outlet port18. While first and second apertures52and54are illustrated as being slot-shaped, it should be understood that first and second apertures52,54can have any shape desired by one skilled in the art. Poppet28is configured to be received within the hollow structure of valve retainer body26, and is movable along an axis X of valve assembly24. Poppet28is preferably formed of a rigid material such as a metal or polymeric material, and includes a proximate end56that is configured to be located proximate first end32of valve retainer body26, and an opposite distal end58that is configured to be located proximate second end36of valve retainer body26. A valve member60is positioned between proximate end56and distal end58. Valve member60is configured to abut a valve seat62that is part of valve retainer body26, when valve assembly24is in the closed position. When valve assembly24is actuated, as will be described in more detail later, valve member60will be moved away from valve seat62, which in turn will permit fluid to flow from inlet16through first apertures52, past valve member60toward the distal end58of poppet28, and through second apertures54into outlet18. Alternatively, if outlet port18functions as an inlet, the flow direction could be configured so that fluid will flow from outlet port18, through second apertures54past valve member60, through first apertures52, and out of inlet port16. Poppet28additionally includes a first seal member64attached to a first depression66formed at proximate end56, and a second seal member68attached to a second depression70formed at distal end58. First and second seal members64and68are similar to first, second, and third O-rings40,44, and48, but are sized to correspond to poppet28. First seal member64is configured to sealingly engage with an interior surface72of valve retainer member26at first end32. Second seal member68is configured to sealingly engage with an interior surface74of adjustable valve seat30. Still referring toFIGS.3-6, adjustable valve seat30is a cylindrical member that is configured to receive distal end58of poppet28. Adjustable valve seat30includes an exterior threaded surface76that is configured to mate with an interior threaded surface78formed at the interior surface of valve retainer member26at second end36thereof. The adjustable valve seat30is described as being “adjustable” to an extent that, as best shown inFIG.5, a terminal end80of the adjustable valve seat30can overlap with second apertures54formed in valve retainer body26, which may restrict flow through the second apertures54when valve member60contacts terminal end80. To increase or decrease the flow through second apertures54formed in valve retainer body26, the amount of threaded engagement between exterior threaded surface76of the adjustable valve seat30and the interior threaded surface78of valve retainer body26can be adjusted (i.e., reduced or increased) such that the terminal end80does not overlap second apertures54. Adjustable valve seat30includes a groove82formed therein that is configured for receipt of an adjustable seat O-ring84that sealingly engages with interior surface72aof valve retainer body26. Valve apparatus10includes a solenoid assembly86that is configured to actuate valve assembly24. Solenoid assembly86includes an adapter bushing88that is configured to connect solenoid assembly86to valve assembly24. In this regard, adapter bushing88includes a hollow cylindrical body90having a first section92having a lesser diameter than a second section94. As best shown inFIG.5, first section92includes an interior thread96that is configured to mate with an outer thread98formed on valve retainer body26. In addition, first section92includes an outer surface100that is configured to mate with opening20of cavity block12. An armature102is positioned within solenoid assembly86. Armature102is a solid member formed of a material that can be magnetically attracted, and includes a mating end104that is configured to mate with an internally threaded end106of poppet28. Mating end104includes a threaded projection108connected to a main body110of armature102by a radially narrowed neck112. Internally threaded end106of poppet28is configured for receipt of the threaded projection108. Radially narrowed neck112is connected to main body110of armature102via a radially expanded shoulder116that has a diameter that is greater than each of threaded projection108, neck112, and main body110. Main body110has a diameter than is greater than threaded projection108and neck112. Armature102is movable such that when a voltage or current is applied to solenoid assembly86, armature102can move poppet28between the open and closed positions. A hollow lower bushing118guides main body110of armature102within adapter bushing88. Lower bushing118includes an inner surface120that extends along an outer surface122of main body110of armature102. Lower bushing118includes a primary body124and a tubular sleeve126. Primary body124includes a threaded surface128that is configured to mate with a threaded surface130of a solenoid housing132that houses a solenoid coil134. An end face136of primary body124that faces radially expanded shoulder116includes a stepped annular recess138that is configured for clearance of a plate spring140that is positioned between shoulder116and annular recess138. Recess138is stepped such that a first annular surface142of recess138is located closer to shoulder116in comparison to a second annular surface144of recess138. Plate spring140is mounted to first annular surface142, and because second annular surface144is located further away from shoulder116, plate spring140is permitted to flex as armature102is moved towards and away from valve assembly24. Plate spring140, as best shown inFIG.4, includes an annular body146having a central aperture148configured for receipt of main body110of armature102. A plurality of secondary apertures150are located radially outward from central aperture148. Secondary apertures150may be round or oval-shaped, but any shape for secondary apertures150may be selected that permits plate spring140to flex as armature102is moved. Plate spring140may be formed of a rigid yet flexible material. Example materials include metal materials and polymeric materials. Plate spring140is designed to valve assembly24to the closed position. Solenoid housing132, as noted above, houses a solenoid coil134. Coil134is mounted to a hollow cylindrical support structure152. As best shown in4and6, coil134includes a pair of electrical leads154that permit a current or voltage to be applied to coil134. An upper bushing156including a pole piece158that is formed of a magnetizable material is located within hollow support structure152. Upper bushing156is a sleeve-like structure including a cylindrical sleeve160that extends along pole piece158, and a radially outwardly extending flange162that is configured to be located between support structure152and a radially inwardly extending wall164of housing132. Pole piece158includes a threaded surface158that mates with a threaded surface160formed in wall164of housing132to fix pole piece158and upper bushing158to housing132. While pole piece158is illustrated as having a central axially extending aperture166, pole piece158is not required to have this feature. A cover piece168is attached to housing132. Cover piece168is designed as a plug that permits a current or voltage application device (not shown) to be coupled to the electrical leads154of coil134. Upon application of a current or voltage to coil134, pole piece158is magnetized such that pole piece158can magnetically attract armature102. As armature102is pulled toward pole piece158, armature102will pull poppet28toward pole piece158and plate spring140will be flexed between radially expanded shoulder116and lower bushing118. As poppet28is pulled toward pole piece158, valve member60will be disengaged from valve seat62of valve retainer body26to open valve assembly24, which permits fluid to travel from inlet16through first apertures52, past valve member60toward the distal end58of poppet28, and through second apertures54into outlet18. To close the valve assembly24, application of the current or voltage to coil134is stopped at which time plate spring140can bias armature102and poppet28in a direction away from pole piece158. Valve member60of poppet28then reengages with valve seat62to close the valve assembly24. The same operation occurs even if the function of valve inlet16and valve outlet18is reversed. It should be understood that the combination of the position of the adjustable valve seat30, a magnitude of the current or voltage applied to coil134, and the spring force exerted by plate spring140provides increased control over the amount of fluid that may be permitted to pass through valve assembly24. In other words, the combination of the position of the adjustable valve seat30, the magnitude of the current or voltage applied to coil134, and the spring force exerted by plate spring140controls the distance that valve member60can be moved relative to valve seat62to increase and decrease the amount of fluid that can pass through valve assembly24. In this regard, as noted above, the position of the adjustable valve seat30can be adjusted by adjusting the amount of threaded engagement between exterior threaded surface76of the adjustable valve seat30and the interior threaded surface78of valve retainer body26. In addition, the spring force of plate spring140can be determined prior to being placed in valve apparatus10to control the amount of bias at which the plate spring140biases valve member60of poppet into engagement with valve seat62. Once the spring force of plate spring140is determined, valve apparatus10can undergo testing to determine the amount of movement of armature102that occurs upon application of different currents or voltages to coil134. In this manner, the proportional amount of fluid flow through valve assembly24at different currents or voltages can be determined prior to being used in a system (not shown) in which valve apparatus is being used. In addition, it should be understood that the spring force of plate spring140can be adjusted by modifying the size and/or number of secondary apertures150, by adjusting a thickness of plate spring140, or through selection of a material that forms plate spring140. Regardless of the manner in which the spring force of the plate spring140is determined, it should be understood that increased proportional control over the distance that valve member60is moved relative to valve seat62can be improved through the combination of the selection of the plate spring140and the voltage or current that is applied to coil134. The data associated with the current or voltage that is applied to coil134may be stored in a memory (not shown) of a controller (not shown) that is attached to the current or voltage application device (not shown). It should also be understood that the valve apparatus10is a balanced design where any fluctuations in the fluid supply pressure will not affect the performance characteristics of the valve apparatus10. In this regard, it should be understood that when the valve apparatus10is in the closed position (i.e., when valve member60of poppet28is in contact with valve seat62of valve retainer26), the fluid force exerted at inlet16is balanced (i.e., opposed) by the force exerted by seal64of poppet28against interior surface72of valve retainer26. Similarly, when the valve apparatus10is in the fully open position (i.e., when valve member60of poppet28is in contact with terminal end80of adjustable valve seat30), the fluid force exerted at outlet18is balanced (i.e., opposed) by the force exerted by seal64of poppet28against interior surface72of valve retainer26. When valve apparatus10is at an intermediate open position (i.e., when valve member60of poppet28is disengaged from valve seat62, but not in contact with terminal end80of adjustable valve seat30), the fluid forces exerted at both inlet16and outlet18are balanced (opposed) by the force exerted by seal64against interior surface72of valve retainer, the force exerted by seal68against interior surface74of adjustable valve seat30, and the force exerted by seal84against surface72aof valve retainer26. Thus, even if the fluid forces exerted at inlet16and outlet18fluctuate, the fluid forces at inlet16and outlet18are balanced by the forces exerted by seals64,68, and84, which enables valve assembly24to provide consistent performance (e.g., fluid output at the correct pressure and amount) throughout the operational pressure range of the valve apparatus10. Now referring toFIGS.7-12, a proportional solenoid valve apparatus200according to a second aspect of the present disclosure will now be described. Valve apparatus200is similar to valve apparatus10described above. Accordingly, features of the valve apparatus200that are common to those of the valve apparatus10will have the same reference numbers, and description of the common features will be omitted. Valve apparatus200includes a housing or ported cavity block202. Cavity block202is substantially similar to cavity block12, but includes a second opening204that communicates with opening20such that cavity22extends completely through cavity block202. A valve assembly206is positioned within cavity22of cavity block202. Valve assembly206includes valve retainer body26, poppet28, adjustable valve seat30, and valve retainer body O-rings40,44, and48. The primary difference between valve assembly206and valve assembly24is that valve assembly206additionally includes an end screw208, a lower diaphragm210, a lower end cap212, an upper diaphragm214, and an upper end cap216. The use of the diaphragms210,214and end caps212,216provide increased sealing of valve assembly206—especially for liquid and low leakage applications. Lower and upper diaphragms210and214are similar annular plates218that include an edge portion220, a central portion222that defines a central aperture224, and an annular bead226that extends between the central portion222and the edge portion220. Edge portion220, in a direction toward central portion222, transitions into a first annular inclined surface228that terminates at bead226. A second annular inclined surface230extends from bead226to central portion222. The use of bead226and first and second inclined surfaces228and230permits diaphragms210and214to slightly flex during use of valve assembly206to assist in sealing valve assembly206. In this regard, the use of diaphragms210,214, end caps212,216, end screw208, and armature102remove the need for sealing members between poppet28and valve retainer26that prevent valve assembly206from leaking. In addition, by removing the need for sealing members between the poppet28and valve retainer26, poppet28is more easily controllable when actuated by solenoid assembly86such that additional proportional control of the valve200is achieved. In this regard, no additional force is required to overcome the friction between poppet28and valve retainer26as is required when there are seal members64and68between poppet28and valve retainer26. Diaphragms210and214may be formed of a rigid yet flexible material such as an elastomeric material or a polymeric material. The edge portion220of lower diaphragm210is sandwiched between lower end cap212and valve retainer member26. In this regard, lower end cap212includes a first cylindrical section232having an interior threaded surface234that mates with a threaded surface236formed on valve retainer member26. A second cylindrical section238having a diameter that is less than the first cylindrical section232is connected to first cylindrical section232by a radially inwardly extending abutment surface240. The abutment surface240faces first end32of valve retainer member26, which in contrast to the first aspect of the present disclosure is open rather than closed. The edge portion220is sandwiched between the abutment surface240and the open first end32of the valve retainer member26. Central portion222of lower diaphragm210is sandwiched between proximate end56of poppet28and end screw208. End screw208includes a threaded shank242that extends through central aperture224and mates with a threaded aperture244formed in proximate end56of poppet28. A head246of threaded screw208extends radially outward from shank242that extends along central portion222to second annular inclined surface230. Head246includes a recess248that is configured for receipt of a tool (not shown) that can rotate end screw208to mate with threaded aperture244of poppet28. The edge portion220of upper diaphragm214is sandwiched between upper end cap216and valve retainer member26. In this regard, upper end cap216includes a first cylindrical section250having an interior threaded surface252that mates with a threaded surface254formed on valve retainer member26. A second cylindrical section256having a diameter that is less than the first cylindrical section250is connected to first cylindrical section250by a radially inwardly extending abutment surface258. The abutment surface258faces second end36of valve retainer member26. The edge portion220is sandwiched between the abutment surface258and the second end36of the valve retainer member26. In this configuration, it is important to note that bead226of lower diaphragm210extends in a direction that is opposite to the direction in which bead226of upper diaphragm214extends. Central portion222of upper diaphragm214is sandwiched between distal end58of poppet28and radially expanded shoulder116of armature102. Armature102includes a threaded shank260that extends through central aperture224and mates with a threaded aperture262formed in proximate end56of poppet28. Radially expanded shoulder116of armature102extends radially outward from shank260and extends along central portion222to second annular inclined surface230. Upper end cap216additionally includes an exterior threading264that mates with the interior thread96of adapter bushing88. With the exception of interior thread96of adapter bushing88coupling to exterior threading264of upper end cap216, adapter bushing88is the same as that described relative to the valve apparatus10. In addition, valve apparatus200includes a solenoid assembly86that includes the same features as that of valve apparatus10. That is, the solenoid assembly86of valve apparatus200includes lower bushing118, plate spring140, solenoid housing132, coil134, leads154, upper bushing156, pole piece158, and cover piece168. Upon application of a current or voltage to coil134, pole piece158is magnetized such that pole piece158can magnetically attract armature102. As armature102is pulled toward pole piece158, armature102will pull poppet28toward pole piece158and plate spring140will be compressed between radially expanded shoulder116and lower bushing118. As poppet28is pulled toward pole piece158, valve member60will be disengaged from valve seat62of valve retainer body26to open valve assembly206, which permits fluid to travel from inlet16through first apertures52, past valve member60toward the distal end58of poppet28, and through second apertures54into outlet18. To close the valve assembly206, application of the current or voltage to coil134is stopped at which time plate spring140can bias armature102and poppet28in a direction away from pole piece158. Valve member60of poppet28then reengages with valve seat62to close the valve assembly206. Even if the functions of inlet16and outlet18are reversed, valve assembly206may operate in the same manner. Similar to valve apparatus10, it should be understood that the combination of the position of the adjustable valve seat30, a magnitude of the current or voltage applied to coil134, and the spring force exerted by plate spring140provides increased control over the amount of fluid that may be permitted to pass through valve assembly206. In other words, the combination of the position of the adjustable valve seat30, the magnitude of the current or voltage applied to coil134, and the spring force exerted by plate spring140controls the distance that valve member60can be moved relative to valve seat62to increase and decrease the amount of fluid that can pass through valve assembly206. In addition, because valve assembly206additionally includes diaphragms210,214, end caps212,216, and end screw208, the need for sealing members between poppet28and valve retainer26is removed. Moreover, by removing the need for sealing members between the poppet28and valve retainer26, poppet28is more easily controllable when actuated by solenoid assembly86such that additional proportional control of the valve200is achieved. In this regard, no additional force is required to overcome the friction between poppet28and valve retainer26as is required when there are seal members between poppet28and valve retainer26. It should also be understood that, similar to valve apparatus10, the valve apparatus200is a balanced design where any fluctuations in fluid pressure will not affect the performance characteristics of the valve apparatus200. In this regard, while valve apparatus200does not include seals64,68, and84, the balanced design is afforded by diaphragms210and214. More specifically, when valve assembly206is in the open or closed position, it should be understood that fluid from inlet16can be located between annular bead226of lower diaphragm210and poppet28. Due to annular bead226formed by inclined surfaces228and230, a force is exerted by lower diaphragm210in a direction orthogonal to inlet16and outlet18(i.e., along axis X) that balances the fluid force exerted at inlet16or outlet18when the valve assembly206is in the open or closed positions, respectively. When valve assembly206is in an intermediate open position (i.e., when valve member60of poppet28is not engaged with either valve seat62of valve retainer26or engaged with adjustable valve seat30), the fluid forces exerted at inlet16and outlet18are balanced (i.e., opposed) by forces exerted on the fluid by each of the annular beads216of both diaphragms210and214. Thus, even if the fluid forces exerted at inlet16and outlet18fluctuate, the fluid forces at inlet16and outlet18are balanced by the forces exerted by diaphragms210and214, which enables consistent performance throughout the operational pressure range of the valve apparatus200. Lastly, it should be understood each of the valve apparatuses10and200described above are capable of being modified to have different flow capabilities over a wider range of fluid pressures, without having to change the overall structure thereof. More specifically, if a flow rate in a particular application is to be changed, previous valve apparatus designs would require a structural redesign to the valve apparatus in the form of, for example, changing an orifice size, adding a spring to balance different flow pressures, or increasing and/or decreasing the size of various components of the valve apparatus. The valve apparatuses10and200of the present disclosure, however, only require minor modifications to, for example, the position of the adjustable valve seat30or the position of the pole piece158to adjust the flow capability of the valve apparatus. In this regard, as noted above, pole piece158is threadingly engaged with housing132. The position of pole piece158, therefore, can be adjusted by adjusting the amount of threaded engagement with housing132, which can permit the poppet28to move a greater or lesser distance when actuated by solenoid assembly86. Thus, by adjusting pole piece158in combination with adjusting the position of adjustable valve seat30, valve apparatuses10and200do not need to be structurally redesigned in order to accommodate different flow outputs over a wider range of pressures. The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure. | 31,420 |
11859730 | While the present invention will be described in connection with presently preferred embodiments, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all alternatives, modifications, and equivalents included within the spirit of the invention and as defined in the appended claims. DETAILED DESCRIPTION OF THE DRAWINGS The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. FIGS.1-3illustrate a hydraulic actuator in accordance with one aspect of the invention.FIG.1more specifically shows the hydraulic actuator10coupled to a gate valve assembly12. The gate valve assembly12includes a valve body14, gate valve16, and a seat assembly18. The gate16is configured so that it can be moved between an open position and a closed position to control the fluid flow through the passageway20. The actuator10is coupled to the bonnet22through bolts24,26which may be removable. It should be noted that although bolts are illustrated, any other type of fastening mechanism may be used to secure the bonnet22to the actuator10. The bonnet20is also coupled to the valve body assembly through bolts28,30. The actuator10includes a housing32that encapsulates a spring34, a cylinder36, a spring lifter assembly38, and a piston40coupled to an operating stem42. There is also provided a pressure compensator44, which can be positioned as shown inFIGS.1-3external to the actuator housing or positioned within the actuator housing as shown inFIGS.4and5. Specifically, in the actuator assembly ofFIGS.1-3, the pressure compensator44is coupled to an exterior wall of the actuator housing32which is used to equalize the pressure inside the actuator housing to the outside seawater pressure. The pressure compensation will be discussed in greater detail below. In operation, the piston40within the actuator housing32is moved upward or downward between a first position and second position which in turn moves the operating stem42so that the gate valve16can be positioned within the passageway20in the valve body14. It should be noted that the upward position can be either an open or closed position of the valve depending on the construction of the gate valve. Now turning toFIGS.2and3, the internal components of the actuator10will be discussed in greater detail. The actuator10includes housing32that is coupled to the bonnet22at a first end and a monolithic housing lid46at a second end. Within the housing32is the hydraulic cylinder36that is threadably attached to the bonnet22. The piston40is positioned within the hydraulic cylinder36at the first end of the actuator housing32adjacent to the bonnet22and is coupled to the operating stem42. The piston40is also coupled to or in direct contact with the spring lifter assembly38which is coupled to the spring34. The spring lifter assembly38is configured so that a first portion is in contact with the piston40and a second portion is in contact with the spring34. The spring lifter assembly38includes a spring lifter48coupled to the piston40at one end and the spring at the other end. The spring34is positioned between the actuator housing32and the spring lifter assembly38and adjacent to the lower portion of the housing lid46. As hydraulic pressure fluids are applied into the cylinder via a hydraulic port50, the spring lifter assembly38is operated as to the move the piston40up and down within the hydraulic cylinder36. Now turning to another embodiment of the present invention,FIGS.4and5illustrate an actuator assembly60having an internal pressure compensator. The actuator60is provided with an actuator housing62that is coupled to a bonnet64(via bolts68) and a housing lid66by bolts70. Although bolts70are used is this particular embodiment, it should be noted any type of mechanical mechanism to attach the lid66and the bonnet64to the housing62may be used. Within the actuator housing62, there is provided a hydraulic cylinder72which is coupled to the bonnet64by bolts74. A piston76is positioned within the hydraulic cylinder72and coupled to spring lifter assembly78. The spring80is positioned so that at one end, it is coupled to the inner surface of the housing lid66and the other end it is in contact with the flange portions82of the spring lifter assembly78. The hydraulic cylinder72may be threadably coupled to the bonnet or bolted (Shown) to the bonnet64as illustrated inFIGS.4and5. The piston76which is positioned within the hydraulic cylinder72is coupled to the spring lifter assembly78and an operating stem84that extends through the bonnet64into the valve assembly86. The positioning of the hydraulic cylinder72adjacent to the bonnet64provides the advantage of reducing the height of the actuator and reduces the operating stem length, thereby allowing for a more rigid construct. A hydraulic control port88and hydraulic assist port may be drilled allowing passage into the hydraulic cylinder72. The control port88provides the connection to the external hydraulic control line used to either open or close the gate valve. The actuator60may be configured to either automatically open or close upon failure of the hydraulic system depending on the valve design. The hydraulic cylinder72is sealed to contain the hydraulic fluid. Specifically, these seals are provided between the piston76and the hydraulic cylinder72and between the operating stem84and the bonnet64, so that the hydraulic fluid is isolated from the other areas of the actuator housing62. In the preferred embodiment, the hydraulic cylinder72contains all the hydraulic fluid, as a result, the spring80is completely isolated from the hydraulic fluid. A packing gland90is also positioned to provide additional primary seals to seal around the operating stem84and bonnet64. The packing gland90may be threadably attached to the bonnet64. The packing gland90provides additional support for packings and primary seals to seal around the operating stem84and any extensions to the operating stem84. In the particular embodiment, the packing gland90is threadably attached to the bonnet64. The packing gland90is sealed with respect to the bonnet64by any conforming type of seal. There is also provided a relief valve between the packing and packing gland seal, if leakage should occur. The relief valve is a one-way valve that will open if the internal pressure at relief valve is greater than the hydrostatic pressure external to the actuator thereby relieving pressure before the pressure becomes great enough to leak past any adjacent seals providing safety for the actuator. The actuator60also includes an internal compensator assembly which is configured to be positioned within a recess92of the actuator lid66. The compensator assembly is used to maintain a constant equilibrium pressure between the spring housing and the sea water. The compensator assembly includes a compensator piston94that is free floating and inner and outer sleeve guides96,98. As the actuator60is descended to depth, water pressure acts on the piston94through port100and equalizes the pressure applied when piston76is moved upwards and displaces the fluid within the compensator assembly towards the compensator piston94. The compensator piston94is free floating and is guided by the inner sleeve guide96and the outer sleeve guide98. In operation, as hydraulic fluid which is contained within the cylinder72is used to actuate the cylinder piston76to move the operating stem84, the internal compensator piston94equalizes the pressure between the sea water external to the actuator and the fluid pressure within the actuator housing/spring housing assembly. This feature provides an automatic internal pressure compensator and enables the pressure within the actuator to be compensated from the external pressure applied by the water depth. During operation of the actuator to move the gate valve102, hydraulic fluid is introduced through the control port88to pressurize the hydraulic piston to move in a first direction, the hydraulic piston76is moved in the first direction, it also moves the operating stem84which in turn moves the valve gate102. This motion also moves the spring lifter assembly78in a first direction to compress the spring80via the spring lifter flanges82. To move the valve gate102in a second direction, the hydraulic pressure is released from the control port88. The spring moves80the operating stem84and hydraulic piston76in the second direction thereby moving the gate valve in the second direction. As the gate valve102is moved in the either first or second direction, the internal pressure compensator equalizes the pressure continuously between the seawater pressure and the fluid pressure within the actuator/spring housing assembly. The advantages provided by the features illustrated in the embodiment ofFIGS.1-5include no drag by the spring since the spring is positioned within a recess at the bottom of the lid. Also, the piston is positioned at the first end of the housing, allowing for a more rigid construction, causing less or no vibration of the system during operation. Another advantage of the actuator systems is that since the cylinder is threadably attached or bolted directly to the bonnet, concentricity of the central channel is maintained so that there is no metal to metal drag and no friction. Also, the present assembly provides an absence of drag on seals or the operating stem, and generally less frictional resistance within the components of the assembly. Finally, coupling the hydraulic cylinder directly to the bonnet, allows for the operating stem to be shorter so that the stem is more rigid and no galling occurs during operation. It will be apparent to those skilled in the art that various modifications and variations can be made in the disclosed systems and processes without departing from the scope of the disclosure. Other examples of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure disclosed herein. It is intended that the specification and examples be considered as exemplary only. | 10,214 |
11859731 | Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the disclosure and such exemplifications are not to be construed as limiting the scope of the invention in any manner. DETAILED DESCRIPTION FIG.4illustrates drop tube segment20in accordance with an exemplary embodiment of the present disclosure. Drop tube segment20includes conduit22spanning first end24and second end26of conduit22. Conduit wall28defines conduit wall interior surface32which defines a fluid path through conduit22from first end24to second end26. Valve body34is moveably positioned in the fluid path of conduit22and moveable from the open position illustrated inFIG.4to a closed position such as the one illustrated inFIG.6. Non-contact valve actuator36is moveable relative to valve body34and positioned outside of conduit22, with conduit wall28interposed between non-contact valve actuator36and the fluid path defined by conduit wall interior surface32. Non-contact valve actuator36is operable to actuate valve body34from the open position illustrated inFIG.4to a closed position such as the one illustrated inFIG.6without physically penetrating conduit wall28. Operation of non-contact valve actuator36will be further described herein below. FIG.1illustrates an exemplary utilization of drop tube segment20in the context of a fueling station. As illustrated inFIG.1, a fueling station may include underground storage tank94having riser pipe100extending upwardly therefrom and drop tube98extending through riser pipe100and into the storage space of underground storage tank94. Tanker truck102can be fluidly connected to underground storage tank94by fill hose104so that the contents of tanker truck102can be deposited in underground storage tank94. Drop tube segment20of the present disclosure can be utilized as described in detail below to limit the amount of fuel deposited by tanker truck102into underground storage tank94. The contents of underground storage tank94can then be accessed by fuel dispenser106for dispensing to end users in, e.g., passenger vehicles and the like. The remainder of this detailed description will describe use of the overfill prevention valve of the present disclosure with respect to a fueling station; however, use of the drop tube segments of the present disclosure are not limited to fueling station installations. The overfill prevention valve of the present disclosure is generally useable in connection with any fluid reservoir into which a drop tube extends. Referring toFIG.6, valve body34is illustrated in a closed position in which a small amount of flow can pass valve body34. When valve body34maintains the open position illustrated inFIG.4, conduit22is sufficiently open to allow passage of fuel at a normal fill rate. For applications in standard configurations this fill rate is generally in the range of 300-500 gallons per minute (gpm). In certain embodiments, the maximum rated flow past valve body34in its open position is 400-450 gpm. In alternative configurations, the flow rate will be about 370 gpm. In applications with remote filling capability, the standard flow rate may be as low as 25 gpm. These flow rates are applicable to all of the embodiments described in this document. With valve body34in the open position as illustrated inFIG.4, the maximum fill rate is accommodated by conduit22. In the closed position illustrated inFIG.6, the maximum fill rate is not allowed and, if filling at such a rate were to continue, the portion of drop tube98upstream of valve body34would fill with a column of fluid. The actuation mechanism which causes valve body34to move from the open position illustrated inFIG.4to the closed position illustrated inFIG.6(which will be described in more detail hereinbelow) causes rapid closing of valve body34, causing the fluid column upstream of valve body34to produce a line shock which will cause fill hose104to jump, which is typically referred to as “hose kick” in the fueling industry. Hose kick alerts the driver to close the delivery valve on the delivery truck and discontinue filling the fuel tank. With valve body34closed as illustrated inFIG.6, but with closure stop50preventing full seating of valve body34against its valve seat, the column of fuel upstream of valve body34in drop tube98will slowly leak past valve body34, allowing fill hose104to drain so that it can be properly disconnected from the fill port connected to underground storage tank94. Valve body34is said to be in a “closed” position when it disallows passage of fluid at the maximum fill rate associated with underground storage tank94. In such a position, a small amount of flow past valve body34may be allowed as described above. In embodiments of the present disclosure, the “leak” flow rate will be about 10% (or less) of the maximum rated flow discussed above. For example, a valve having maximum rated flow of 400 gpm will have a leak flow rate of 40 gpm or less. Any time this document refers to a leak flow rate or a leak condition, such reference is to a flow rate of about 10% or less of the maximum rated flow of the conduit. Even with the “leak” flow eliminated, as described herein with respect to the various embodiments, a “drain” rate of about 2% or less of the maximum flow rate may be allowed to pass the valve bodies of certain embodiments of the present disclosure. In alternative embodiments, the “drain” rate may be about 0.66 GPM or less. Similarly, any time a “drain” flow rate is mentioned in this document, it signifies a flow rate of about 2% or less of the maximum flow rate. In alternative embodiments of the present disclosure, each and every embodiment disclosed herein may incorporate a drain flow rate, although such incorporation is not necessary with respect to all embodiment disclosed herein. Referring toFIGS.2-7, the functional details of an exemplary overflow prevention valve in accordance with the present disclosure will now be described. Referring toFIG.4, valve body34is pivotally connected relative to drop tube segment20. In an exemplary embodiment, valve body34may be pivotally connected by a rod connected to conduit wall interior surface32and spanning conduit22of drop tube segment20. In the embodiment illustrated inFIGS.2-7, valve body34comprises a butterfly valve having valve halves108,110pivotally connected relative to drop tube segment20. Valve halves108,110can be biased into the open position illustrated inFIG.4, e.g., by a torsion spring. Arm112extends from valve half108and carries valve body magnet44. With underground storage tank94filled to less than its capacity, tanker truck102can be utilized to provide additional motor fuel to underground storage tank94. As underground storage tank94nears capacity, non-contact valve actuator36will actuate valve body34from the open position illustrated inFIG.4toward the closed position illustrated inFIG.6. Drop tube segment20includes non-contact valve actuator36positioned about conduit wall exterior surface30, with conduit wall28interposed between and physically separating non-contact valve actuator36from valve body34. As will be described hereinbelow, non-contact valve actuator36is capable of actuating valve body34from the open position illustrated inFIG.4to a closed position such as the one illustrated inFIG.6without physically penetrating conduit wall28. In the exemplary embodiment illustrated inFIGS.2-7, non-contact valve actuator36comprises a hollow cylinder sized to fit about and surround conduit wall exterior surface30. Non-contact valve actuator36rests against stop114when the upper level of the fuel filling underground storage tank94is positioned below non-contact valve actuator36. Upward travel of non-contact valve actuator36may similarly be limited by, e.g., stop116(FIG.2). Stop116may also key non-contact valve actuator36to conduit wall exterior surface30to prohibit relative rotation between non-contact valve actuator36and conduit wall exterior surface30. Non-contact valve actuator36comprises a float having buoyancy characteristics such that it is buoyant on a surface of motor fuel. In one exemplary embodiment, float36has a specific gravity less than 0.7 so that it is buoyant on a surface of a quantity of motor fuel. As the liquid level in underground storage tank94rises, the top surface of fuel contained in underground storage tank94will encounter float36. In one exemplary embodiment, when underground storage tank94achieves a liquid level corresponding to underground storage tank94being about 90% full, float36will travel upwardly until valve actuator magnet42is aligned with valve body magnet44. Alternative configurations of the present disclosure will include valve actuators that actuate the primary valve at about 90%. This position of float36is illustrated inFIG.5, which also illustrates valve body magnet44moving from the at rest position illustrated inFIG.4to an actuated position, as illustrated inFIG.5. In this exemplary embodiment, valve actuator magnet42repels valve body magnet44to actuate valve body34from the open position illustrated inFIG.4toward the closed position illustrated inFIG.6. In the open position illustrated inFIG.4, valve body34is shielded from contact by fluid passing through conduit22by deflector48. As illustrated inFIG.3, deflector48covers valve halves108,110and arm112when valve body34maintains the open position illustrated inFIGS.3and4. As float36rises and brings valve actuator magnet42into alignment with valve body magnet44, valve body magnet44causes valve half108to rotate from the open position illustrated inFIG.4to an intermediate position as illustrated inFIG.5. In this position, flow F of fluid passing through conduit22can contact the upper surface of valve half108. A portion of this flow is deflected from the upper surface of valve half108onto the upper surface of valve half110. Flow F in the valve position illustrated inFIG.5causes valve halves108to move against the biasing force of the torsion spring acting to bias valve halves108,110into the open position illustrated inFIG.4until valve halves108,110achieve the closed position illustrated inFIG.6. As described above, when valve body34maintains the closed position illustrated inFIG.6, the maximum fill rate associated with underground storage tank94can no longer pass valve body34. Further, the column of fluid maintained in the portion of drop tube98upstream from valve body34maintains valve body34in the closed position illustrated inFIG.6. If filling is halted, the column of fluid upstream of valve body34will eventually drain past valve body34in the leak position (described in greater detail below) and valve body34will be returned by the biasing force of the torsion spring to its at rest position, as illustrated, e.g., inFIG.4. As the volume of fuel contained in underground storage tank94continues to rise, as fluid passes valve body34in the leak position illustrated inFIG.6, float36will continue to rise until closure stop actuator magnet38aligns with closure stop magnet46as illustrated inFIG.7. Closure stop50, in the exemplary embodiment illustrated inFIGS.2-7, comprises a rotatable cam having cam extension118extending therefrom. With cam extension118positioned as illustrated inFIG.6, cam extension118prevents valve half110of valve body34from fully seating against its associated valve seat. As closure stop50is actuated from its at rest position as illustrated inFIG.6, it is moved out of contact with valve half110and the weight of the column of fuel positioned upstream of valve body34causes valve half110to fully seat against its associated valve seat, as illustrated inFIG.7. In this position, valve body34is designed to prevent flow through conduit22. In one exemplary embodiment, float36will rise into the position causing actuation of closure stop50when underground storage tank is 95% full. As fuel is drawn out of underground storage tank94by fuel dispenser106, float36will return to a position in which it is no longer operable to actuate closure stop50and fluid will leak past valve body34until the column of fluid upstream of valve body34is depleted and valve body34returns to the normally biased position illustrated inFIG.4. In the exemplary embodiment illustrated inFIG.2-7, closure stop actuator magnet38repels closure stop magnet46to cause actuation of closure stop50. Closure stop50may be biased into the at rest position illustrated inFIGS.4-5by, e.g., gravity and/or a torsion spring. Magnets38,42,44and46may be any form of ferromagnetic material and/or any other item possessing magnetic qualities. Generally, “magnet” as used in this document is meant to denote any item having the ability to repel and/or attract another item through the use of a magnetic field. While the embodiment illustrated inFIGS.2-7uses magnetic repulsion to actuate valve body34and closure stop50, the present disclosure also contemplates use of magnetic attraction to actuate the valve body and closure stop. For example,FIG.8illustrates an alternative embodiment valve body54comprised of valve halves120,122, with arm112extending from valve half122. In this embodiment, valve actuator magnet42and valve body magnet44A are configured so that with valve actuator magnet42positioned proximate to valve body magnet44similar to the position of the previous embodiment illustrated inFIG.5, valve actuator magnet42will attract valve body magnet44A and cause actuation of valve body54in a similar manner to that described above with respect to the embodiment illustrated inFIGS.2-7. In this embodiment, closure stop50is identical to the closure stop associated with the embodiment illustrated inFIGS.2-7and is not described in detail here for the sake of brevity. FIGS.9-13illustrate an alternative embodiment overfill prevention valve in accordance with the present disclosure. Referring toFIG.11, valve body74is illustrated in a closed position, with poppet valve52(which will be described in further detail below) in an open position. In this configuration, a small amount of flow can pass valve body74. When valve body74maintains the open position illustrated inFIG.9, conduit62is sufficiently open to allow passage of fuel at a normal fill rate. As described above, for applications in standard configurations, this fill rate is generally in the range of 300 to 500 gpm. In applications with remote filling capability, the standard flow rate may be as low as 25 gpm. With valve body74in the open position illustrated inFIG.9, the maximum fill rate is accommodated by conduit62. In the closed position illustrated inFIG.11, and with poppet valve52open, the maximum fill rate is not allowed and, if filling at such a rate were to continue, the portion of drop tube98upstream of valve body74would fill with a column of fluid. The actuation mechanism which causes valve body74to move from the open position illustrated inFIG.9to the closed position illustrated inFIG.11(which will be described in more detail below) causes rapid closing of valve body74, causing the fluid column upstream of valve body34to produce a line shock causing hose kick as described above. With valve body74closed as illustrated inFIG.11, but with poppet valve52open, the column of fuel upstream of valve body74in drop tube98will slowly leak past valve body74, allowing fill hose104to drain so that it can be properly disconnected from the fill port connected to underground storage tank94. Valve body74is said to be in a “closed” position when it disallows passage of fluid at the maximum fill rate associated with underground storage tank94. In this exemplary embodiment, the closed position is achieved when valve body74is fully seated against its associated valve seat. The closed condition of valve body74may be associated with an open condition of poppet valve52or a closed condition of poppet valve52, the operation of which will be further described below. Referring toFIG.9, valve body74is pivotally connected relative to drop tube segment60. In an exemplary embodiment, valve body74may be pivotally connected by a rod connected to conduit wall interior surface72. In the embodiment illustrated inFIGS.9-14, valve body74comprises a flapper valve. Flapper valve74can be biased into the open position illustrated inFIG.9, e.g., by a torsion spring. Secured to the body of flapper valve74is valve body magnet44b. With underground storage tank94filled to less than its capacity, tanker truck102can be utilized to provide additional motor fuel to underground storage tank94(FIG.1). As underground storage tank94nears capacity, non-contact valve actuator76will actuate valve body74from the open position illustrated inFIG.9toward the closed position illustrated inFIG.11. Similar to the embodiment illustrated inFIGS.2-9, drop tube segment60includes non-contact valve actuator76positioned about conduit wall exterior surface70, with conduit wall68interposed between and physically separating non-contact valve actuator76from valve body74. As described in detail below, non-contact valve actuator76is capable of actuating valve body74from the open position illustrated inFIG.9to a closed position such as the one illustrated inFIG.11, without physically penetrating conduit wall68. Similar to non-contact valve actuator36described above, non-contact valve actuator76comprises a hollow cylinder sized to fit about and surround conduit wall exterior surface70. Non-contact valve actuator76rests atop stop126when the upper level of the fuel filling underground storage tank94is positioned below non-contact valve actuator76. Upward travel of non-contact valve actuator76may similarly be limited by, e.g., stop124. Similar to non-contact valve actuator36, non-contact valve actuator76comprises a float having buoyancy characteristics such that it is buoyant on a surface of motor fuel. In one exemplary embodiment, float36has a specific gravity less than 0.7 so that it is buoyant on a surface of a quantity of motor fuel. As the liquid level in underground storage tank94rises, the top surface of fuel contained in underground storage tank94will encounter float76. In one exemplary embodiment, when underground storage tank94achieves a liquid level corresponding to underground storage tank94being about 90% full, float76will travel upwardly until valve actuator magnet42bis aligned with valve body magnet44b. This position of float36is illustrated inFIG.10, which also illustrates valve body magnet44bmoving from the at rest position illustrated inFIG.9to an actuated position as illustrated inFIG.10. In this exemplary embodiment, valve actuator magnet42brepels valve body magnet44bto actuate valve body74from the open position illustrated inFIG.9toward the closed position illustrated inFIG.10. In the open position illustrated inFIG.9, valve body74is not susceptible to actuation from the open position illustrated inFIG.9toward the closed position illustrated inFIG.10by a flow of liquid traversing conduit62. Valve body74is at least partially shielded from contact by fluid passing through conduit62by deflector48b. Deflector48bcomprises a number of vanes oriented along the longitudinal axis of conduit64and further comprises a plate extending transverse the longitudinal axis of conduit62and positioned upstream of valve body74when valve body74maintains the open position illustrated inFIG.9. With valve body74is the open position illustrated inFIG.9, deflector48bshields valve body74from a flow of fluid through conduit62. Deflector48bas well as deflector48described above, not only provide a shield to prevent a quantity of fluid flowing through the conduit from contacting the valve body, but also create an impediment to accidentally contacting the valve body with an implement such as a dipstick which may be inserted through drop tube98to determine the level of fluid in underground storage tank94. As float76rises and brings valve actuator magnet42binto alignment with valve body magnet44b, valve body magnet44bcauses valve body74to rotate from the open position illustrated inFIG.9to an intermediate position as illustrated inFIG.10. In this position, flow F1of fluid passing through conduit62can contact the upper surface of valve body74. Flow F1in the valve position illustrated inFIG.10causes valve body74to move against biasing force of torsion spring128, which acts to bias valve body74into the open position illustrated inFIG.9, until valve body74achieves the closed position illustrated inFIG.11. As described above, when valve body74maintains the closed position illustrated inFIG.10, the maximum fill rate associated with underground storage tank94can no longer pass valve body74. Further, the column of fluid maintained in the portion of drop tube98upstream from valve body74maintains valve body74in the closed position illustrated inFIG.6. If filling is halted, the column of fluid upstream of valve body74will eventually drain past valve body74in the leak position and valve body74will be returned by the biasing force of torsion spring128to its at rest position, as illustrated, e.g., inFIG.9. As the volume of fuel contained in underground storage tank94continues to rise, as fluid passes valve body74in the leak position illustrated inFIG.10, float36will continue to rise until closure stop actuator magnet38baligns with closure stop magnet46bas illustrated inFIG.12. Closure stop50b, in the exemplary embodiment illustrated inFIGS.9-13, comprises a piston axially translatable relative to cylinder130. Each of the piston and cylinder forming a part of closure stop50bmay have opposing surfaces transverse to the axis along which the piston reciprocates relative to cylinder130and against which bears a compression spring to bias closure stop50binto the leak position illustrated inFIG.11. Closure stop50bincludes cam extension118bextending therefrom. With cam extension118bpositioned as illustrated inFIG.11, cam extension118pushes poppet valve52against the biasing force of spring78until poppet valve52is no longer seated against poppet valve seat58and poppet valve port56is placed in fluid communication with conduit62. As closure stop50bis actuated from its at rest position illustrated inFIG.9-11, it is moved out of contact with poppet valve52and the weight of the column of fuel positioned upstream of valve body74together with the biasing force of spring78causes poppet valve52to fully seat against poppet valve seat58so that poppet valve port56is no longer in fluid communication with conduit62. In this position, valve body74and poppet valve52are designed to prevent flow through conduit22. In one exemplary embodiment, float76will rise into the position causing actuation of closure stop50bwhen underground storage tank is 95% full. As fuel is drawn out of underground storage tank94by fuel dispenser106, float76will return to a position in which it is no longer operable to actuate closure stop50band fluid will leak past valve body74until the column of fluid upstream of valve body34is depleted and valve body34returns to the normally biased position illustrated inFIG.4. In the exemplary embodiment illustrated inFIGS.9-13, closure stop actuator magnet38brepels closure stop magnet46bto cause actuation of closure stop50b. Closure stop50bmay, in alternative embodiments be actuated by an attractive force between closure stop actuator magnet38band closure stop magnet46b. For example, an end of closure stop50bmay be spaced from conduit wall interior surface72, e.g., by a compression spring. In such an embodiment, a stop positioned outwardly from closure stop50bwould prevent the aforementioned compression spring from extending the piston of closure stop50bmore than a predetermined distance through cylinder130. Specifically, the stop of this form of the present disclosure would prevent the piston of closure stop50bfrom extending further than a position in which cam extension118bis positioned to contact poppet valve52. In such an embodiment, closure stop actuator magnet38band closure stop magnet46bwill be configured such that they will be attracted to each other so that positioning of closure stop actuator magnet38bin the position illustrated inFIG.12will cause closure stop magnet46bto be attracted toward closure stop actuator magnet38bagainst the biasing force of the aforementioned compression spring. FIGS.14-18illustrate a further alternative embodiment overfill prevention valve in accordance with the present disclosure. Referring toFIG.14, drop tube segment80includes conduit82spanning first end84and second end86of conduit82. Conduit wall88defines conduit wall interior surface92which defines a fluid path through conduit82from first end84to second end86. Referring, e.g., toFIG.15, valve body74operates in identical fashion to valve body74illustrated above with respect to the embodiments shown inFIGS.9-13. Therefore, details concerning the operation of valve body74cwill not be provided, for the sake of brevity. As with the embodiment illustrated inFIGS.9-13, valve body74is movably positioned in the fluid path of conduit82and moveable from an open position to a closed position. Valve body74cis functionally identical to valve body74, including the inclusion of a poppet valve and associated poppet valve port; however, non-contact valve actuator96(FIG.14) is structurally and functionally different than the previously described non-contact valve actuators. Referring toFIG.14, non-contact valve actuator96includes first float132and second float134. First float132includes main body136defining shoulder138. First float132includes guide channel140and guide rod apertures142. Second float134includes main body144, stop146, guide extension148, and guide rod apertures150. Guide extension148is sized and shaped to fit within guide channel140of first float132such that guide channel140cooperates with guide extension148to guide relative movement of first float132and second float134. In construction, second float134is positioned with guide extension148occupying guide channel140. In this position, guide rod apertures142of first float132align with guide rod apertures150of second float134. Guide rods152are then passed through guide rod apertures150of second float134and guide rod apertures142of first float132and are thereafter secured to guide rod retainers154of drop tube segment80, with main body136of first float132occupying first float channel156and main body144of second float134positioned between guide rod retainers154and154′. To complete securement of non-contact valve actuator96to drop tube segment80, splash shield158is secured to drop tube segment80by, e.g. threaded fasteners. In its secured position, splash shield158retains guide rods152within guide rod retainers154. Referring toFIG.15, first float132maintains an at rest position with shoulder138of main body136abutting shoulder160formed in conduit wall exterior surface90. As illustrated inFIG.16, upward travel of first float132is limited by shoulder162formed in conduit wall exterior surface90. As illustrated inFIG.17, second float134maintains an at rest position in which main body144abuts guide rod retainers154′. Upward travel of second float134can be limited by guide rod retainers154. Referring toFIGS.15and16, first float132carries valve actuator magnet42c. Valve actuator magnet42cfunctions to actuate valve body74cin an identical fashion to the actuation of valve body74described above with reference toFIGS.9and10. Unlike the previously described embodiments, first float132does not incorporate a closure stop actuator. In the embodiment illustrated inFIGS.14-18, the closure stop actuator takes the form of closure stop actuator magnet38cwhich is carried by second float134. Second float134is actuatable independent of first float132and functions to actuate closure stop50cin the same fashion as described above with respect to closure stop50b(seeFIGS.11and12). FIGS.19-32illustrate another embodiment of the present disclosure. Referring toFIGS.19and20, splash guard158dcovers float76dand closure stop actuator magnet38dis secured in magnet holder192d. Guide rods152dare inserted through longitudinal apertures in float76d(covered from view inFIG.19) so that float76can move along guide rods152dlike the embodiment previously described and illustrated inFIGS.14-18. Referring toFIG.21, guide rods152dare inserted through apertures in magnet holder192to connect magnet holder192to drop pipe segment60dso that holder192can move along guide rods152dwhen ridge198of float76drises to engage extension196to lift magnet holder192. Referring toFIG.22, flapper valve body74d(like flapper valve body74inFIG.9) is illustrated in an open position to allow passage of fuel through valve body74at a normal flow rate, in the ranges previously described above. Referring toFIG.28, valve body74d(like flapper valve body74inFIG.11) is illustrated in a closed position, and because poppet valve52dis in an open position, a small amount of fluid can still pass through valve body74d. Like previous embodiments, the initial transition of valve body74dfrom the open position illustrated inFIG.22to the closed position illustrated inFIG.28causes rapid closing of valve body74dbecause valve body74dis moved into the path of and is collided with the liquid stream flow. Referring toFIG.22, valve body74dis pivotally connected to drop tube segment60dand, in an exemplary embodiment, may be pivotally connected by a rod connected to conduit wall interior surface72d. Valve body74dis biased in the open position by torsion spring128d, which has a lower spring constant than that disclosed inFIGS.9-14, and hold-open magnet190on float76dhas an attractive force that also urges valve body74dinto the open position when float76dmaintains its lowered position, i.e., it has not yet begun to float on a quantity of product in underground storage tank94. Specifically, hold-open magnet190and valve magnet44dare structured and arranged such that they have a magnetic attraction to each other. As storage tank94(shown inFIG.1) nears capacity, float76dwill rise to actuate valve body74dfrom the open position inFIG.22to the closed position illustrated inFIG.28. Referring toFIGS.19-32, similar to first and second floats132and132inFIGS.14-18, guide rods152dare passed through guide rod slots150dto slidingly secure float76dto drop tube segment60dalong conduit wall exterior surface70dand physically separated from valve body74d. Sharing the same buoyancy characteristics as non-contact valve actuator36inFIGS.4-8, in one exemplary embodiment, when the liquid level in underground storage tank94reaches about 90%, float76dwill begin to rise to transition valve body74dfrom the open position inFIG.22to the closed position inFIG.28. Before this transition, when valve body74dis in the open position, deflector48dshields valve body74dfrom being actuated by the flow of liquid through conduit62d. When the liquid level in storage tank94has buoyed float76dupward to actuate valve body74dto an intermediate position, out of the upright but not yet in the closed position, as illustrated inFIG.26, the flow of fluid through conduit62dbegins to actuate valve body74dtoward the closed position illustrated inFIG.28. Specifically, inFIG.26, the rising liquid level will urge float76dupward so that hold-open magnet190is no longer aligned with, and thus no longer attracts leftward (in the view ofFIG.26), valve magnet44d. Instead, repelling valve actuator magnet42dis moved into alignment with valve magnet44dto repel valve magnet44dand urge valve body74dto rotate downward, as shown by arrows A1. Repelling valve actuator magnet42dand valve magnet44dare structured and arranged such that they magnetically repel one another. The repulsion of valve actuator magnet42dovercomes the bias of torsion spring128dto actuate valve body74ddownward, on its way to achieving the closed position. Flow F2, illustrated inFIG.26, urges valve body74dagainst the biasing force of the torsion spring128das hold-open magnet190is no longer aligned with valve magnet44dto urge valve body74dto the open position. Once the valve body74dis in the closed position illustrated inFIG.28, fluid through conduit62dcan no longer pass valve body74dat the maximum rate because valve body74dis in the leak position, as previously described. Poppet valve52d, in the exemplary embodiment inFIGS.19-32, is substantially the same structure as poppet valve52billustrated inFIGS.9-13. For example, referring specifically toFIG.28, like in previous embodiments, valve body74dis in the closed position, but poppet valve52dis open to allow a small amount of liquid to flow through valve body74d. However, fully seating poppet valve52dagainst poppet valve seat58ddiffers from the process previously described and illustrated inFIGS.12and13. Referring back toFIG.19a, magnet holder192is illustrated holding closure stop actuator magnet38dand having a pair of arms194with extensions196extending from each arm194. Each extension196is situated distance Di (FIG.21) from ridge198formed along float76d. Referring now toFIG.27, magnet holder192has remained stationary while float76dhas risen Di so that ridges198are adjacent extensions196. At the same time, referring toFIG.28, closure stop50dincludes cam extension118dthat selectively pushes poppet valve52dupward and out of engagement with poppet valve seat58d. Closure stop actuator magnet38dand closure stop magnet46dshare a magnetic attraction that urges closure stop magnet46dto the left (in the view illustrated inFIG.28) against a closure stop spring (not shown) bias to engage cam extension118dwith poppet valve52d, thereby creating the leak condition. Specifically, the closure stop spring (not shown) will bias closure stop50dinto a position in which cam extension118ddoes not engage poppet valve52d; however, magnetic attraction shared by closure stop actuator magnet38dand closure stop magnet46dwill overcome this spring bias to engage cam extension118dwith poppet valve52das illustrated inFIG.28. Referring now toFIGS.29and30, float76dhas risen so that ridges198have engaged extensions196to lift magnet holder192. This lifting slides closure stop actuator magnet38dupward and out of alignment with closure stop magnet46dand consequently, closure stop50dshifts rightward due to the closure stop spring bias. Cam extension118ddisengages poppet valve52dallowing poppet valve52dto fully seat against poppet valve seat58d. While the valve body of poppet valve52dis not illustrated in its seated position inFIG.30(FIG.30is meant to illustrate the initial movement of closure stop50dfrom the position illustrated inFIG.28), poppet valve52dwill return to a seated position such as the one illustrated inFIG.32just subsequent to movement of closure stop50dinto the position illustrated inFIG.30. As the fluid level in underground storage tank94lowers, closure stop actuator magnet38dis returned to the position illustrated inFIG.28to unseat poppet valve52dand allow flow at the previously mentioned leak flow rate. Prior to the unseating of poppet valve52d, fluid may pass valve body74at the “drain” rate described hereinabove. In any event, as conduit62dis cleared of the column of fluid that will accumulate when valve body74dmaintains the closed position, torsion spring128dwill return valve body74dto the fully opened position illustrated inFIG.22. FIGS.33-42illustrate another embodiment of the present disclosure. Referring toFIG.33, float76eis illustrated in magnetic communication with shuttle200e. Float76ehas a substantially equal buoyancy as floats in previous embodiments and is not in contact with shuttle200e, which is located interior of conduit wall interior surface72e(FIG.34). Instead, in the present embodiment, float76eand shuttle200eeach carry a pair of roller magnets202eand204e, respectively, which attract one another, so that as the liquid level in conduit62e reaches a level at which float76ebegins to rise, float76ewill actuate the corresponding rise of shuttle200e. Roller magnets202eare cylindrical magnets having an opposite polarity to cylindrical roller magnets204e. Specifically, adjacent roller magnet pairs202e/204ehave opposite polarity. Further, roller magnets202eand204eare aligned with one another, i.e., they extend a similar distance both into and out of the section plane shown inFIG.33. As illustrated inFIG.34, roller magnets202eare positioned exterior of the conduit wall, i.e., exterior of conduit wall exterior surface70e. Similarly, roller magnets204eare positioned interior of the conduit wall, i.e., interior of conduit wall interior surface72e. Referring toFIG.34, shuttle200eis illustrated with first flapper valve206eand second flapper valve208ebiased upright in a fully open position. Torsion spring128ebiases first flapper valve206einto the open position and upper latch210eof shuttle200eholds first flapper valve206ein the open position, as illustrated. First flapper valve206ehas first roller212eextending through a yoke extending upwardly from flapper valve206e. First roller212eis engaged at a recess juxtaposed with upper latch210e, as illustrated inFIG.4, when first flapper valve206emaintains the closed position. In this position, second flapper valve208eis biased upright due to its planar engagement with first flapper valve206e. Further, second flapper valve208eincludes upper magnet216epositioned through stem218eof second flapper valve208e. Magnet220esecured in valve base222eshares a magnetic attraction with upper magnet216eto urge second flapper valve208einto the fully opened position illustrated inFIG.34. Like first flapper valve206e, second flapper valve208ehas a second roller224eextending between a yoke that projects from second flapper valve208e. Second roller224eoccupies notch226eof shuttle200ein the fully opened position illustrated inFIG.34. In the embodiment inFIGS.33-43, float76ebegins to rise when the liquid level in tank94(shown inFIG.1) reaches a sufficient height, as previously described for other embodiments. Roller magnets202eattract roller magnets204eso that float76elifts shuttle200e, as float76erises. Referring toFIGS.34and35, first and second flapper valves206eand208eare illustrated in the open position. Comparatively, referring toFIGS.38and39, when first flapper valve206eis in an intermediate position, between open and closed, the two pairs of roller magnets,202eand204e, have risen relative to first and second flapper valves206eand208e. This rising of both float76eand shuttle200eactuates the closing of both first and second flapper valves206eand208e, as described below. Referring back toFIG.34, first and second flapper valves206eand208eare illustrated in the fully open position. As the liquid level in tank94(shown inFIG.1) causes float76eto rise, shuttle200ewill rise to actuate the closure of first and second flapper valves206eand208e. When this happens, both first and second rollers212eand224eride along the vertical wall surfaces of shuttle200e. As float76erises and, owing to the magnetic attraction between roller magnets202eand204e, shuttle200erises, first roller212eand second roller224ewill ride along upper ramp228eand the vertical wall forming lower notch226e, respectively, to attain the position illustrated inFIG.37. In this position, the magnetic attraction between upper magnet216eand magnet220econtinues to hold second flapper valve208ein the fully opened position illustrated inFIG.38. In the position illustrated inFIG.37, the fluid flowing through the conduit will actuate first flapper valve206einto the closed position as described above with respect to various alternative flapper valve embodiments. With first flapper valve206eclosed and second flapper valve208estill open, as illustrated inFIG.38, the leak position is achieved. As float76econtinues to rise, second roller224ewill ride along lower ramp230euntil achieving the position illustrated inFIG.39.FIGS.37aand38asequentially illustrate the change in position of float76eand shuttle200eto effect this movement. As second flapper valve208eis forced by the interaction of second roller224eand lower ramp230efrom the position illustrated inFIG.38to the position illustrated inFIG.39, the magnetic attraction between upper magnet216eand magnet220eis broken. With second flapper valve208emaintaining the position illustrated inFIG.39, the flow of fluid through the conduit will actuate second flapper valve208einto a closed position, as described above with respect to the various flapper valve embodiments of the present disclosure. With both first and second flapper valves206eand208eclosed as illustrated inFIG.40, fluid may continue to flow through conduit62eat the drain flow rate described above, e.g., at 2% of maximum flow rate. As the column of fluid drains past first flapper valve206eand second flapper valve208e, torsion spring128ewill return both first flapper valve206eand second flapper valve208e(owing to its seated position with respect to its valve seat, which is formed in first flapper valve206e) to the open position. As the liquid level and flow decrease, float76ewill descend and upward bias of torsion spring128ewill begin to return both first and second flapper valves206eand208eto the open position. When this happens, referring fromFIG.41toFIG.42, first and second rollers212eand224ewill reengage upper and lower ramps228eand230e, respectively, and the lowering of shuttle200eand upward rolling of the rollers will reset the valves and shuttle200eto the open position illustrated inFIG.35. It is important to note that cam232e(which is rigidly secured to first flapper valve206efor rotation therewith) precludes shuttle200efrom achieving its fully lowered position, as illustrated inFIG.34, unless first flapper valve206eis rotated to a position that is either fully open or nearly fully open. This is done so that shuttle200ecannot interfere with the opening of first flapper valve206e. FIGS.43-50illustrate another embodiment of the present disclosure wherein the mechanism for actuating the closure of the two interior valves is float76fconnected to a magnetic shaft coupling via link303fand lever arm302f. Once again, the two interior valves, first flapper valve304fand second flapper valve306f, each transition from an open to a closed position as the liquid level in tank94(shown inFIG.1) rises past a certain threshold, as described for previous embodiments. However, this embodiment uses a rotational magnetic shaft coupling to transition first flapper valve304fand second flapper valve306ffrom open to closed positions. Specifically, referring toFIG.44, outer magnetic coupler314fis rotationally supported by a bearing on the exterior of conduit wall exterior surface70f, while inner magnetic coupler316fis rotationally supported by a bearing and supported on conduit wall interior surface72fEach of outer magnetic coupler314and inner magnetic coupler316include a plurality of bearings spaced about their perimeter, in the usual arrangement of a magnetic shaft coupler. The polarity of such magnets is configured such that movement of outer magnetic coupler314outside of fluid conduit62fyields corresponding rotational movement of inner magnetic coupler316fon the interior of conduit62f. Referring toFIG.44, both first flapper valve304fand second flapper valve306fare illustrated in the open position. First flapper valve304fis biased in the upright position by torsion spring128fand held in this upright position by overhead latch308f. Second flapper valve306fis held in the upright position because it is in planar engagement with first flapper valve304f, making second flapper valve306fupright whenever first flapper valve304fis as well. Further, even without engagement by first flapper valve304f, second flapper valve306fwould be held in place by the magnetic attraction between flapper valve magnet312fthat is secured to pivot arm322f(as further described below) and magnet313f, which is secured to second flapper valve306. Referring toFIG.45, as the liquid level in tank94(shown inFIG.1) reaches a certain level, float76fbegins to rise, in the same way as described for previous embodiments. Also as previously described, deflector48fprevents liquid flow from urging either flapper valve downward until the given valve has been disengaged from the upright position. As float76frises, link303f(FIG.43a), which is pivotably connected both to float76fand to lever arm302fis pulled upward with float76f, thereby turning actuating outer magnetic coupler314fcounterclockwise from the perspective illustrated inFIG.43a. This counterclockwise rotation acts on both first and second flapper valves304fand306fto transition each from an open to a closed position as described below. Referring toFIGS.45-47, as float76frotates outer magnetic coupler314f, inner magnetic coupler316frotates as well. Inner magnetic coupler316fincludes cammed surface318fthat rotates to actuate overhead latch308fout of locking engagement with first flapper valve, as illustrated inFIG.45. As illustrated inFIG.45, latch308fis pivotally connected to conduit wall interior surface72fso that it will ride along cam surface318fand, from the perspective illustrated inFIG.45, rotate counterclockwise as it rides ever higher along the cammed surface318fof inner magnet coupler316f. In a position illustrated inFIG.45, overhead latch308no longer engages first flapper valve304fto hold it in the open position. Further, foot309fof overhead latch308forces first flapper valve304to rotate from its fully opened position. As rotation of inner magnet coupler316fcontinues, latch308fcontinues to be rotated counterclockwise to the further rotated position illustrated inFIG.46. In this position, foot309fsufficiently places first flapper valve304fin the fluid stream such that the fluid stream causes closing of first flapper valve304fas described above with respect to a variety of alternative embodiments. This position is illustrated inFIG.47.FIG.47aillustrates overhead latch308fin an open position, allowing first flapper valve304fto achieve the closed position, as previously described. In a position illustrated inFIG.47a, overhead latch308fhas rotated the maximum amount provided by its interaction with cam surface318f. The position illustrated inFIG.47corresponds to the leak position. In this position, the closure stop (in the form of second flapper valve306f) maintains an open position such that first flapper valve304fmaintains the “leak” condition. From the position illustrated inFIGS.47and47a, when float76fcontinues to ascend, outer magnetic coupler314fis further rotated as link303fis pulled upwardly by float76fto rotate lever arm302f, causing corresponding rotation of inner magnetic coupler316fto the position illustrated inFIGS.48and48a. In this position, cam320f, which forms an integral part of inner magnetic coupler316f, actuates pivot arm322f, which carries second flapper valve magnet312f. Actuation of lever arm322f, as illustrated inFIG.48abreaks the magnetic attraction between second flapper valve magnet312fand magnet313f, which is secured to second flapper valve306f. In this position, there is no longer a magnetic attraction holding open second flapper valve306f. Therefore, second flapper valve306fbegins to rotate into a closed position under its own weight, and the force of the fluid flowing through conduit62f.FIGS.49and49afurther illustrate this configuration. With both first and second flapper valves304fand306fclosed, as illustrated inFIGS.49and49a, fluid may continue to flow through conduit62fat the drain rate described above, e.g., at 2% of maximum flow rate. As the column of fluid drains past first flapper valve304fand second flapper valve306f, torsion spring128fwill return both first flapper valve304fand second flapper valve306f(owing to a seated position with respect to its valve seat, which is formed in first flapper valve304f) to the open position. As illustrated inFIG.50, as first flapper valve304fand second flapper valve306fare returned from a fully closed position illustrated inFIGS.49and49ato the fully opened position illustrated inFIG.44, first flapper valve304fcontacts foot309f. If float76fhas returned to its fully lowered position, as illustrated inFIG.44, then overhead latch308fwill no longer be rotated outwardly as illustrated inFIG.50, but rather will maintain the position illustrated inFIG.44. In this position, ramped end324fof first flapper valve304can ride along the radiused outer profile of overhead latch308fto effect a minor counterclockwise rotation of latch308f(with respect to the perspective ofFIG.50), such that ramped end324fof first flapper valve304fcan be secured by latch308fas illustrated inFIG.44. Details of the actuation mechanism described above can be found inFIGS.51-56.FIG.52illustrates inner magnet coupler306fin the same position illustrated inFIG.44. Alternative side elevational views of the construct in this position are also provided inFIGS.51and53.FIG.54provides a perspective view of inner magnetic coupler316f. Further,FIG.55provides a perspective view of overhead latch308f. Similarly,FIG.56provides a perspective view of pivot arm322fincluding pivot aperture323fand magnet holding aperture325f. FIGS.57-59illustrate drop tube adaptor400secured to drop tube402. Drop tube adaptor400may be threadedly engaged via female threads406to either end of any of the overfill prevention valves described in this document. Drop tube adapter400may further be secured to drop tube402via annular groove414. Specifically, as illustrated inFIG.58, O-ring416is positioned within annular groove414(FIG.57), and drop tube adaptor400is thereafter inserted into drop tube402. In this position, drop tube402can be roll crimped to create exterior annular groove410, as illustrated inFIG.58. Drop tube adaptor400further includes through bores408, into which drop tube402can be deformed to form deformations412as illustrated inFIG.58. A fastener such as a rivet or bolt may then be used to further secure drop tube adaptor400to drive tube402. As described above, the overfill prevention valve in accordance with the present disclosure can include a valve actuator means for actuating a valve body from an open position to a closed position while the valve actuator means is positioned outside of the fluid path and without requiring a physical penetration of the wall defining the fluid path. Exemplary embodiments of the valve actuator means include the various float/magnet/actuator combinations described above. Further, an overfill prevention valve in accordance with the present disclosure can include a leak means for selectively allowing a quantity of fluid to leak past a valve body when the valve body is in the closed position. Leak actuator means for actuating the leak means from a non-leak position in which the leak means does not allow the quantity of fluid to leak past the valve body to a leaked position in which the leak means allows the quantity of fluid to leak past the valve body include the various float/magnet/actuator combinations described above. The leak means may take the form of a closure stop which prevents full seating of the valve body in a closed position, as described above. The leak means may further take the form of a closure stop in the form of a secondary valve such as a poppet valve or a flapper valve which can be unseated when the primary valve maintains a closed position. Any of the drop tube segments including an overfill prevention valve described above can be connected at their first and second ends to the remainder of drop tube98by a variety of connections including, e.g., threaded connections. Threaded adaptors may be utilized to effect such connections and o-rings may be provided to seal the drop tube segments of the present disclosure to the remainder of the drop tube. While this disclosure has been described as having exemplary designs, the present disclosure can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains and which fall within the limits of the appended claims. | 52,413 |
11859732 | DETAILED DESCRIPTION Initially, this disclosure is by way of example only, not by limitation. The illustrative constructions and associated methods disclosed herein are not limited to use or application for sealing any specific assembly or in any specific environment. That is, the disclosed technology is not limited to use in sealing fluid ends as described in the illustrative embodiments. Thus, although the instrumentalities described herein are for the convenience of explanation, shown and described with respect to exemplary embodiments, the skilled artisan understands that the principles herein may be applied equally in sealing other types of high pressure flow devices. FIG.1is a simplified isometric cross-sectional depiction of a hydraulic fracturing fluid end200that is constructed in accordance with previously attempted solutions. The fluid end200comprises a housing or fluid end body201, which is generally a manifold used to deliver highly-pressurized corrosive and/or abrasive fluids, typically used in hydraulic fracturing processes in the oil and gas industry. Fluid may pass through the fluid end200at pressures that range from 5,000-15,000 pounds per square inch (psi). Fluid ends200used in high pressure hydraulic fracturing operations typically move fluid at a minimum of 8,000 psi. However, normally, the fluid end200will move fluid at pressures around 10,000-15,000 psi. The fluid end body201typically has a first conduit220and a second conduit221formed within the body201that intersect to form an internal chamber222. The first conduit220is typically orthogonal to the second conduit221. The first conduit220may have aligned first and second sections223and224that are situated on opposite sides of the internal chamber222. The first section223may be referred to as a discharge bore, and the second section224may be referred to as an intake bore. Likewise, the second conduit221may have aligned third and fourth sections225and226that are situated on opposite sides of the internal chamber222. The third section225may be referred to as a plunger bore, and the fourth section226may be referred to as a suction bore. The sections223,224,225, and226each may independently interconnect the internal chamber222to an external surface227of the fluid end200. A plunger228reciprocates within the fluid end body201to increase the pressure of fluid being discharged from the fluid end200. As shown inFIG.1, the plunger228may be disposed within the third section225of the second conduit221. The plunger228is disposed within a plunger packing213. The plunger packing213comprises a plurality of packing seals219. The plunger228is powered by an engine operatively engaged with the fluid end200. In high pressure hydraulic fracturing operations, the engine preferably has a power output of at least 2,250 horsepower. Valve seats229are also shown supported within the first conduit220. The valve seats229may support valves, such as a ball valve, used to control the movement of high pressure fluid within the body201. There are sealing areas in the fluid end200that experience erosion during operation. For example, a number of components seal to the fluid end body201. As discussed above, the sacrificial member for erosion is the fluid end body201instead of the less complex and less expensive mating component. For example, the fluid end body201defines a discharge opening202that opens into the discharge bore223. The discharge opening202depicted in these embodiments is sealed closed by inserting a closure or discharge plug or cover204into the discharge bore223and securing it by advancing a threaded retaining nut206into the body201. The retaining nut206may also be referred to as a retainer. The discharge plug204supports a seal208that seals against the walls of the fluid end body201defining the discharge bore223.FIG.2is a simplified cross-sectional depiction of the discharge plug204that has a groove207into which the seal208is mounted. In these illustrative embodiments the groove207is rectangular but the contemplated embodiments are not so limited. The skilled artisan understands that the configuration of the groove207is largely determined by what shape is required to mount the type of seal selected. The groove207intersects an outer surface215of the discharge plug204, permitting the seal208to be sized so that a portion not mounted within the groove207extends beyond the outer surface215to pressingly engage against the walls of the fluid end body201defining the discharge bore223. In this construction the highly-pressurized corrosive and/or abrasive fluid can be injected between the seal208and walls defining the discharge bore223, causing erosion of the seal surface formed by the walls defining the discharge bore223. Fluid end bodies have conventionally been made of heat-treated carbon steel, so it was not uncommon for the fluid end body201to crack before any sacrificial erosion of the body progressed to the point of creating leakage between the discharge plug204and the discharge bore223. However, progress in the technology has introduced stainless steel body construction resulting in a significantly longer operating life. As a result, this erosion is no longer negligible but is instead a consideration for reducing erosion in modern fluid end construction. One leading source of discharge bore223erosion in conventional fluid ends is the seal208mounted in the discharge plug204and extending therefrom to seal against a sealing surface formed by the fluid end body201. The technology disclosed herein is configured to transfer that erosion wear from the fluid end body201to the less complex and less expensive discharge plug204. FIG.3is an exploded cross-sectional depiction of a fluid end230having a housing or fluid end body232. The fluid end230is constructed in accordance with the technology disclosed herein to, in numerous places, transfer the erosion wear from the body to the less complex and less expensive component that is sealed to the body. The fluid end body232forms a number of interconnected bores or conduits, including a first conduit300. The first conduit300comprises a discharge bore234and an intake bore302positioned on opposite sides of an internal chamber304. The discharge bore234defines a discharge opening235that is similar to the discharge opening202in the conventional fluid end200depicted inFIG.1. Likewise, the intake bore302defines an intake opening231formed opposite the discharge opening235. The first conduit300forms multi-dimensional diameters at different longitudinal locations between the discharge opening235and the intake opening231. The discharge opening235is sealed closed by inserting a closure or discharge plug236into the discharge opening235and securing it in place by advancing a threaded retaining nut238, as shown inFIG.9. Unlike the conventional discharge plug204inFIG.1, the discharge plug236does not have a seal mounted to it that seals against the walls surrounding the discharge bore234. Instead, the discharge plug236defines a sealing surface237for a seal242, shown inFIG.4. The sealing surface237is axially spaced between a first surface251and an opposite second surface253of the plug236. The seal242is mounted in an endless groove or recess240formed in the walls of the fluid end body232surrounding the discharge bore234, as shown inFIGS.3and4. FIG.4is a simplified cross-sectional enlargement depicting the construction of the seal242positioned within the groove240formed in the fluid end body232. The groove240opens into the discharge bore234. The seal242in these illustrative embodiments is mounted in the groove240to include an outer radial surface, and is thereby supported by the fluid end body232. The groove240is characterized by a pair of parallel sidewalls306joined by a base308. The groove240opens towards a centerline of the conduit within which it is formed. Alternatively, as shown by groove266inFIGS.6and7, the groove may open in a direction parallel to a centerline of the conduit within which it is formed. As above, the rectangular shape of the groove240is merely illustrative and not limiting of the contemplated embodiments. Any shape necessary to properly mount a desired seal is contemplated, whether the seal is elastomeric, spring, metal, and the like. The groove240intersects the discharge bore234permitting the seal242to be sized so that a portion of the seal242not contained in the groove240extends beyond the groove240and beyond the bore234to pressingly seal against the sealing surface237defined by the discharge plug236, as shown inFIG.4. The seal construction depicted inFIG.4transfers the erosion wear from the fluid end body232to the discharge plug236. Such transfer of erosion significantly improves fluid end operations because repairs involving the discharge plug236are significantly less complex and less expensive than repairs involving the fluid end body232, which typically involve weld-repair. Furthermore, weld-repairing the fluid end body232makes it susceptible to premature fatigue cracking in the repaired area. Further, even more operating life can be achieved by applying an erosion-resistant surface treatment to the discharge plug236, such as a high velocity oxygen fuel (HVOF) treatment, a tungsten carbide coating, material carburizing, and the like. Replacing instead of repairing an eroded discharge plug236is typically feasible, making it advantageously possible to repair a leaking valve constructed according to this technology in the field and thereby significantly reducing down time. Returning toFIG.3, another endless groove or recess241is formed in the fluid end body232. The groove241intersects the discharge bore234and is configured to mount a seal (not depicted) that extends from the groove241to seal against a sealing surface formed by a discharge valve seat, like the valve seat229shown inFIG.1. Similarly, another endless groove or recess243is formed in the fluid end body232. The groove243intersects the intake bore302and is configured to mount a seal (not depicted) that extends from the groove243to seal against a sealing surface formed by a suction valve seat, like the valve seat229shown inFIG.1. The grooves241and243may be shaped identically to the groove240. Continuing withFIG.3, the fluid end body232includes a second conduit310. The second conduit310includes a plunger bore252and a suction bore247positioned on opposite sides of the internal chamber304. The suction bore247is sealed closed by inserting a closure or suction plug or cover244defining a sealing surface245and securing it in place by advancing a threaded retaining nut246within the body232, as shown inFIG.9. Like the discharge plug236, the sealing surface245is axially spaced between a first surface255and an opposite second surface261of the suction plug244. An endless groove or recess248is formed in the walls of the fluid end body232defining the suction bore247. The groove248may be construed identically to the groove240. The groove248is configured for mounting a seal, like the seal242shown inFIG.4. The seal may extend from the groove248and seal against the sealing surface245of the suction plug244. Such positioning transfers the wear from the fluid end body232to the suction plug244in comparison to previously attempted solutions and in accordance with the embodiments of this technology. Continuing withFIG.3, the plunger bore252defines a plunger opening250. The plunger bore252is sized to closely receive a stuffing box sleeve254that is sealed in place by advancing a threaded retaining nut256, as shown inFIG.9. Because the sleeve254is secured within the fluid end body232by a retaining nut256, no threads are formed in the sleeve254for mating with the fluid end body232or other component. Specifically, no threads are formed in an outer surface of the sleeve254along a length of the sleeve254. The plunger bore252includes a first segment312and a second segment314. The first segment312is positioned closer to the internal chamber304and the suction bore247than the second segment314. The second segment314has a greater diameter than the first segment312. Threads may be formed in the walls of the fluid end body232surrounding at least a portion of the second segment314. The threads may mate with threads formed on the retaining nut256. An endless groove or recess257is formed in the walls of the fluid end body232surrounding the first segment312. The groove257is configured to house a seal260, as shown inFIG.5. The groove257may be identical to the groove240. Likewise, the seal260may be identical to the seal242. Continuing withFIG.3, the stuffing box sleeve254is characterized by a tubular sleeve. The sleeve254comprises a first portion316joined to a second portion318. The first and second portions316and318each have a cylindrical shape, such that the sleeve254may be considered primarily cylindrical. The first portion316has an outer diameter, D1. The second portion318has an outer diameter, D2. The diameter D2is greater than the diameter D1. The diameter D2is also greater than a maximum diameter of the groove257. The sleeve254is installed within the plunger bore252such that the first portion316is closely received within the first segment310and the second portion318is closely received within the second segment314, as shown inFIG.9. The difference between the diameters D1and D2and the diameters of the plunger bore252prevent further movement of the sleeve254into the fluid end body232, as shown inFIG.9. Continuing withFIGS.3and9, the diameter D1is constant along at least a portion of the length of the first portion316of the sleeve254. The diameter D1may be constant along the entire length of the first portion316, with the exception of a tapered surface319between the first portion316and a first surface322of the sleeve254. No grooves are formed in the outer surface of the first portion316for housing a seal. Rather, the outer surface of the first portion316has a sealing surface259for the seal260, as shown inFIG.5. The diameter D2is constant along at least a portion of the length of the second portion318. The diameter D2may be constant along the entire length of the second portion318, with the exception of one or more grooves formed in the outer surface of the second portion318for housing a seal or receiving lubrication. The area of the outer surface of the sleeve254having the one or more grooves may be referred to as a third portion of the sleeve254. An inner diameter of the third portion may be the same as the inner diameter of the second portion318. FIG.5is a simplified cross-sectional depiction of the body232having the groove257. Again, the groove257intersects the plunger bore252permitting a portion including an outer radial surface of a radial seal260to be mounted in the groove257. Another portion of the seal260not mounted in the groove257extends from the groove257to pressingly seal against the sealing surface259of the sleeve254. Although in these depicted embodiments a radial seal is used, the contemplated embodiments are not so limited. The skilled artisan readily understands that other types of seals could be used instead of or in addition to the radial seal depicted, such as axial seals, crush seals, and the like. Turning back toFIGS.3and9, the first and second portions316and318of the sleeve254define a central passage320. The central passage320interconnects a first and second outer surface322and324of the sleeve254. The first outer surface322may be joined to the first portion316of the sleeve254. The first outer surface322may be joined to the outer surface of the first portion316via the tapered surface319. The second outer surface324may be joined the second portion318or the third portion of the sleeve254. The retaining nut256may engage the second surface324of the sleeve254, as shown inFIG.9. Continuing withFIG.3, the first portion316has an inner diameter, D3. The second portion318has an inner diameter, D4. The diameter D4is greater than the diameter D3. The diameter D3may be constant along the length of the first portion316, and the diameter D4may be constant along the length of the second portion318, and if included, the third portion. An inner surface of the second portion318may transition to an inner surface of the first portion316at a right angle, such that an internal seat326is formed within the second portion318. The transition between the inner surface of the second portion318and the inner surface of the first portion316may be referred to as a first transition. Similarly, an outer surface of the first portion316is joined to an outer surface of the second portion318at a right angle. In alternative embodiments, the first portion may be joined to the second portion by a tapered portion, as shown for example inFIG.8. The transition between the outer surface of the first portion316and the outer surface of the second portion318may be referred to as a second transition. The first and second transitions may also be referred to as a fourth portion of the sleeve254. Continuing withFIG.9, the plunger packing213, including the plurality of packing seals219, is installed within the second portion318of the sleeve254such that the plunger packing213abuts the internal seat326. No portion of the plunger packing213is installed within the first portion316of the sleeve254, as shown inFIG.9. A portion of the plunger packing213may also be installed within the third portion of the sleeve254. The plunger228is disposed within at least a portion of the sleeve254and the plunger packing213. FIG.6depicts another embodiment of a fluid end330comprising a fluid end body332. A number of additional endless grooves or recesses are formed in the fluid end body332for mounting various seals to transfer the wear away from the body332to the mating component in accordance with embodiments of this technology. For example, a groove266is formed in the fluid end body332intersecting a discharge bore334. Consistent with this whole description, the groove266permits mounting an axial seal268, shown inFIG.7. The seal268is configured to extend from the groove266to seal against a leading face of a discharge plug, like the discharge plug236shown inFIG.3.FIG.7is a simplified enlarged depiction of the fluid end body332having the groove266into which the axial seal268is mounted. In these illustrative embodiments the seal268is configured to extend beyond the walls defining the discharge bore334to seal against a discharge plug236as it is urged downward by advancing a retaining nut, like the retaining nut238, shown inFIG.3. Importantly, the simplified seal construction depicted inFIG.7and elsewhere is in no way limiting of the contemplated embodiments and scope of the claimed technology. In alternative embodiments a radial seal or a crush seal and the like can be employed to transfer the erosion wear from the fluid end body232or332to the mating component. A crush seal refers to a seal construction that acts at least to some degree both axially and radially. For example, a groove272having only two walls is shown inFIG.6. The walls of the groove272extend concentrically around a plunger bore336. A stuffing box sleeve may be formed to have side walls that fully overlies the groove272when it is positioned in the plunger bore336, as shown for example inFIG.15. This allows the seal to act as a crush seal because it seals axially and radially against the installed sleeve. Returning toFIG.6, the fluid end body332may have other surfaces forming endless grooves or recesses for mounting various other seals. For example, a groove270is formed in a suction bore338for mounting a seal that is configured to seal against a sealing surface of a suction plug, like the suction plug244shown inFIG.3. In the same way the fluid end body332can have grooves274and276for mounting seals that are configured to seal against sealing surfaces of a discharge valve seat and a suction valve seat, respectively. Likewise, the fluid end body332can have a groove278for mounting a seal that is configured to seal against a suction manifold (not depicted). What's common in any event is the seal construction of this technology transfers the seal wear from the fluid end body332to the less complex and less expensive mating component that is attached to the fluid end body332. FIG.8depicts another embodiment of a fluid end340having a fluid end body342. The fluid end340is generally identical to the fluid end330, but includes another embodiment of a plunger bore344. The plunger bore344is similar to the plunger bore252, but is sized to receive another embodiment of a stuffing box sleeve346. The stuffing box sleeve346is identical to the stuffing box sleeve254with a few exceptions. The stuffing box sleeve346comprises a first portion348joined to a second portion350by a tapered portion352. The first portion348is installed within a first segment354of the plunger bore344and the second portion350is installed within a second segment356of the plunger bore344. A groove358is formed in the walls of the fluid end body342surrounding the first segment354. The groove358may be identical to the groove257. A seal360is shown installed within the groove358and engaging an outer sealing surface of the first portion348. A seal362may also be installed within a groove364formed in an outer surface of the second portion350of the sleeve346. Such area of the sleeve346may be referred to as a third portion of the sleeve346. As the stuffing box sleeve346is inserted into the plunger bore344, air pressure forms in a space defined in the clearance gap between the outer diameter of the stuffing box sleeve346and the walls of the fluid end body342defining the plunger bore344and between the seal360and the seal362at the opposing end of the stuffing box sleeve346. The air pressure exerts a force urging the stuffing box sleeve346out of the plunger bore344, complicating manufacture and degrading the seal integrity at the lower end of the stuffing box sleeve346. A breather opening284can be formed between that space and ambient space above the stuffing box sleeve346to vent the air pressure. FIG.8also depicts a conventional construction of the seal362that is mounted in the groove364formed by the stuffing box sleeve346and extends from that groove364to seal against the walls of the fluid end body342defining the plunger bore344. The contemplated embodiments can include combinations of the conventional construction and the construction of this technology where other matters come into play. FIG.8also depicts employing the open-cylinder-shaped stuffing box sleeve346and securing it in place by advancing a retaining nut, like the retaining nut256shown inFIG.3. That construction is illustrative and in no way limiting of the contemplated technology. Other configurations can be employed as well. For example, the skilled artisan understands that a conventional stuffing box can be employed that combines a stuffing box sleeve and a retaining nut, unitarily, into one component. In other conventional constructions, a stuffing box may be used in combination with a seal carrier insert that mates with the stuffing box and provides the groove for mounting the seal. In yet other contemplated embodiments, a stuffing box sleeve can be modified to a construction combining a substantially cylindrical-shaped stuffing box to which is mated a seal surface insert that provides the sealing surface. Returning momentarily toFIGS.3and9, the sleeve254also protects the walls of the fluid end body232surrounding the plunger bore252from erosion by providing an inner surface against which the plunger packing213seals. That, again, by design transfers the wear from the fluid end body232to the less complex and less expensive sleeve254. With reference toFIGS.10-14, another embodiment of a fluid end400is shown. The fluid end400comprises a fluid end body402releasably attached to a connect plate404. The fluid end400is constructed similar to those embodiments described in United States Patent Publication No. 2019/0178243, in the name of Nowell et al., the entire contents of which are incorporated herein by reference. The fluid end body402and attached connect plate404may be referred to herein as the fluid end body or housing406. With reference toFIG.12, a first conduit408and a second conduit410are formed in the housing406. The conduits408and410intersect to form an internal chamber412. As shown inFIGS.10and11, a plurality of the first and second conduits408and410are formed in the fluid end400and positioned in a side-by-side relationship. The first conduit408includes a discharge bore414and an intake bore416positioned on opposite sides of the internal chamber412. The second conduit410includes a plunger bore418and a suction bore420positioned on opposite sides of the internal chamber412. Continuing withFIG.12, a discharge plug422is installed within the discharge bore414and a suction plug424is installed within the suction bore420. The plugs422and424are retained within the housing406using a plurality of retainers426. Each retainer426is secured to the housing406using a fastening system428, like that described in United States Patent Publication No. 2020/0300240, authored by Nowell et al., the entire contents of which are incorporated herein by reference. Like the discharge and suction plugs236and244shown inFIG.3, no grooves are formed in the outer surface of the plugs422and424for housing a seal. Instead, an endless groove430is formed in the walls of the housing406surrounding the discharge bore414for housing a seal432. Likewise, an endless groove434is formed in the walls of the housing406surrounding the suction bore420for housing a seal436. During operation, the seals432and436engage an outer sealing surface of the plugs422and424. Over time, the seals432and436wear against the outer sealing surface of the plugs422and424. If the outer surface of the plugs422and424begins to erode, the plugs422and424may be removed and replaced with a new plug. Turning toFIG.14, the groove434is characterized by two side walls440joined by a base442. The groove240, shown inFIG.4, has two side walls306joined to the base308at a right angle or with small radius corners. For example, the radius corners may be approximately 0.015 inches. In contrast, the groove434, shown inFIG.14, has side walls440joined to the base442via much larger radius corners444. The radius is approximately 0.150 inches. The larger radius corners444make the groove434have a rounded cross-sectional shape. In operation, the larger radius corners444help relieve stress in the walls surrounding the groove434, helping to increase the life of the fluid end400. In alternative embodiments, the radius corners may be even larger in size, such that the groove has the shape of a half circle. In further alternative embodiments, the walls forming the groove may have multiple sections with different radii. Continuing withFIG.12, a stuffing box sleeve446is installed within the plunger bore418. The stuffing box sleeve446is generally identical to the stuffing box sleeve254, shown inFIG.3, with a few exceptions. The sleeve446comprises a first portion448joined to a second portion450. The first and second portions448and450each have a cylindrical shape, such that the sleeve446may be considered primarily cylindrical. The first portion448has an outer diameter, D1. The second portion450has an outer diameter, D2. The diameter D2is greater than the diameter D1. The diameter D2is also greater than a maximum diameter of a groove452formed in the walls surrounding the plunger bore418. The sleeve446is installed within the plunger bore418such that the first portion448is installed within a first segment454of the plunger bore418and the second portion450is installed within a second segment456of the plunger bore418. The difference between the diameters D1and D2and the diameters of the plunger bore418prevent further movement of the sleeve446into the housing406. Continuing withFIG.12, the diameter D1is constant along at least a portion of the length of the first portion448of the sleeve446. The diameter D1may be constant along the entire length of the first portion448, with the exception of a tapered surface472, shown inFIG.13. No grooves are formed in the outer surface of the first portion448for housing a seal. Rather, the outer surface of the first portion448serves as a sealing surface for a seal458, as shown inFIG.13. The diameter D2is constant along at least a portion of the length of the second portion450. The diameter D2may be constant along the entire length of the second portion450, with the exception of one or more grooves formed in the outer surface of the second portion450for housing a seal or for providing space for lubrication to be delivered to the interior of the housing406. The outer surface of the sleeve446having the one or more grooves may be referred to as a third portion of the sleeve446. An inner diameter of the third portion may be the same as the inner diameter of the second portion450, with the exception of one or more lubrication holes. The second portion450may further comprise one or more passages451interconnecting the inner and outer surfaces of the second portion450, as shown inFIG.12. The one or more passages451are in fluid communication with a lube port453formed in the housing406. During operation, lubrication is delivered to the interior of the sleeve446via the lube port453and the one or more passages451. The first and second portions448and450of the sleeve446define a central passage. The central passage interconnects a first and second outer surface460and462of the sleeve446. The first outer surface460may be joined to the first portion448of the sleeve446. The first surface460may join the outer surface of the first portion448via the tapered surface472, shown inFIG.13. The second outer surface462may be joined the second portion450or the third portion of the sleeve446. A retainer464may engage the second surface462of the sleeve446and secure the sleeve446within the plunger bore418. The retainer464shown inFIG.12is secured to the housing406using a fastening system, like that shown in United States Patent Publication No. 2020/0300240, authored by Nowell et al. In alternative embodiments, the retainer464may thread into the walls of the housing406. Continuing withFIG.12, the first portion448has an inner diameter, D3. The second portion450has an inner diameter, D4. The diameter D4is greater than the diameter D3. An inner surface of the second portion450may transition to an inner surface of the first portion448at a right angle, such that an internal seat466is formed within the second portion450. The transition between the inner surface of the second portion450and the inner surface of the first portion448may be referred to as a first transition. Turning toFIG.13, the inner surface of the first portion448may have a slightly convex portion468joined to a straight portion470. The convex portion468may extend between the internal seat466and the straight portion470. Because the first portion448includes the convex portion468, the first portion448may also have an inner diameter, D5. The diameter D3is greater than the diameter D5. The convex portion468helps increase the wall thickness of the first portion448, which helps alleviate stress within the sleeve446during operation. In alternative embodiments, the inner surface of the first portion448may be shaped like the sleeve254shown inFIG.3. The outer surface of the first portion448may also include the tapered surface472adjacent the first surface460. Continuing withFIG.12, an outer surface of the first portion448is joined to an outer surface of the second portion450at a right angle. In alternative embodiments, the first portion may be joined to the second portion by a tapered portion, as shown for example inFIG.8. The transition between the outer surface of the first portion448and the outer surface of the second portion450may be referred to as a second transition. The first and second transitions may also be referred to as a fourth portion of the sleeve446. Continuing withFIGS.12and13, the groove452is formed in the walls surrounding the first segment454of the plunger bore418. The groove452is identical to the groove434. In alternative embodiments, the grooves434and452formed in the fluid end400may be shaped like any one of the other grooves described herein. Turning toFIGS.15and16, another embodiment of a fluid end500is shown. The fluid end500is identical to the fluid end400, with the exception of its plunger bore502. A groove504formed in the walls surrounding a first segment506of the plunger bore502only has two side walls508and510, as shown inFIG.16. The side walls508and510may intersect at a right angle or a radius corner. Another embodiment of a stuffing box sleeve512is shown installed within the plunger bore502. The sleeve512is identical to the sleeve446, but may have a shorter first portion514and a longer second portion516. When the sleeve512is installed within the plunger bore502, a base518of the second portion516forms a third wall of the groove504. A seal520installed within the groove504may be identical to the seal454, shown inFIG.13. During operation, the seal520wears against an outer sealing surface of the first portion514of the sleeve512. Turning toFIGS.17-22, another embodiment of a fluid end600is shown. The fluid end600comprises a housing602having an external surface604and internal chamber606, as shown inFIG.19. The housing602is shaped similar to that shown inFIG.1, in that it is of single-piece construction and includes a flanged portion608. The flanged portion608is configured to receive a plurality of stay rods used to attach the fluid end600to a power end. First and second intersecting conduits610and612are formed in the housing602. The first conduit610has first and second sections614and616, each of which independently interconnects the internal chamber606and the external surface604of the housing602. The second conduit612has third and fourth sections618and620, each of which independently interconnects the internal chamber606and the external surface604. Continuing withFIGS.19-22, the fluid end600uses another embodiment of a sleeve622. The sleeve622is of single-piece construction and comprises opposed first and second surfaces624and626joined by an outer intermediate surface628. In contrast to the other sleeve embodiments disclosed herein, the outer intermediate surface628of the sleeve622has a constant outer diameter along the entire length of the sleeve622. The sleeve622defines a central passage630and has an internal shoulder632formed therein. The internal shoulder632is positioned closer to the first surface624than the second surface626of the sleeve622. A plunger packing634is installed within the sleeve622through the second surface626until it abuts the internal shoulder632. The plunger packing634comprises a plurality of packing seals635. Similar to the other sleeve embodiments disclosed herein, no grooves are formed in the outer intermediate surface628of the sleeve622for housing a seal. Likewise, no threads are formed in the outer intermediate surface628for engaging the housing602or another component. The sleeve622may be made of steel, and not be coated with any abrasive material. If the sleeve622begins to erode over time, the sleeve622may be removed and replaced with a new sleeve. Continuing withFIG.19, an endless groove636is formed within the walls of the housing602surrounding the third section618. The groove636is positioned closer to the internal chamber606than the external surface604of the housing602and may be shaped like any of the endless grooves disclosed herein. An annular seal638is installed within the groove636. When the sleeve622is installed within the third section618, the seal638engages the outer intermediate surface628of the sleeve622. Over time, the seal638wears against the intermediate surface628of the sleeve622. If the sleeve622begins to erode, it can be removed and replaced with a new sleeve. The housing602further comprises an internal shoulder640formed within the third section618between the groove636and the internal chamber606. Axial movement of the sleeve622within the third section618is prevented by engagement of the first surface624of the sleeve622with the internal shoulder640. When installed within the third section618, no portion of the sleeve622projects from the external surface604of the housing602. The sleeve622is held within the third section618by a retainer650. The retainer650has a threaded outer surface652and defines a threaded central opening654. The threaded outer surface652mates with internal threads656formed in the walls of the housing602. When the retainer650is installed within the housing602a first surface658of the retainer650abuts the second surface626of the sleeve622, but the retainer650does not engage the plunger packing634. Continuing withFIG.19, a packing nut660having a threaded outer surface662is installed within the retainer650. The threaded outer surface662of the packing nut660mates with the threaded central opening654of the retainer650. The packing nut660is turned within the retainer650until a first surface664of the packing nut660engages and compresses the plunger packing634. A reciprocating plunger670is disposed within the packing nut660, retainer650, plunger packing634, and the sleeve622. In alternative embodiments, the housing602may be configured to use one of the other embodiments of retainers disclosed herein. The other components installed within the housing602and shown inFIG.19are similar to those disclosed herein. In alternative embodiments, the sleeve may have different shapes and sizes but still function to form a second sidewall of the groove. In further alternative embodiments, the suction and discharge plugs may be configured to form one of the sidewalls of a two-walled groove formed in the housing. Summarizing, this technology contemplates a high pressure fluid flow apparatus constructed of a body defining a flow passage, a closure mounted to the body, and a means for sealing between the body and the closure. For purposes of this description and meaning of the claims the term “closure” means a component that is attached or otherwise joined to the body to provide a high-pressure fluid seal between the body and the closure. In some embodiments such as the described fluid end embodiments “closure” encompasses nonmoving components joined to the body to seal an opening such as but not limited to the discharge plug, suction plug, discharge valve seat, suction valve seat, stuffing box sleeve, discharge flange, suction manifold, and the like. The term “means for sealing” means the described structures and structural equivalents thereof that mount a seal to a body instead of a mating closure to transfer the wear in comparison to previously attempted solutions from the body to the closure. “Means for sealing” expressly does not encompass previously attempted solutions that mount a seal to the closure to extend therefrom and seal against the body. The various features and alternative details of construction of the apparatuses described herein for the practice of the present technology will readily occur to the skilled artisan in view of the foregoing discussion, and it is to be understood that even though numerous characteristics and advantages of various embodiments of the present technology have been set forth in the foregoing description, together with details of the structure and function of various embodiments of the technology, this detailed description is illustrative only, and changes may be made in detail, especially in matters of structure and arrangements of parts within the principles of the present technology to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | 39,883 |
11859733 | DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS In the following, an embodiment of the present invention (hereinafter, referred to as “this embodiment”) will be described with reference to the attached drawings. In this description, the same reference signs are given to the same components throughout the description. A valve device1according to this embodiment will be described first with reference toFIGS.1to4. FIG.1is a sectional view showing the valve device1.FIG.2is a top view showing an adjusting screw8and a first rotary jig10for rotating the adjusting screw8.FIG.3is a top view showing a lock nut9.FIG.4is a schematic view showing a second rotary jig11for rotating the lock nut9, in which (a) is a schematic top view of the second rotary jig11, and (b) is a schematic sectional view of the second rotary jig11. The valve device1according to this embodiment is provided in a fluid control device (not shown) used for manufacture of a semiconductor. The fluid control device is used for a thin film formation step for forming a predetermined thin film on a substrate such as a semiconductor wafer, etc. by an ALD (Atomic Layer Deposition) process. As shown inFIG.1, the valve device1is provided with a flow passage block2, a diaphragm3, a diaphragm holder4, an actuator5serving as a driving portion, a bonnet6, a spacer7, and the adjusting screw8and the lock nut9serving as position adjusting members. The valve device1is an air-operated valve that opens the diaphragm3by introducing driving air serving as driving fluid into the actuator5. The flow passage block2has, as a flow passage, a fluid inflow flow passage21, a fluid outflow flow passage22, and a recessed portion23for receiving the bonnet6. One end (an upper end inFIG.1) of the fluid inflow flow passage21is communicated with one end (the upper end inFIG.1) of the fluid outflow flow passage22through the recessed portion23. A ring-shaped valve seat24is provided on a peripheral edge of the one end of the fluid inflow flow passage21. The flow passage block2is provided with a circumferential wall231forming the recessed portion23. On the recessed portion23, an internal thread232that is to be threaded with the bonnet6is formed. The diaphragm3is a valve body that opens and closes the fluid inflow flow passage21by being separated away from the valve seat24or by being pressed against the valve seat24. The diaphragm3is a diaphragm member that separates the flow passage side and the actuator5side. In addition, the diaphragm3is formed to have an arc shape raised toward the actuator5side (the upper side inFIG.1) in a natural state, and is made of, for example, a nickel alloy thin plate, etc. In general, the diaphragm3is held against the valve seat24by the diaphragm holder4. The diaphragm holder4is a holding member for holding the diaphragm3against the valve seat24. The diaphragm holder4is accommodated in the bonnet6. In addition, the diaphragm holder4has: a disc-shaped holder main body41serving as a guided portion; a disc-shaped upper projecting portion42that projects from the holder main body41toward the actuator5side (the upper side inFIG.1) and that has a diameter that is smaller than that of the holder main body41; and a disc-shaped lower projecting portion43serving as an insertion portion that projects from the holder main body41toward the flow passage block2side (the lower side inFIG.1) and that has a diameter that is smaller than that of the holder main body41but larger than that of the upper projecting portion42. The holder main body41, the upper projecting portion42, and the lower projecting portion43are formed coaxially. The holder main body41is formed with an upper surface411serving as contact surface and a lower surface412serving as a movement restricting surface on the opposite side from the upper surface411. The upper surface411is formed so as to be located at the outer side of the upper projecting portion42and so as to face an end surface (a lower end surface inFIG.1) of the adjusting screw8on the flow passage block2side. The lower surface412is formed so as to be located at the outer side of the lower projecting portion43and so as to face an end surface (an upper end surface inFIG.1) of the spacer7on the actuator5side. In addition, in this embodiment, the lower projecting portion43is provided on the holder main body41by being fitted thereto. However, the present invention is not limited thereto, and for example, the lower projecting portion43may be formed integrally with the holder main body41. The actuator5causes the diaphragm3to be pressed against or separated away from the valve seat24via the diaphragm holder4accommodated in the bonnet6, and thereby, the fluid inflow flow passage21is communicated with or shut off from the fluid outflow flow passage22. The actuator5has a case51that is provided above the bonnet6, a piston52that is slidably accommodated in the case51, a coil spring53serving as a biasing member that pushes the piston52against the flow passage block2side, and a stem54that is moved in the axial direction (the vertical direction inFIG.1) cooperatively with the piston52. The case51is a frame member for accommodating the piston52and the coil spring53. The case51has a first case511serving as an upper having a bottomed cylindrical shape and a second case512serving as a lower case that is joined with the first case511by being threaded thereto. The piston52is slidably accommodated in an accommodating space513that is formed by joining the first case511and the second case512. The coil spring53is accommodated above the piston52. The first case511has a cylindrical circumferential wall511aand a columnar top wall511bthat is provided on one end (the upper end inFIG.1) of the circumferential wall511a. On an inner circumferential surface of other end (lower end inFIG.1) of the circumferential wall511a, an internal thread511cthat is threaded to the second case512is formed. At the center of the top wall511b, a stem guide hole511dis formed so as to penetrate through in the axial direction (the vertical direction inFIG.1) of the stem54. The driving air is introduced into the actuator5from a driving-air supply control unit (not shown) via the stem guide hole511d. In the top wall511b, a ring-shaped groove511eserving as a spring accommodating chamber for accommodating the coil spring53is formed so as to surround the stem guide hole511d. The coil spring53is accommodated in the ring-shaped groove511ein a compressed state such that one end (the upper end inFIG.1) thereof is in contact with a bottom portion of the ring-shaped groove511eand other end (lower end inFIG.1) thereof is in contact with a first piston521of the piston52, which will be described later. In the circumferential wall511a, a through hole511fand a through hole511gfor venting air are formed by penetrating through the circumferential wall511ain the radial direction so as not to interfere with the internal thread511c. The through hole511gis located below the through hole511f. In the top wall511b, a pair of engagement holes511hwith which a third rotary jig for rotating the actuator5is to be engaged are formed so as not to interfere with the stem guide hole511d. The second case512has: a cylindrical circumferential wall512a; a disc-shaped bottom wall512bprovided on one end (lower end inFIG.1) of the circumferential wall512a; and a cylindrical extended portion514that extends from the bottom wall512btoward the flow passage block2side (the lower side inFIG.1). On an outer circumferential surface of the circumferential wall512a, an external thread512cthat is threaded to the internal thread511cis formed. In the circumferential wall512a, a through hole512dfor venting air is formed by penetrating through the circumferential wall512ain the radial direction so as not to interfere with the external thread512c. The through hole511gof the first case511is communicated with the through hole512dof the second case512. In the bottom wall512band the extended portion514, a through hole512einto which the stem54is inserted is formed. On an outer circumferential surface of the extended portion514, an external thread515that is threaded to the bonnet6is provided. The bottom wall512bis formed with a ring-shaped flat contact surface512fthat is located at the outer circumferential side from the extended portion514so as to face the bonnet6. The piston52has the first piston521serving as an upper piston and a second piston522serving as a lower that is located below the first piston521inFIG.1. A counter plate55that is located between the first piston521and the second piston522is fixed on an inner circumferential surface of the first case511. A through hole through which the stem54is inserted is formed at the center of the counter plate55. A first air introduction chamber56is formed between the second piston522and the second case512. A second air introduction chamber57is formed between the first piston521and the counter plate55. One end (the upper end inFIG.1) of the stem54is inserted into the stem guide hole511dof the first case511. The stem54is formed with an axial direction flow passage54a, a first radial flow passage54b, and a second radial flow passage54cfor introducing the driving air into the first air introduction chamber56and the second air introduction chamber57. In addition, in this embodiment, the stem54has a first shaft unit that extends upwards from the center portion of the first piston521and a second shaft unit that is formed separately from the first shaft unit and that extends in the vertical direction from the center portion of the second piston522. However, the present invention is not limited thereto, and for example, the stem54may have a shaft unit that is formed of the first shaft unit and the second shaft unit in an integral form. The axial direction flow passage54ais communicated with the stem guide hole511d. The first radial flow passage54bis formed on a tip end (a lower end inFIG.1) of the axial direction flow passage54a, and thereby, the axial direction flow passage54ais communicated with the first air introduction chamber56. The second radial flow passage54cis formed in the vicinity of the center portion of the axial direction flow passage54a, and thereby, the axial direction flow passage54ais communicated with the second air introduction chamber57. A first communicating chamber58is formed between the first piston521and the first case511. The first communicating chamber58is communicated with the outside through the through hole511f. A second communicating chamber59is formed between the second piston522and the counter plate55. The second communicating chamber59is communicated with the outside through the through hole511gand the through hole512d. An O ring12is interposed between the stem guide hole511dand one end of the stem54. An O ring13is interposed between the first piston521and the first case511. An O ring14is interposed between the counter plate55and the first case511. An O ring15is interposed between the counter plate55and the stem54. An O ring16is interposed between the second piston522and the second case512. An O ring17is interposed between the stem54and the through hole512e. The bonnet6is a cylindrical joint member that joins the flow passage block2and the actuator5. The diaphragm holder4, the adjusting screw8, and the lock nut9are accommodated in the bonnet6. On an outer circumferential surface of the bonnet6, an external thread61that is threaded to the internal thread232of the recessed portion23of the flow passage block2is formed. With such a configuration, the bonnet6is attached to the flow passage block2by threading the internal thread232and the external thread61together. In addition, an outer circumferential surface of the bonnet6is provided with a hexagonal projected portion62that can be engaged with monkey wrench, etc. The hexagonal projected portion62is located on the actuator5side (in other words, above the external thread61) from the external thread61. An inner circumferential surface of the bonnet6located on the actuator5side (above inFIG.1) is formed with an internal thread63. The adjusting screw8, the lock nut9, and the extended portion514of the actuator5are threaded to the internal thread63in this order. An upper end of the bonnet6is formed with a ring-shaped flat positioning surface64that faces the contact surface512fof the actuator5. By threading the external thread515of the extended portion514and the internal thread63of the bonnet6, it is possible to screw the extended portion514of the actuator5into the inner circumferential surface of the bonnet6until the contact surface512fand the positioning surface64are brought into contact. With such a configuration, the actuator5is positioned by the contact between the contact surface512fand the positioning surface64. On a lower end of the bonnet6serving as an end portion located on the flow passage block2side (downward inFIG.1), a ring-shaped annular portion65having the inner diameter that is smaller than the inner diameter of the internal thread63is formed. The holder main body41of the diaphragm holder4is guided in the vertical direction by an inner circumferential surface of the annular portion65. The bonnet6is formed such that the internal thread63and the annular portion65do not overlap with each other in the vertical direction. The ring-shaped spacer7having the inner diameter that is smaller than the inner diameter of the annular portion65is provided between the lower end of the bonnet6and a bottom surface of the recessed portion23of the flow passage block2. An outer circumferential edge of the diaphragm3is retained between the spacer7and the bottom surface of the recessed portion23and is fixed by screwing the bonnet6into the internal thread232of the recessed portion23. The lower projecting portion43of the diaphragm holder4that is brought into contact with the diaphragm3is inserted into an inner circumferential side of the spacer7. The adjusting screw8is a cylindrical position adjusting member for adjusting a valve opening position of the diaphragm3via the diaphragm holder4correspondingly to a screwed amount the adjusting screw8with respect to the internal thread63of the bonnet6. Here, the valve opening position of the diaphragm3refers to the position of the apex of the diaphragm3. In addition, the adjusting screw8is provided along the vertical direction between the lock nut9and the diaphragm holder4. In this embodiment, the stem54of the actuator5and the upper projecting portion42of the diaphragm holder4are inserted in an inner circumferential side of the adjusting screw8so as to come into contact with each other. However, the present invention is not limited thereto, and for example, either one of the stem54and the upper projecting portion42may be inserted into the inner circumferential side of the adjusting screw8. The adjusting screw8has: a cylindrical large-diameter portion81serving as a threaded portion that is threaded to the internal thread63; and a cylindrical small-diameter portion82that is located at the flow passage block2side (downward inFIG.1) of the large-diameter portion81and that has the outer diameter that is smaller than the outer diameter of the large-diameter portion81. The large-diameter portion81and the small-diameter portion82are formed coaxially. On an outer circumferential surface of the large-diameter portion81, an external thread811that is threaded to the internal thread63of the bonnet6is formed. An end surface (an upper end surface inFIG.1) of the large-diameter portion81on the actuator5side is in contact with the lock nut9. The small-diameter portion82is provided such that a tip end (a lower end inFIG.1) of the small-diameter portion82is inserted into the annular portion65of the bonnet6. An end surface (a lower end surface inFIG.1) of the small-diameter portion82on the flow passage block2side is in contact with the upper surface411serving as contact surface of the holder main body41of the diaphragm holder4. As shown inFIGS.1and2, on an inner circumferential surface of the adjusting screw8, first engagement portions83to which the first rotary jig10for rotating the adjusting screw8is to be engaged are formed. As shown inFIG.2, the first engagement portions83are formed of six semicircular recessed grooves831that are formed in the inner circumferential surface of the adjusting screw8at predetermined intervals in a top view. The first rotary jig10is a hexagonal wrench. Corner portions of the first rotary jig10can respectively be received in the six recessed grooves831. In this embodiment, the recessed grooves831are provided so as to extend to the small-diameter portion82by penetrating through the large-diameter portion81in the vertical direction. However, the present invention is not limited thereto, and for example, the recessed grooves831may be provided so as to penetrate only through the large-diameter portion81in the vertical direction, or the large-diameter portion81may be provided only at a part of the large-diameter portion81in the vertical direction. As the adjusting screw8is rotated in one direction (for example, in the clockwise direction) by using the first rotary jig10, the adjusting screw8is moved toward the flow passage block2side (downward inFIG.1) while being screwed into the internal thread63of the bonnet6. By doing so, the diaphragm holder4is moved toward the flow passage block2side (downward inFIG.1) together with the adjusting screw8. As the diaphragm3is pushed toward the flow passage block2side (downward inFIG.1) by the movement of the diaphragm holder4, a gap formed between the apex of the diaphragm3and the valve seat24(in other words, the Cv value) is made smaller. On the other hand, as the adjusting screw8is rotated in the other direction (for example, in the counterclockwise direction) by using the first rotary jig10, the adjusting screw8is moved toward the actuator5side (upward inFIG.1) while being loosened with respect to the internal thread63of the bonnet6. By doing so, the diaphragm holder4is moved toward the actuator5side (upward inFIG.1) by a restoring force of the diaphragm3, and thereby, the gap formed between the apex of the diaphragm3and the valve seat24(in other words, the Cv value) is increased. As described above, the adjusting screw8can adjust the Cv value at the time of assembly of the valve device1by adjusting the valve opening position of the diaphragm3via the diaphragm holder4correspondingly to the screwed amount of the adjusting screw8with respect to the internal thread63of the bonnet6. Therefore, when the valve device1is fully opened, it is possible to suppress the variation in the flow rate of the fluid flowing through the fluid inflow flow passage21and the fluid outflow flow passage22. Furthermore, the movement of the diaphragm holder4toward the flow passage block2side (downward inFIG.1) is restricted by the contact between the lower surface412serving as a movement restricting surface of the holder main body41and the upper surface of the spacer7. With such a configuration, it is possible to suppress both of excessive screwing of the adjusting screw8into the internal thread63while making the gap formed between the apex of the diaphragm3and the valve seat24(in other words, the Cv value) smaller excessively and excessive pressing of the diaphragm3against the valve seat24by the diaphragm holder4when the valve device1is closed. The lock nut9is a ring-shaped lock member that locks the adjusting screw8after the valve opening position of the diaphragm3has been adjusted. In addition, the lock nut9is provided along the vertical direction between the extended portion514of the actuator5and the adjusting screw8. In this embodiment, the stem54of the actuator5is inserted through the inner circumferential side of the lock nut9. However, the present invention is not limited thereto, and for example, the upper projecting portion42of the diaphragm holder4may be inserted through the lock nut9, or the stem54and the upper projecting portion42may be inserted so as to come into contact with each other. On an outer circumferential surface of the lock nut9, an external thread91that is threaded to the internal thread63of the bonnet6is formed. An end surface (a lower end surface inFIG.1) of the lock nut9on the flow passage block2side comes into contact with an end surface of the large-diameter portion81of the adjusting screw8. As shown inFIGS.1,3, and4, in an end surface (an upper end surface inFIG.1) of the lock nut9on the actuator5side, second engagement portions92with which the second rotary jig11for rotating the lock nut9is to be engaged are formed. As shown inFIGS.1and3, the second engagement portions92are formed of a pair of engagement holes921. As shown inFIG.4, the second rotary jig11has a cylindrical jig main body111, a hexagonal projected portion112that is provided on an outer circumferential surface of the one end of the jig main body111and that can engage with the hexagonal wrench, and a pair of projections113that project from other end of the jig main body111and that can engage with a pair of engagement holes921. Because the jig main body111of the second rotary jig11is formed with a through hole through which the first rotary jig10can be inserted, it is possible to use the first rotary jig10by inserting it through an inner circumferential side of the jig main body111of the second rotary jig11. The lock nut9is screwed into the internal thread63of the bonnet6by being rotated in one direction (for example, in the clockwise direction) by the second rotary jig11. By doing so, the lock nut9can lock the adjusting screw8, and so, it is possible to suppress the variation in the Cv value due to the loosening of the adjusting screw8. Therefore, when the valve device1is fully opened, it is possible to further suppress the variation in the flow rate of the fluid flowing through the fluid inflow flow passage21and the fluid outflow flow passage22. In addition, the first engagement portions83that engage with the first rotary jig10are formed in a region of the adjusting screw8that does not overlap with the lock nut9in a top view, and the second engagement portions92that engage with the second rotary jig11are formed in a region of the lock nut9that overlaps with the adjusting screw8in a top view. With such a configuration, the first rotary jig10can engage with the first engagement portions83of the adjusting screw8without interfering with the lock nut9, and at the same time, the second rotary jig11through which the first rotary jig10is inserted can engage with the second engagement portions92of the lock nut9(seeFIG.6). In a state in which the rotation of the adjusting screw8is restricted by the first rotary jig10, the lock nut9is screwed by the second rotary jig11to tighten and lock the adjusting screw8with a reliability. By doing so, the rotation (co-rotation) of the adjusting screw8caused by screwing the lock nut9can be suppressed, and therefore, it is possible to prevent the Cv value from being changed after the adjustment. Therefore, when the valve device1is fully opened, it is possible to further suppress the variation in the flow rate of the fluid flowing through the fluid inflow flow passage21and the fluid outflow flow passage22. The first engagement portions83of the adjusting screw8are located at the radially inward side from the second engagement portions92of the lock nut9. With such a configuration, the first rotary jig10can engage with the first engagement portions83that are located at the radially inward side from the second engagement portions92by being inserted into the inner circumferential side of the lock nut9formed between the pair of engagement holes921(seeFIG.6). As described above, it is possible to use the first rotary jig10and the second rotary jig11by engaging them with the first engagement portions83and the second engagement portions92, respectively, at the same time without causing interference therebetween. In this embodiment, the first engagement portions83and the second engagement portions92are formed in the region of the adjusting screw8that does not overlap with the lock nut9in a top view and in the region of the lock nut9that overlaps with the adjusting screw8in a top view, respectively. However, the present invention is not limited thereto, and for example, the first engagement portions83and the second engagement portions92may be formed in the region of the adjusting screw8that overlaps with the lock nut9in a top view and in the region of the lock nut9that overlaps with the adjusting screw8in a top view, respectively. Furthermore, in a state in which the contact surface512fof the actuator5and the positioning surface64of the bonnet6are in brought into contact by the threading between the external thread515of the extended portion514of the actuator5and the internal thread63of the bonnet6, a clearance is formed between the extended portion514and the lock nut9. With such a configuration, the contact between the extended portion514and the lock nut9can be avoided, and therefore, it is possible to perform the positioning of the actuator5with a high accuracy by causing the contact surface512fand the positioning surface64to come into contact. In addition, it is possible to make the dimension of the valve device1in the vertical direction constant. Next, a manufacturing method of the valve device1for manufacturing the valve device1will be described with reference toFIGS.5and6. FIG.5is a flow chart showing the manufacturing method of the valve device1for manufacturing the valve device1.FIG.6is a schematic view showing a state in which the adjusting screw8is being locked by screwing the lock nut9by using the second rotary jig11in a state in which the rotation of the adjusting screw8is restricted by the first rotary jig10. As shown inFIG.5, in Step S1, the diaphragm3is first arranged on the flow passage block2. Specifically, in Step S1, the diaphragm3is arranged on the bottom surface of the recessed portion23of the flow passage block2such that both of the fluid inflow flow passage21and the fluid outflow flow passage22are covered by the diaphragm3. Next, in Step S2, the bonnet6is attached to the flow passage block2. Specifically, Step S2includes a spacer mounting step in which the spacer7is mounted on the diaphragm3so as to cover the outer circumferential edge of the diaphragm3and a bonnet screwing step in which the bonnet6is screwed into the recessed portion23of the flow passage block2to fix the spacer7and the outer circumferential edge of the diaphragm3. Next, in Step S3, the diaphragm holder4is arranged on the bonnet6so as to come into contact with the diaphragm3. Next, in Step S4, the valve opening position of the diaphragm3is adjusted via the diaphragm holder4by threading the adjusting screw8to the internal thread63of the bonnet6by using the first rotary jig10. By doing so, it is possible to adjust the Cv value during the assembly of the valve device1. Next, in Step S5, the adjusting screw8is locked by screwing the lock nut9into the internal thread63of the bonnet6by using the second rotary jig11. Specifically, in Step S5, as shown inFIG.6, in a state in which the rotation of the adjusting screw8is restricted by the first rotary jig10, the adjusting screw8is tightened and locked with a reliability by screwing the lock nut9by using the second rotary jig11. By doing so, the rotation (the co-rotation) of the adjusting screw8caused by screwing the lock nut9can be suppressed, and therefore, it is possible to prevent the Cv value from being changed after the adjustment. Therefore, when the valve device1is fully opened, it is possible to further suppress the variation in the flow rate of the fluid flowing through the fluid inflow flow passage21and the fluid outflow flow passage22. Finally, in Step S6, the actuator5is attached to the bonnet6. Specifically, in Step S6, the extended portion514of the actuator5in an assembly state is screwed to the internal thread63of the bonnet6to cause the contact surface512fof the actuator5to come into contact with the positioning surface64of the bonnet6, and thereby, it is possible to perform the positioning of the actuator5. Next, operation of the valve device1will be described. In a case in which the driving-air supply control unit supplies the driving air to the actuator5of the valve device1via the stem guide hole511d, the driving air is introduced to the first air introduction chamber56via the axial direction flow passage54aand the first radial flow passage54band is introduced to the second air introduction chamber57via the axial direction flow passage54aand the second radial flow passage54c. With such a configuration, the piston52is moved upward inFIG.1together with the stem54against the biasing force exerted by the coil spring53such that volumes of the first air introduction chamber56and the second air introduction chamber57are increased. The diaphragm3is then moved away from the valve seat24by moving upwards together with the diaphragm holder4by its own restoring force. In other words, the diaphragm3opens the fluid inflow flow passage21by the upward movement of the piston52and the stem54. Therefore, the fluid such as process gas, etc. is supplied to the fluid outflow flow passage22from the fluid inflow flow passage21via a gap formed between the valve seat24and the diaphragm3. On the other hand, in a case in which the driving-air supply control unit is not supplying the driving air to the actuator5of the valve device1via the stem guide hole511d, the piston52is moved downward inFIG.1together with the stem54by the biasing force exerted by the coil spring53. The diaphragm3is then pressed against the valve seat24via the diaphragm holder4by the downward movement of the stem54. In other words, the diaphragm3closes the fluid inflow flow passage21by the movement of the piston52, the stem54, and the diaphragm holder4. Therefore, the vaporized fluid such as process gas, etc. is not supplied from the fluid inflow flow passage21to the fluid outflow flow passage22. The volumes of the first air introduction chamber56and the second air introduction chamber57are reduced along with the movement of the piston52and the stem54. At this time, the air in the first air introduction chamber56is discharged to the driving-air supply control unit via the first radial flow passage54b, the axial direction flow passage54a, and the stem guide hole511d, and the air in the second air introduction chamber57is discharged to the driving-air supply control unit via the second radial flow passage54c, the axial direction flow passage54a, and the stem guide hole511d. As described above, in the driving-air supply control unit, by controlling the supply of the driving air to the actuator5of the valve device1, it is possible to switch the opened state and closed state of the diaphragm3with respect to the valve seat24. Therefore, according to the valve device1as described above, it is possible to control the supply of the fluid from the fluid inflow flow passage21to the fluid outflow flow passage22. In this embodiment, the valve device1is a valve device of a constantly closed type (normally closed type). However, the present invention is not limited thereto, and for example, the valve device1may be a valve device of a constantly opened type (normally opened type). Next, an example of the fluid control device to which the valve device1according to this embodiment is applied will be described with reference toFIG.7. FIG.7is a perspective view showing an example of the fluid control device to which the valve device1is applied. The fluid control device shown inFIG.7is provided with a metallic base plate BS that is arranged along the width directions W1and W2and that is extended in the longitudinal directions G1and G2. W1refers to the front side direction, W2refers to the back side direction, G1refers to the upstream side direction, and G2refers to the downstream side direction. Various fluid apparatuses991A to991E are mounted on the base plate BS via a plurality of flow passage blocks992, and flow passages (not shown) through which the fluid flows from the upstream side G1toward the downstream side G2are respectively formed by the plurality of flow passage blocks992. In the above, “the fluid apparatus” is an apparatus that is used for the fluid control device for controlling the flow of the fluid, and such an apparatus includes a body that defines the fluid flow passages and has at least two flow passage openings that open at a surface of the body. Specifically, the open/close valves (two-way valves)991A, regulators991B, pressure gauges991C, open/close valves (three-way valves)991D, mass flow controllers991E, and so forth are included; however, the present invention is not limited thereto. An introduction pipe993is connected to the flow passage opening of the above-described flow passages (not shown) on the upstream side. The valve device1according to this embodiment can be applied to the various valve devices such as the open/close valves991A and991D, the regulators991B, and so forth described above. Next, operational advantages according to this embodiment will be described. The valve device1according to this embodiment is provided with: the flow passage block2in which the fluid inflow flow passage21is formed; the diaphragm3configured to open and close the fluid inflow flow passage21; the diaphragm holder4configured to hold the diaphragm3; the actuator5configured to push down the diaphragm3via the diaphragm holder4; the cylindrical bonnet6formed with the internal thread63on the inner circumferential surface, the bonnet6being configured to join the flow passage block2and the actuator5; the cylindrical adjusting screw8threaded to the internal thread63, the adjusting screw8being configured to come into contact with the diaphragm holder4to adjust the valve opening position of the diaphragm3; and the annular lock nut9configured to lock the adjusting screw8by being screwed into the internal thread63. The fluid control device according to this embodiment is the fluid control device including the plurality of fluid apparatuses arranged from the upstream side toward the downstream side, wherein the plurality of fluid apparatuses includes the valve device1described above. The manufacturing method of the valve device1for manufacturing the valve device1according to this embodiment includes: a diaphragm arranging step of arranging the diaphragm3to the flow passage block2in which the fluid inflow flow passage21is formed, the diaphragm3being configured to open and close the fluid inflow flow passage21; a bonnet attaching step of attaching the cylindrical bonnet6to the flow passage block2, the bonnet6being formed with the internal thread63on the inner circumferential surface thereof; a diaphragm-holder arranging step of arranging the diaphragm holder4on the bonnet6so as to come into contact with the diaphragm3; a valve-opening-position adjusting step of adjusting the valve opening position of the diaphragm3via the diaphragm holder4by threading the cylindrical adjusting screw8to the internal thread63; a locking step of locking an adjusting screw by screwing the ring-shaped lock nut9to the internal thread63; and an actuator attaching step of attaching the actuator5to the bonnet6, the actuator5being configured to push down the diaphragm3via the diaphragm holder4. According to such a configuration, the adjusting screw8can adjust the adjusting screw8can adjust the Cv value at the time of assembly of the valve device1by adjusting the valve opening position of the diaphragm3via the diaphragm holder4in accordance with the screwed amount of the adjusting screw8to the internal thread63of the bonnet6. In addition, because the adjusting screw8can be tightened and locked by screwing the lock nut9, it is possible to suppress the variation in the Cv value due to the loosening of the adjusting screw8. Therefore, when the valve device1is fully opened, it is possible to further suppress the variation in the flow rate of the fluid flowing through the fluid inflow flow passage21and the fluid outflow flow passage22. In addition, in this embodiment, the first engagement portions83are formed in the region of the adjusting screw8that does not overlap with the lock nut9, the first engagement portions83being configured such that the first rotary jig10is engaged with the first engagement portions83, and the second engagement portions92are formed in the lock nut9, the second engagement portions92being configured such that the second rotary jig11is engaged with the second engagement portions92. According to such a configuration, the first rotary jig10can engage with the first engagement portions83of the adjusting screw8without interfering with the lock nut9, and at the same time, the second rotary jig11can engage with the second engagement portions92of the lock nut9. In addition, in this embodiment, the first engagement portions83are positioned at the radially inward side from the second engagement portions92. According to such a configuration, the first rotary jig10can engage with the first engagement portions83that are located at the radially inward side from the second engagement portions92by being inserted into the inner circumferential side of the lock nut9formed between the pair of engagement holes921. In addition, in this embodiment, the actuator5has the case51, the case51has: the cylindrical extended portion514provided so as to extend toward the flow passage block2side, the extended portion514being formed with the external thread515on the outer circumferential surface, and the external thread515being configured to be threaded to the internal thread63; and the ring-shaped contact surface512flocated at the outer circumferential side from the extended portion514, the contact surface512ffacing the bonnet6, the bonnet6is formed with the ring-shaped positioning surface64facing the contact surface512f, and the clearance is formed between the extended portion514and the lock nut9in a state in which the contact surface512fand the positioning surface64are brought into contact by threading the external thread515and the internal thread63. According to such a configuration, the contact between the extended portion514and the lock nut9can be avoided, and therefore, it is possible to perform the positioning of the actuator5with a high accuracy by causing the contact surface512fand the positioning surface64to come into contact. In addition, it is possible to make the dimension of the valve device1in the vertical direction constant. In addition, in this embodiment, the annular portion65is formed on the lower end of the bonnet6located on the flow passage block2side, the annular portion65having the inner diameter that is smaller than the inner diameter of the internal thread63, the ring-shaped spacer7is provided between the lower end and the flow passage block2, the spacer7having the inner diameter that is smaller than the inner diameter of the annular portion65, the diaphragm holder4has: the holder main body41having the lower surface412facing the spacer7, the holder main body41being configured to be guided by the annular portion65; the lower projecting portion43configured to be inserted into the inner circumferential side of the spacer7, the lower projecting portion43being located at the flow passage block2side from the holder main body41, and the movement of the diaphragm holder4toward the flow passage block2side is restricted by the contact between the lower surface412of the holder main body41and the spacer7. According to such a configuration, it is possible to suppress excessive screwing of the adjusting screw8into the internal thread63while making the gap formed between the apex of the diaphragm3and the valve seat24(in other words, the Cv value) smaller excessively In addition, in this embodiment, in the locking step, the adjusting screw8is locked by threading the lock nut9to the internal thread63in a state in which the rotation of the adjusting screw8is restricted. According to such a configuration, the rotation (the co-rotation) of the adjusting screw8caused by screwing the lock nut9can be suppressed, and therefore, it is possible to prevent the Cv value from being changed after the adjustment. Therefore, when the valve device1is fully opened, it is possible to further suppress the variation in the flow rate of the fluid flowing through the fluid inflow flow passage21and the fluid outflow flow passage22. Embodiments of this invention were described above, but the above embodiments are merely examples of applications of this invention, and the technical scope of this invention is not limited to the specific constitutions of the above embodiments. (First Modification) Next, a valve device1aaccording to a first modification will be described with reference toFIG.8. In this modification, the description of the configurations that are the same as those in the above-described embodiment is omitted, and the differences with respect to the embodiment described above will be mainly described. FIG.8is a sectional view showing a relevant portion of the valve device1aaccording to the first modification. In the above-described embodiment, the screwed amount of the adjusting screw8is restricted by the contact between the lower surface412of the holder main body41and the spacer7. However, the present invention is not limited thereto, and for example, as shown inFIG.8, the screwed amount may be restricted by the contact between a middle diameter portion84serving as a screwed amount restricting portion of the adjusting screw8and the annular portion65. As shown inFIG.8, in this modification, the adjusting screw8has, in addition to the large-diameter portion81and the small-diameter portion82, the ring-shaped middle diameter portion84having the outer diameter that is smaller than the outer diameter of the large-diameter portion81, but larger than the outer diameter of the small-diameter portion82. The middle diameter portion84is provided between the large-diameter portion81and the small-diameter portion82along the vertical direction so as to face the annular portion65of the bonnet6. With the valve device1aaccording to this modification, similarly to the above-described embodiment, it is possible to suppress excessive screwing of the adjusting screw8into the internal thread63. In addition, it is possible to make the ring-shaped spacer7to have the inner diameter that is same as the inner diameter of the annular portion65, and it is possible to omit the lower projecting portion43of the diaphragm holder4in the above-described embodiment, thereby achieving simplification of the configuration of the diaphragm holder4(seeFIG.8). (Second Modification) Next, a valve device1baccording to a second modification will be described with reference toFIG.9. In this modification, the description of the configurations that are the same as those in the above-described embodiment is omitted, and the differences with respect to the embodiment described above will be mainly described. FIG.9is a sectional view showing a relevant portion of the valve device1baccording to the second modification. In the above-described embodiment, the adjusting screw8and the lock nut9are provided so as not be overlapped along the vertical direction. However, the present invention is not limited thereto, and for example, as shown inFIG.9, the adjusting screw8and the lock nut9may be provided so as to be overlapped along the vertical direction. As shown inFIG.9, in this modification, the first engagement portions83are formed of a pair of engagement holes831athat are formed in an end surface of the adjusting screw8on the actuator5side. The second engagement portions92are formed of six semicircular recessed grooves921athat are formed in an inner circumferential surface of the lock nut9at predetermined intervals in a top view. As described above, the first engagement portions83and the second engagement portions92may not necessarily be formed of the six semicircular recessed grooves831and the pair of engagement holes921, respectively. With the valve device1baccording to this modification, by providing the adjusting screw8and the lock nut9so as to be overlapped along the vertical direction, it is possible to reduce the dimension of the bonnet6accommodating the adjusting screw8and the lock nut9in the vertical direction. Therefore, it is possible to achieve reduction in the size of the valve device1. This application claims priority based on Japanese Patent Application No. 2019-141073 filed with the Japan Patent Office on Jul. 31, 2019, the entire contents of which are incorporated into this specification. | 44,857 |
11859734 | DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS Before explaining at least one embodiment of the inventive concept(s) in detail by way of exemplary drawings, experimentation, results, and laboratory procedures, it is to be understood that the inventive concept(s) is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings, experimentation and/or results. The inventive concept(s) is capable of other embodiments or of being practiced or carried out in various ways. The language used herein is intended to be given the broadest possible scope and meaning; and the embodiments are meant to be exemplary—not exhaustive. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting. Unless otherwise defined, scientific and technical terms used in connection with the presently disclosed and claimed inventive concept(s) shall have the meanings commonly understood by those of ordinary skill in the art. Further, unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular. The foregoing techniques and procedures are generally performed according to conventional methods well known in the art and as described in various general and more specific references cited and discussed throughout the present specification. The nomenclatures utilized in connection with, and the laboratory procedures and techniques of, analytical chemistry, synthetic organic chemistry, and medicinal and pharmaceutical chemistry described herein are those well-known and commonly used in the art. Standard techniques are used for chemical syntheses and chemical analyses. All the articles, compositions and/or methods disclosed and claimed herein can be made and executed without undue experimentation, given the present disclosure. While the articles, compositions and methods of the inventive concept(s) have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the articles, compositions and/or methods and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit and scope of the inventive concept(s). All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the inventive concept(s) as defined by the appended claims. As utilized under the present disclosure, the following terms, unless otherwise indicated, shall be understood to have the following meanings: The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” The use of the term “or” in the claims is used to mean “and/or” unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and “and/or.” Throughout this application, the term “about” is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects. The use of the term “at least one” will be understood to include one as well as any quantity more than one, including but not limited to, 2, 3, 4, 5, 10, 15, 20, 40, 50, 100, etc. The term “at least one” may extend up to 100 or 1000 or more, depending on the term to which it is attached; in addition, the quantities of 100/1000 are not to be considered limiting, as higher limits may also produce satisfactory results. In addition, the use of the term “at least one of X, Y, and Z” will be understood to include X alone, Y alone, and Z alone, as well as any combination of X, Y, and Z. As used in this specification and claim(s), the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps. The term “or combinations thereof” as used herein refers to all permutations and combinations of the listed items preceding the term. For example, “A, B, C, or combinations thereof” is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, MB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context. As used herein, the term “reagent” refers to any element, compound, ion, or molecule with which any portion of the fluid sample, or complex derived from the fluid sample, may react, for example to form a detectable signal. The reagents may be, but are not limited to, indicator dyes, metals, polymers, enzymes, proteins, peptides, nucleic acids, nucleotides, saccharides, lipids, antibodies, electrochemically-reactive substances, chemicals, radioactive elements or compounds, labels, or other analytes known to persons having ordinary skill in the art. The reagents may be placed on or incorporated into carriers (substrates) such as papers, membranes, polymers, or other carriers known in the art. The reagents may be dry, or wet. More than one reagent may be placed on a carrier. Typical chemical reactions which involve the reagents include, but are not limited to, dye binding, enzymatic, immunologic, oxidation or reduction chemistries. In the following detailed description of embodiments of the inventive concept, numerous specific details are set forth in order to provide a more thorough understanding of the inventive concept. However, it will be apparent to one of ordinary skill in the art that the inventive concept within the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the instant disclosure. Finally, as used herein any reference to “one embodiment” or “an embodiment” means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment. The volume of the fluid sample which the microfluidic device can receive can vary widely, for example between about 10 μL to about 1200 μL, and is usually in a range from about 10 μL to about 40 μL. The sample volumes which the fluid sample is apportioned into can vary, but typically, such samples have volumes of about 1 μL to 20 μL per reagent, although they may range from 0.1 μL to 200 μL per reagent, for example, depending on the type of fluid sample and the number of portions into which the fluid sample is separated. The microfluidic device, in non-limiting embodiments, may be made of plastics such as polycarbonate, polystyrene, polyacrylates, or polyurethane, alternatively or in addition to, they can be made from silicates, and/or glass. When moisture absorption by the plastic is not a substantial concern, the plastics preferably used may include, but are not limited to, ABS, acetals, acrylics, acrylonitrile, cellulose acetate, ethyl cellulose, alkylvinylalcohols, polyaryletherketones, polyetheretherketones, polyetherketones, melamine formaldehyde, phenolic formaldehyde, polyamides (e.g., nylon 6, nylon 66, nylon 12), polyamide-imide, polydicyclopentadiene, polyether-imides, polyethersulfones, polyimides, polyphenyleneoxides, polyphthalamide, methylmethacrylate, polyurethanes, polysulfones, polyethersulfones and vinyl formal. When moisture absorption is of concern, preferably the plastics used to make the chip include, but are not limited to: polystyrene, polypropylene, polybutadiene, polybutylene, epoxies, Teflon™, PET, PTFE and chloro-fluoroethylenes, polyvinylidene fluoride, PE-TFE, PE-CTFE, liquid crystal polymers, Mylar®, polyester, LDPE, HDPE, polymethylpentene, polyphenylene sulfide, polyolefins, PVC, and chlorinated PVC. In one embodiment, the principle of operation of the system of the presently claimed and disclosed inventive concepts is that the sample is provided to a reagent in a reagent area (reaction chamber) through the use of a unidirectional hydrophilic capillary flow principle where the sample flows from a sample entry port, through the reaction chamber, towards an exit port. The microfluidic device may have a vent which is open to air during flow of the fluid sample. The valves disclosed herein are for controlling flow, stopping, advancing, or inhibiting “backflow” of the subsamples therein (as explained below for example). Described herein, and shown in the accompanying figures, are several non-limiting embodiments of microfluidic devices and sample analysis systems of the presently claimed and disclosed inventive concepts which may be used for analyzing a fluid sample according to the presently claimed and disclosed inventive concepts. The fluid sample is generally from a biological source. A “liquid” refers to any substance in a fluid state having no fixed shape but a substantially fixed volume. The microfluidic devices of the presently claimed and disclosed inventive concepts typically use smaller channels (referred to herein as microchannels or microconduits) than have been used by previous workers in the field. In particular, the microchannels (microconduits) used in the presently claimed and disclosed inventive concept(s) typically have widths in the range of about 5 μm to 1000 μm, such as about 10 μm to 500 μm, whereas channels an order of magnitude larger have typically been used by others when capillary forces are used to move fluids. Depths of the microchannels are typically in a range of 5 μm to 100 μm. The minimum dimension for the microchannels is generally about 5 μm, unless it is desired to use smaller channels to filter out components in the sample being analyzed. It is also possible to control movement of the samples in the microchannels by treating the microchannels to become either hydrophilic or hydrophobic depending on whether fluid movement is desired or not. The resistance to movement can be overcome by a pressure difference, for example, by applying pumping, vacuum, electroosmosis, heating, or additional capillary force. As a result, liquids can move from one region of the device to another as required for the analysis being carried out. The microfluidic devices of the presently claimed and disclosed inventive concepts, also referred to herein as “chips” or “microfluidic chips,” are generally small and flat, typically, but not limited to, about 0.5 to 2 square inches (12.5 to 50 mm2) or disks having, but not limited to, a radius of about 15 to 60 mm. The volume of apportioned fluid sample introduced into a particular microfluidic circuit will be small. By way of non-limiting example, the sample typically will contain only about 0.1 to 10 μL for each assay, although the total volume of a specimen may range from 10 to 200 μL. In one embodiment, the microfluidic device of the presently claimed and disclosed inventive concepts comprises a square or rectangular strip or card, or disk. The microfluidic devices (chips) used in the presently claimed and disclosed inventive concepts generally are intended to be disposable after a single use. Generally, disposable chips will be made of inexpensive materials to the extent possible, while being compatible with the reagents and the samples to be analyzed. The microchannels of the microfluidic devices described herein typically are hydrophilic, which in one embodiment is defined regarding the contact angle formed at a solid surface by a liquid sample or reagent. Typically, a surface is considered hydrophilic if the contact angle is less than 90° and hydrophobic if the contact angle is greater than 90°. Plasma induced polymerization may be carried out at the surface of the passageways. The microfluidic devices of the presently claimed and disclosed inventive concepts may also be made with other methods used to control the surface energy of the capillary (microchannel) walls, such as coating with hydrophilic or hydrophobic materials, grafting, or corona treatments. The surface energy of the capillary walls may be adjusted, i.e., the degree of hydrophilicity or hydrophobicity, for use with the intended sample fluid, for example, to prevent deposits on the walls of a hydrophobic passageway or to assure that none of the liquid is left in a passageway. For most passageways in the presently claimed and disclosed inventive concepts, the surface is generally hydrophilic since the liquid tends to wet the surface and the surface tension force causes the liquid to flow in the passageway. For example, the surface energy of capillary passageways can be adjusted by known methods so the contact angle of water is between 10° to 60° when the passageway is to contact whole blood or a contact angle of 25° to 80° when the passageway is to contact urine. Since a fluid sample may be introduced into the microfluidic device in several ways, the actual shape of the opening in the sample entry port may vary. The shape of the opening is not considered critical to the performance, since several shapes may be satisfactory. For example, it may be merely a circular opening into which the sample is placed. Alternatively, the opening may be tapered to engage a corresponding shape in a pipette, capillary, or outlet which deposits the sample. Such ports may be sealed closed so nothing can enter the microfluidic chip until the port is engaged by the device holding the sample fluid, such as a syringe or pipette. Depending on the carrier type, the sample may be introduced by a positive pressure, as when a plunger is used to force the sample into the entry port. Alternatively, the sample may be merely placed at the opening of the entry port and capillary action used and atmospheric pressure to pull or push the sample into the microfluidic device. Excess sample is preferably not to be left on a surface however, since cross-contamination may occur. Also, in alternate embodiments, the sample may be placed at the opening of the entry port and a vacuum used to pull the sample into the microfluidic chip. As has been discussed, when the opening is small, sufficient capillary forces are created by the interaction of the passage walls and the surface tension of the liquid. Typically, biological samples contain water and the walls of the entry port and associated passageways will be hydrophilic so the sample will be drawn into the microfluidic chip even absent added pressure. The microfluidic device in certain embodiments contains mechanisms or means for separating cellular components from the plasma. For example, a separation area may contain membranes or glass fibers for separating red blood cells from plasma so they do not interfere with the analysis of plasma. One or more blood anti-coagulants (e.g., heparin, EDTA, oxalates, sodium citrate, acid citrate dextrose, and sodium fluoride/potassium-oxalate) may be included in the microchannel, reagent area, or elsewhere to prevent coagulation, and hemolytic reagents may be included to cause lysis of cells. Any of the chambers or microchannels of the microfluidic device may comprise microstructures known in the art used to assure uniform contact and mixing of the liquid sample with a reagent or other agent disposed in the reagent area or in the microchannel. In some cases, the reagents are liquids coated on a porous support and dried. For example, the microstructures may comprise an array of posts disposed in a reagent area so the liquid sample must pass from the entry port in a non-linear, non-direct, direction. The liquid is constantly forced to change direction as it passes through the array of posts. Each of the posts may contain one or more wedge-shaped cutouts which facilitate the movement of the liquid as discussed in U.S. Pat. No. 6,296,126, for example. Other types of microstructures which are useful are known to persons having ordinary skill in the art and include (but are not limited to) three-dimensional post shapes with cross-sectional shapes that can be circles, stars, triangles, squares, pentagons, octagons, hexagons, heptagons, ellipses, crosses or rectangles or combinations thereof. Microstructures with two-dimensional shapes such as a ramp leading to reagents on plateaus may also be useful. Microfluidic devices of the presently claimed and disclosed inventive concepts have many applications. Analyses may be carried out on samples of many fluids of biological origin which are fluids or have been fluidized including, but not limited to, blood, plasma, serum, urine, bladder wash, saliva, sputum, spinal fluid, intestinal fluid, intraperitoneal fluid, food, cystic fluids, ascites, sweat, tears, feces, semen, nipple aspirates, and pus. As noted above, blood is of particular interest. Also included are processed biological fluids such as milk, juices, wines, beer, and liquors. Fluids of non-biological origin or which may be contaminated, such as water, are also included. A sample of the fluid to be tested is deposited in the entry port of the microfluidic device and apportioned into several subsamples which are distributed into a plurality of reaction chambers (reagent areas) to react with a reagent therein and to be analyzed after the reaction. Biological samples analyzed may be obtained from any biological sample including humans or any other mammal, birds, fish, reptiles, amphibians, insects, crustaceans, marine animals, plants, fungi, and microorganisms. The reacted sample will be assayed for the substance, or analyte of interest. The fluid sample may be assessed for contamination microorganisms such asE. coli, Pseudomonassp.,H. pylori, Streptococcussp.,Chlamydiaand mononucleosis pathogens. Metals which may be detected include, but are not limited to, iron, manganese, sodium, potassium, lithium, calcium, and magnesium. In many applications, it is desired to measure a color, light or wavelength emission developed by the reaction of reagents with the sample fluid and which may be measured or detected by analyzers known to those of ordinary skill in the art. It is also feasible to make electrical measurements of the sample, using electrodes positioned in the small wells in the chip. Examples of such analyses include electrochemical signal transducers based on amperometric, impedimetric, or potentimetric detection methods. Examples include the detection of oxidative and reductive chemistries and the detection of binding events. It is contemplated that virtually any reagent used in the fields of biological, chemical, or biochemical analyses could be used in the microfluidic devices of the presently claimed and disclosed inventive concepts. Reagents may undergo changes whereby the intensity, nature, frequency, or type of the signal generated is proportional to the concentration of the analyte measured in the clinical specimen. These reagents may contain indicator dyes, metals, enzymes, polymers, antibodies, electrochemically reactive ingredients and various other chemicals placed onto carriers (also referred to herein as reagent substrates). Carriers often used are papers, membranes or polymers with various sample uptake and transport properties. Liquid reagents, when used, are preferably isolated by barrier materials which prevent migration of water throughout the device, thus avoiding changes in the concentration through transpiration or evaporation and preventing moisture from reaching the dry reagents. Any method of detecting and measuring an analyte in a liquid sample can be used in the microfluidic devices of the presently claimed and disclosed inventive concepts. A variety of assays for detecting analytes are well known in the art and include, for example, enzyme inhibition assays, antibody stains, latex agglutination, and immunoassays, e.g., radioimmunoassay. The term “antibody” herein is used in the broadest sense and refers to, for example, intact monoclonal antibodies, polyclonal antibodies, multispecific antibodies (e.g., bispecific antibodies), and to antibody fragments that exhibit the desired biological activity (e.g., antigen-binding). The antibody can be of any type or class (e.g., IgG, IgE, IgM, IgD, and IgA) or sub-class (e.g., IgG1, IgG2, IgG3, IgG4, IgA1 and IgA2). Immunoassays as noted, including radioimmunoassay and enzyme-linked immunoassays, are useful in the methods of the presently claimed and disclosed inventive concepts. A variety of immunoassay formats, including, for example, competitive and non-competitive immunoassay formats, antigen capture assays and two-antibody sandwich assays can be used in the methods of the invention. Enzyme-linked immunosorbent assays (ELISAs) can be used in the presently claimed and disclosed inventive concepts. With an enzyme immunoassay, an enzyme is typically conjugated to the second antibody, generally by means of glutaraldehyde or periodate. As will be readily recognized, however, a wide variety of different conjugation techniques exist which are readily available to one skilled in the art. In certain embodiments, the analytes are detected and measured using chemiluminescent detection. For example, in certain embodiments, analyte-specific antibodies are used to capture an analyte present in the biological sample and an antibody specific for the specific antibodies and labeled with a chemiluminescent label is used to detect the analyte present in the sample. Any chemiluminescent label and detection system can be used in the present devices and methods. Chemiluminescent secondary antibodies can be obtained commercially from various sources. Methods of detecting chemiluminescent secondary antibodies are known in the art and are not further discussed herein in detail. Examples of assays that may be carried out using the microfluidic devices described herein include, but are not limited to, tests for blood gases, clotting factors, immunogens, bacteria, and proteins. In one embodiment the assays that may be detected with the test device is a “luminescent O2channel assay” (LOCI®) which includes the use of for example, Sandwich Assays based on an analyte-specific antibody and a biotinylated antibody wherein specific wavelengths are generated by the fluid subsample and detected by the test device. Reagent configurations for the assay method include for example Sandwich Formats based on an antigen or an antibody, a Competitive Format, or a Sandwich Format with Extended Linker and may be used in immunoassays, infectious disease testing, and DNA testing. Specific blood chemicals which may be measured include, but are not limited to, TSH, free T4, free T3, Total PSA, free PSA, AFP, CEA, CA15.3, CA 19-9, CA 125, Cardiac Troponin-I, NT-pro BNP, myoglobin, mass CKMB (MMB), BNP, Ferritin, Vitamin B12, Folate, total B-HCG, FSH, LH, prolactin, estradiol, testosterone, progesterone, and digoxin. Fluorescent detection also can be useful for detecting analytes in the presently claimed and disclosed inventive concepts. Useful fluorochromes include, but are not limited to, DAPI, fluorescein, lanthanide metals, Hoechst 33258, R-phycocyanin, B-phycoerythrin, R-phycoerythrin, rhodamine, Texas red and lissamine. Fluorescent compounds, can be chemically coupled to antibodies without altering their binding capacity. When activated by illumination with light of a particular wavelength, the fluorochrome-labelled antibody adsorbs the light energy, inducing a state of excitability in the molecule, followed by emission of the light at a characteristic color visually detectable with a light microscope. Radioimmunoassays (RIAs) can be useful in certain methods of the invention. Such assays are well known in the art. Radioimmunoassays can be performed, for example, with125I-labeled primary or secondary antibody. Separation steps are possible in which an analyte is reacted with reagent in a first reaction chamber and then the reacted reagent or sample is directed to a second reaction chamber for further reaction. In addition, a reagent can be re-suspended in a first reaction chamber and moved to a second reaction chamber for a reaction. An analyte or reagent can be trapped in a first or second chamber and a determination made of free versus bound reagent. Determining a free versus bound reagent is particularly useful for multizone immunoassay and nucleic acid assays. There are various types of multizone immunoassays that could be adapted to this device. With adaption of immunochromatography assays, reagent filters are placed into separate wells and need not be in physical contact as chromatographic forces are not in play. Immunoassays or DNA assay can be developed for detection of bacteria such as Gram-negative species (e.g.,E. coli, Enterobacter, Pseudomonas, Klebsiella) and Gram-positive species (e.g.,Staphylococcus aureus, Enterococcus). Immunoassays can be developed for complete panels of proteins and peptides such as albumin, hemoglobin, myoglobulin, α-1-microglobulin, immunoglobulins, enzymes, glycoproteins, protease inhibitors, drugs and cytokines. The device may be used in analysis of urine for one or more components therein or aspects thereof, such as, but not limited to, leukocytes, nitrites, urobilinogen, proteins, albumin, creatinine, uristatin, calcium oxalate, myoglobin, pH, blood, specific gravity, ketone, bilirubin and glucose. Referring now to the drawings, and more particularly toFIGS.1-6, shown therein is an exemplary embodiment of a microfluidic device10constructed in accordance with the inventive concepts disclosed and claimed herein. The microfluidic device10comprises a first substrate12, a valve13including a resilient diaphragm14and an actuator16, and a second substrate18. The first substrate12includes a first side20and an opposing second side22. The first substrate12has an opening24extending through the first substrate12from the first side20to the second side22. The opening24may have a cross-section of any suitable geometry, including, but not limited to, circular, oval, square, or rectangular. The opening24may be molded or cut into the first substrate12, or otherwise pre-fabricated.—The first substrate12may be transparent to allow for imaging and observation of the fluid sample as it is passed through the microfluidic device10. The resilient diaphragm14can be deformed under pressure. The resilient diaphragm14may have a thickness suitable for allowing deformation upon application of a mechanical force or pressure. The mechanical pressure, for example, and not by way of limitation, may be a pneumatic pressure that pushes the resilient diaphragm14away from the second side22of the first substrate12. The resilient diaphragm14may be deformed from a substantially planar configuration to a non-planar configuration. In one embodiment, the resilient diaphragm14may be sized such that the it may be deformed upon application of a pressure of about 30 psi. In another embodiment, the resilient diaphragm may be sized such that it may be deformed under application of a pressure of about 14.7-50 psi. The resilient diaphragm14may also include indentations, recesses, or depressions to form a raised peripheral edge36. The raised peripheral edge36surrounds and defines a distensible region38of the resilient diaphragm14that remains unattached to the second side22of the first substrate12. The distensible region38may at least partially overlie the opening24of the second side22of the first substrate12. The distensible region38may be deformed upon application of appropriate mechanical force. The distensible region38may have any suitable shape and geometry. The resilient diaphragm14may be substantially unsupported in the distensible region38where it is unattached to the second side22of the first substrate12. As such, deformation of the resilient diaphragm14will cause the distensible region38to extend away from the second side22of the first substrate12due to the application of mechanical force, such as, for example, pneumatic force. The resilient diaphragm14of the valve13is secured to the second side22of the first substrate12to surround the opening24extending from the first side20to the second side22of the first substrate12. The actuator16is secured to the first side20of the first substrate12surround the opening24on the first side20. The actuator16, the first substrate12and the resilient diaphragm14cooperate to form a gas-tight chamber42. The gas-tight chamber42is used to apply pneumatic pressure to the resilient diaphragm14and the actuator16. Referring now toFIG.3, shown therein is a cross-section view of the layers of the resilient diaphragm14of the microfluidic device10. The resilient diaphragm14may be formed of material including, but not limited to, one or more layers of a polymer, a metal, and/or the like. In some embodiments, the resilient diaphragm14may comprise at least one inner gas impervious material layer44, at least one outer polymeric material layer46, and at least two layers of plastic48coating the gas impervious material layer44. In one embodiment, the gas impervious material layer44is formed of aluminum. The gas impervious material layer44of the resilient diaphragm14may be formed of materials including, but not limited to, aluminum, copper, tin, or gold. The at least one polymeric material layer46may improve channel seal. The polymeric material layer46may be formed of materials including, but not limited to, polystyrene or polyisoprenes. The at least two plastic layers48may be formed of materials including, but not limited to, nylon, PET, acrylonitrile, butadiene, styrene, polyethylene, or combinations thereof. The at least one plastic layers48may reduce tearing of the thinned gas impervious material layer44. For example, the resilient diaphragm14may include a gas impervious material layer44of aluminum sandwiched between layers of plastic48with an outer polymeric layer46as rubber sealing layer. In some embodiments, the resilient diaphragm14may only be metalized on one side, instead of having a gas impervious layer44sandwiched between plastic layers48. The gas impervious material layer44of the resilient diaphragm14may be mated to the at least one plastic layer48to form the resilient diaphragm14by vapor deposition, electrolysis, thermal/adhesive bonding, and bound/thinned by pressing through rollers. The actuator16may be formed of a flexible yet pierceable material, penetrable material, a rigid material, and/or a rigid yet pierceable and/or penetrable material. The actuator16may have a blister region40unattached to the first side20of the first substrate12. The blister region40of the actuator16overlies the opening24. The actuator16may be substantially unsupported in the blister region40where it is unattached to the first side20of the first substrate12. As such, deformation of the actuator16may cause the blister region40to expand away from the first side20of the first substrate12due to the application of mechanical force. The actuator16may include at least one gas impervious material layer44and at least one layer of plastic48. In one embodiment, the gas impervious material layer44is formed of aluminum. The gas impervious material layer44of the actuator16may be formed of materials including, but not limited to, aluminum, copper, tin, or gold. The at least one plastic layer48may be formed of materials including, but not limited to, nylon, PET, acrylonitrile, butadiene, styrene, polyethylene, or combinations thereof. The at least one plastic layer48may reduce tearing of the thinned gas impervious material layer44. The gas impervious material layer44of the actuator16may be mated to the at least one plastic layer48to form the actuator16by vapor deposition, electrolysis, thermal/adhesive bonding, and bound/thinned by pressing through rollers. The second substrate18has a first side26, an opposing second side28, and at least one channel30formed in the second side28. In some embodiments, the second substrate18may also include a plurality of the channels30, and the plurality of channels30may be interconnected. The channel30may have a first end32and a second end34. The first end32of the channel30may be of a size and shape such as to house a reagent, a volume of fluid, and/or a microstructure, such as, for example, a vent, container, filter, and/or the like. In some embodiments, the second substrate18may include a sample receiving reservoir in fluid communication with the second end34of the channel30. The second substrate18is secured to the first substrate12such that the second side22of the first substrate12, including the resilient diaphragm14, and the second side28of the second substrate18are in face-to-face contact. It will be appreciated there are several ways the various components of the microfluidic device10can be formed in the second substrate18, such as, but not limited to, injection molding, laser ablation, diamond milling, embossing, and combinations thereof, for example. The second substrate18may be secured (permanently or detachably) to the first substrate12in any suitable manner, such as by molding, ultrasonic welding, radiofrequency welding, bonding, gluing, double-sided adhesive tapes, and combinations thereof, for example, provided that a substantially fluid-impermeable connection is formed between the first substrate and the second substrate. It will be appreciated by those of ordinary skill in the art that the first substrate12and the second substrate18may be formed of one or more layers. For example, the second substrate18may be formed of a first layer provided with a slot or groove and a second layer may be connected to the first layer to form a channel. The first layer in turn would be secured to the first substrate as described above. A volume of gas is disposed in the gas-tight chamber42to pressurize the gas-tight chamber42and expand the resilient diaphragm14such that the resilient diaphragm14is disposed in the channel30between the first end32and the second end34(FIG.5). The resilient diaphragm14retracts from the channel30to open the channel30from the first end32and the second end34when the gas-tight chamber42is depressurized (FIG.6). Referring toFIG.5, shown therein is a cross-sectional view of the microfluidic device10in a pressurized condition. A volume of gas, such as, for example, propane, is disposed in the gas-tight chamber42to pressurize the gas-tight chamber42. A sufficient amount of gas is disposed in the gas-tight chamber42to cause the deformation of the actuator16and the resilient diaphragm14. The actuator16may be deformed to extend away from the first side20of the first substrate12, forming a blister over the opening24. The resilient diaphragm14may be deformed to extend away from the second side22of the first substrate12where at least a portion of the resilient diaphragm14may become deposed in the channel30between the first end32and the second end34, forming a fluid-tight seal between the first end32of the channel30and the second end34of the channel30. Referring toFIG.6, shown therein is a cross-sectional view of the microfluidic device10in a depressurized condition. Depressurization of the gas-tight chamber42results in the resilient diaphragm14retracting from the channel30to open the channel30from the first end32and the second end34. The gas-tight chamber42may be depressurized by, for example, by the application of force to the actuator16, to allow for the rupture of the actuator16(depicted by reference numeral49). Depressurizing the gas-tight chamber42causes in the resilient diaphragm14to retract and lie substantially flat against the second side22of the first substrate12. Retracting the resilient diaphragm15from the channel30allows for fluid communication between the first end32and the second end34of the channel30. Referring now toFIGS.7A-7G and8, shown therein is an exploded view and assembled view, respectively, of another exemplary embodiment of the microfluidic device10aconstructed in accordance to the inventive concepts disclosed herein. In this embodiment, the microfluidic device10aincludes a first substrate12a, a plurality of resilient diaphragms14a-14f, a plurality of actuators16a-16f, a second substrate18a, a third substrate18b, a fourth substrate18c, and a fifth substrate18d. Each of the first, second, third, fourth, and fifth substrates18a-18dfurther includes a spindle port50extending axially through each of the first, second, third, fourth, and fifth substrates18a-18d. In this embodiment, the plurality of actuators16a-16fand the plurality of resilient diaphragms14a-14fis shown inFIGS.7A and7C, respectively, have varying geometric configurations, such as circular (14a-14e;16a-16e) and rectangular (14f,16f). In this embodiment, the first substrate12a, as shown inFIG.7B, has a first side (not shown), an opposing second side22a, and a plurality of openings24aextending through the first substrate12afrom the first side to the second side22aof the first substrate12a. The plurality of resilient diaphragms14a-14f, as shown inFIG.7C, may be secured to the second side22aof the first substrate21asuch that each of the resilient diaphragms14a-14fmay surround each of the plurality of openings24aextending from the first side to the second side22aof the first substrate12a. The plurality of actuators16a-16f, as shown inFIG.7A, may be secured to the first side of the first substrate12asuch that each of the plurality of actuators16a-16fsurround each of the plurality of openings24aon the first side of the first substrate12a. The first substrate12a, each of the plurality of actuators16a-16f, and each of the plurality of resilient diaphragms14a-14f, cooperate to form a plurality of gas-tight chambers (not shown). Each of the second, third, fourth, and fifth substrate18a-18d, as shown inFIGS.7D-7G, respectively, has a first side (not shown), and a second side28a-28dopposing the first side. The second substrate18a, as shown inFIG.7D, includes a plurality of channels30aand a sample receiving reservoir52extending through the second substrate18ain the form of slots. The second substrate18afurther includes a rectangular through hole55extending from the first side of the second substrate18ato the second side28bof the third substrate18b. Connection of the second substrate18ato the first substrate12aand the third substrate18bdefines the channels30aand the sample receiving reservoir52. The plurality of channels30aeach having a first end32aand a second end34a. The first end32aof each of the plurality of channels30asized and shaped to house a reagent or other fluid and/or a microstructure, such as a vent, container, and/or the like. The second end34aof each of the plurality of channels30aoperable to be in fluid communication with the sample receiving reservoir52and/or the one or more filters54. The second substrate18amay be secured to the first substrate12asuch that the second side22aof the first substrate12a, including the plurality of resilient diaphragms14a-14fattached thereto, and the first side of the second substrate18aare in face-to-face contact. The third, fourth, and fifth substrates18b-18d, as shown inFIGS.7E-7G, respectively, each includes a plurality of vent holes56b-56dthat extend axially through each of the third, fourth, and fifth substrates18b-18d. Each of the plurality of vent holes56b-56dcorresponding to the first end32aof one or more of the plurality of channels30a. The third substrate18b, as shown inFIG.7E, has a plurality of parallel through holes57, positioned in a row, extending axially through the third substrate18bfrom the first side to the second side28bof the third substrate18b. The fourth substrate18c, as shown inFIG.7F, has a plurality of parallel channels58formed in the second side28cthat extend longitudinally along the fourth substrate18c. Each of the plurality of parallel channels58having a first end60and a second end62. Each of the second end62of the plurality of parallel channels58terminate correspondingly to the positions of each of the plurality of parallel through holes57on the second side28bof third substrate18b. The fifth substrate18d, as shown inFIG.7G, is secured to the fourth substrate18csuch that the second side28cof the fourth substrate18cand the first side of the fifth substrate18dare in face-to-face contact. Similarly, the fourth substrate18cis secured to the third substrate18bsuch that the second side28bof the third substrate18band the first side of the fourth substrate18care in face-to-face contact. The third substrate18bis secured to the second substrate18asuch that the second side28aof the second substrate18aand the first side of the third substrate18bare in face-to-face contact. The second substrate18ais secured to the first substrate12asuch that the second side22aof the first substrate12aand the first side of the second substrate18aare in face-to-face contact. A volume of gas is disposed in the gas-tight chambers formed by the plurality of actuators16a-16f, the plurality of resilient diaphragms14a-14f, and the first substrate12a, to pressurize the gas-tight chamber and, thereby, deform each of the plurality of actuators16a-16fand each of the plurality of resilient diaphragms14a-14f. At least one of the plurality of resilient diaphragms14a-14fdeforms to extend through the rectangular through hole55extending from the first side of the second substrate18ato the second side28bof the third substrate18b. Each of the plurality of resilient diaphragms14a-14fare deformed such that at least a portion of each of the resilient diaphragms14a-14fis disposed in each of the plurality of channels30abetween the first end32aand the second end34a, forming a fluid-tight seal between the first end32aof each of the plurality of channels30aand the second end34aof each of the plurality of channels30a, as shown inFIG.8. The microfluidic devices10and10amay be referred to as a “cartridge,” “chip” or “disk.” The microfluidic device10is generally small and flat, having a shape and dimensions as discussed elsewhere herein. The microfluidic device10is shown as having a rectangular shape, however it will be understood that the shapes of the microfluidic devices of the presently claimed and disclosed inventive concepts, include but are not limited to, round, rectangular, trapezoidal, irregular, oval, star, or any other geometric shape which allows the microfluidic passageways therein to function in accordance with the presently claimed and disclosed inventive concepts. It will be appreciated there are several ways the various components of the microfluidic channel system22can be formed in the base portion12, such as, but not limited to, injection molding, laser ablation, diamond milling, embossing, and combinations thereof, for example. Fluid samples and subsamples thereof may be propelled into and through the microchannels of the microfluidic devices described herein by passive or active fluidics including, but not limited to, capillary force, syringe pump, pistons, pneumatic, actuators, centrifugation, solenoids, linear actuators, peristaltic pump, electrophoresis, memory alloy valves, surface acoustic wave, or combinations of the above. The fluid samples and subsamples thereof may be mixed before, during, or after exposure to the reagents in the reagent areas. Mixing may be by passive or active mechanisms. For example, passive mechanisms include, but are not limited to, herring bone features, posts, or chevrons, and active mechanisms include, but are not limited to, piezo electric motors, surface acoustic wave means, centrifugal force, electrophoresis, and magnetic movement of particles, and combinations thereof. Reagents may be disposed or deposited in the reagent areas (or elsewhere in the microchannel) as dry powders, lyophilized spheres or granules, dried on a surface of the reagent area chamber, as liquids, for example, in pouches or blister packs, or on substrates as discussed elsewhere herein. In general, whole blood samples will need to be exposed to an anticoagulant (e.g., heparin) in the reagent area or in a portion of the microchannel upstream of the reagent area. Samples to be hemolyzed will generally require a surfactant or lysing agent (e.g., Saponin) in the reagent area or upstream thereof. In a microchannel designed to assay a whole blood sample to be hemolyzed, the microchannel may be absent a discrete reagent area such that the surfactant or lysing agent may simply be deposited in a channel between the valve and the exit port (or metering area, if present). The microchannels described herein are shown generally as linear thereby allowing a substantially straight-line flow of fluid therethrough. It is to be understood, however, that the present inventive concepts are not limited to straight flow paths and may comprise curved, angled, or otherwise non-linear microchannel flow paths. It is to be further understood that a first portion of a microchannel may be straight, and a second portion of the same microchannel may be curved, angled, or otherwise non-linear. The microfluidic device of the presently disclosed and claimed inventive concepts may further include one or more sensors in fluidic communication with the microchannel for detecting some aspect of the subsample therein. Such sensors are well known in the art, and therefore no further discussion thereof is deemed necessary. From the above description, it is clear that the inventive concept(s) disclosed herein is well adapted to carry out the objects and to attain the advantages mentioned herein as well as those inherent in the inventive concept disclosed herein. While exemplary embodiments of the inventive concept disclosed herein have been described for purposes of this disclosure, it will be understood that numerous changes may be made which will readily suggest themselves to those skilled in the art and which are accomplished without departing from the scope of the inventive concept disclosed herein and defined by the appended claims. The following is a list of non-limiting illustrative embodiments of the inventive concepts disclosed herein: An illustrative microfluidic device, comprising:a first substrate having a first side, a second side opposite the first side, and an opening extending through the first substrate from the first side to the second side;a resilient diaphragm secured to the second side of the first substrate to surround the opening of the first substrate;an actuator secured to the first side of the first substrate to as to surround the opening of the first substrate, the first substrate, the resilient diaphragm, and the actuator cooperating to form a gas-tight chamber; anda second substrate having a first side, a second side opposite the first side, and a channel formed in the second side, the channel having a first end and a second end, the second substrate secured to the first substrate so the second side of the first substrate and the second side of the second substrate are in face-to-face contact and a least a portion of the resilient diaphragm positioned between the first end of the channel and the second end of the channel,wherein a volume of gas is disposable in the gas-tight chamber to pressurize the gas-tight chamber and expand the resilient diaphragm so at least a portion of the resilient diaphragm is disposed in the channel between the first end and the second in a way to form a fluid-tight seal between the first end of the channel and the second end of the channel, andwherein upon the gas-tight chamber being depressurized, the resilient diaphragm is retractable from the channel to open the channel from the first end and the second end. The illustrative microfluidic device wherein the volume of gas is disposed in the gas-tight chamber to pressurize the gas-tight chamber and expand the resilient diaphragm so at least a portion of the resilient diaphragm is disposed in the channel between the first end and the second in a way to form a fluid-tight seal between the first end of the channel and the second end of the channel. The illustrative microfluidic device wherein the resilient diaphragm comprises at least one layer of gas impervious material. The illustrative microfluidic device wherein the gas impervious material is aluminum. The illustrative microfluidic device wherein the second substrate has a coefficient of friction, and wherein the resilient diaphragm comprises an outer layer having a coefficient of friction greater than the coefficient of friction of the second substrate. The illustrative microfluidic device wherein the outer layer of the resilient diaphragm is a polymeric material. The illustrative microfluidic device wherein the resilient diaphragm comprises:at least one inner layer of gas impervious material;at least one outer layer of polymeric material; andat least one layer of plastic interposed between the inner layer and the outer layer. The illustrative microfluidic device wherein the actuator comprises at least one layer of gas impervious material. The illustrative microfluidic device wherein the gas impervious material is aluminum. The illustrative microfluidic device further comprising a reagent disposed in the channel at the first end thereof. The illustrative microfluidic device wherein the first layer has a sample receiving reservoir in fluid communication with the second end of the channel. The illustrative microfluidic device wherein each of the first layer and the second layer has a spindle receiving opening aligned with one another. An illustrative method of forming a microfluidic device, comprising:obtaining a first substrate having a first side, a second side opposite the first side, and an opening extending through the first substrate from the first side to the second side;securing a resilient diaphragm to the second side of the first substrate to surround the opening of the first substrate;securing an actuator to the first side of the first substrate to surround the opening of the first substrate and so the first substrate, the resilient diaphragm, and the actuator cooperate to form a gas-tight chamber;obtaining a second substrate having a first side, a second side opposite the first side, and a channel formed in the second side, the channel having a first end and a second end;securing the second substrate to the first substrate so the second side of the first substrate and the second side of the second substrate are in face-to-face contact and a least a portion of the resilient diaphragm is positioned between the first end of the channel and the second end of the channel; andpressurizing the gas-tight chamber to expand the resilient diaphragm so at least a portion of the resilient diaphragm is disposed in the channel between the first end and the second to form a fluid-tight seal between the first end of the channel and the second end of the channel. The illustrative method further comprising disposing a reagent in the channel of the second substrate at the first end thereof. An illustrative method of controlling fluid flow through a microfluidic device comprising:depressurizing the gas-tight chamber to cause the resilient diaphragm to retract from the channel to open the channel from the first end and the second end. The illustrative method wherein the step of depressurizing the gas-tight chamber comprises rupturing the actuator. | 52,296 |
11859735 | DETAILED DESCRIPTION OF THE PRESENT INVENTION InFIG.1, number1indicates, as a whole, a clamping device1, designed to perform the laying operations of umbilicals, elongated bodies CA of substantially axial-symmetrical shape (wherein inFIG.1only a portion of a longitudinal cross-section of an exemplar is illustrated with broken lines for drawing economy) or tubes in general. In particular, these devices shall be distributed at constant angular pitch transversally to a given direction D which, in use, is substantially coaxial with the central axis of the portion of the CA body to be clamped. Therefore, the clamping devices1are arranged so as to apply, in use, a plurality of axial forces to a body CA that are proportional to the sum of the radial loads modulated with the friction coefficient between the clamping device and the elongated body. This axial force is the resultant of the frictional forces generated between the sheath M, delimiting the body CA externally, and the set of saddles1. With reference toFIG.7again, the clamping devices1are coupled together through a frame102which can be modular and therefore provided with at least a portion104which can be opened to allow transversal coupling with a body CA. With reference toFIG.7again, it is noticeable that the clamping devices1are connected to the frame102through the interposition of linear actuators106, which are arranged between reinforced portions108of the frame102and a spherical articulation110which is arranged at the back of each individual clamping device1. With reference toFIG.1, the clamping device1extends along the given direction D and comprises a support10of given angular extension, shaped to copy the outer shape of the body CA (as better described below). The support10embodies at least one interface22/23provided, at the front thereof, with a plurality of laminar bodies20. The function of these bodies, made of metal, is radially to interact with the sheath M of the body CA through a notched outer face24, better shown inFIGS.5and6. Each interface22and23is made of plastic, which can be temporarily deformed and, in the case of bodies CA of particularly large diameter, the support10must have adequate dimensions and, if useful, it may also have more than two interfaces22/23. Moreover, each of the laminar bodies20is at least partially included (embedded) in the plastic of the same interfaces22,23. With reference toFIG.5, the support10includes a pair of these interfaces22and23to maximize the ability to copy the outer surface of the axial-symmetrical body CA with the laminar bodies20, in a wide range of radial dimensions. In view of what described above it is easily understood that the choice of representing, in the attached figures, the support10with only two interfaces22and23is exclusively due to economy of drawing. In view of the above description, the laminar bodies20are suitable to perform a tangential action on the body CA to generate an axial force for balancing the axial load applied on the body CA and, as they are incorporated in the interface22/23, they are longitudinally and radially movable to the extent it is allowed by the stiffness of the plastic of which the same interface22/23is made. The intensity of this action is proportional to the tangential load applied by the body CA in axial direction to the laminar bodies20and to the contact area between the external faces24of the laminar bodies20and the sheath M. With reference toFIGS.1,2,3and5, the clamping device1has a base12at the back, which is suitable to absorb the force associated with the radial and tangential forces acting, in use, on the clamping device1once it has been connected to a fixed structure. Each laminar body20extends longitudinally (in direction D) and is integrated into, and is backside delimited by, a respective elongate member30and30′, one of which is visible inFIG.3. Each elongated member30/30′ is made of metal, without however limiting the scope of the present invention, and is coupled to the support10in a tilting manner around a respective longitudinal axis A/A′ parallel to the direction D. In particular, the support10has, for each elongated member30/30′, a respective cylindrical seat32/32′, open at the front and better visible inFIG.5and inFIG.8. Each elongated member30/30′ is delimited at the back by a respective cylindrical face facing the respective seat32/32′, whose radius is slightly greater than a radius of the respective elongated member30/30′. With reference toFIG.3and toFIG.6, each elongated member30/30′ is shaped similarly to a cradle longitudinally delimited by two respective end portions44, each of which is substantially L-shaped, even if this feature does not limit the protective scope of the invention. It is noticeable that each elongated member30/30′ is rotoidally coupled to the support10through a respective head45(FIGS.2,3,5,6,9,10). Each head45is shaped like a longitudinal closing member of the seat32/32′ and is therefore provided with a toroidal projection45′, whose function is to allow the same head45to resist against the axial forces acting on the respective elongated member30/30′. The head45is housed, in a conjugated way, in a transversal seat11of the support10, and this seat11is therefore partially toroidal as well as coaxial with the respective axis A/A′. Each end portion44is coupled to the respective head45through a pin35; each pin35is coaxial with the respective axis A/A′ and is provided with a shank350, which engages, with radial clearance, a central hole450(FIG.6) of the same head45, and that is therefore connected to the support10. Therefore, the coupling between each elongated member30/30′ and the support10through the respective seat32/32′ is with radial clearance; therefore, as it will be better explained below, in use each elongated member30/30′ is free to rotate around the respective axis A/A′ when no external load is applied. Obviously, the sizing of each end portion44and the distance from the heads of the laminar bodies20allow to define the maximum longitudinal displacement elastically allowed for each interface22/23. With reference toFIGS.5and6, the clamping device1comprises a centring unit34for each elongated member30/30′ to maintain the respective elongated member30/30′ aligned with the direction D and centred with respect to the seat32/32′. This centring unit34comprises the pair of pins35(one for each end portion44) of each elongated member30/30′ and a toroidal interface36(shown only inFIG.6) constituted by an elastic member, for example a gasket made of rubber, of the type usually called “O-ring”, which engages the hole450and is therefore carried by each pin35in a substantially coaxial way. The choice of this type of interface allows the elongated members30/30′ to adhere cylindrically, and therefore in a form-fitting manner, to the respective seats32/32′ under the thrust of a force transversal to the given direction D which is slightly greater than a minimum threshold value based on the mechanical characteristics of the toroidal interface36, and therefore once the elongated members30/30′ have been rotated relative to their axis A/A° axis up to an angular position defined by the outer conformation of the sheath M of the body CA. It is easily understood that this angular position balances the transversal thrusts on the portions of longitudinal edge of each elongated member30/30′. This feature allows the clamping device1to be adapted to the conformation of the sheath of substantially cylindrical elongated bodies CA in a wide dimensional range while the clamping ability of the clamping device1remains unchanged. Therefore, this ability allows each elongated member30/30′, in use, to couple in a form-fitting manner to the corresponding seat32/32′, and therefore to adhere thereto in an angularly fixed manner by friction. It is useful to specify that the toroidal projection45′ of each head45is rigidly connected to the respective seat11so that the support10incorporates it so as to be equivalent to a single body. The connection may be done, for instance but without limitation, through welding. Therefore, each elongated member30/30′ is carried by the support10through two respective end portions44, each of which is rotoidally coupled to a head45through a centring unit34. With reference toFIGS.1,2and3again, and with particular reference toFIG.5, the coupling between the support10and the base12is mediated by a damping unit50comprising a sandwich-shaped body52made of elastic material, for example, but with no limitation, by coupling rubber sheets and plates made of metal, usually of steel. In view of the above description, the dampening unit50is of the tangential type. Moreover, in view of the above description, in order to stop the body CA in a stable position it could be necessary to construct a clamp200provided with a plurality of clamping devices1distributed both radially (as inFIG.7) in a single-layer clamp100, and axially at regular pitch (hereinafter “layered” or similar), so as to have a multilayer clamp200, shown inFIG.12, where only a longitudinal portion thereof is shown for the sake of drawing economy. In view of the description above, each clamping device1allows an axial displacement of the respective laminar bodies20given by the combination of the displacement of the same interfaces22/23with respect to the respective end portions44and the sandwich-shaped body52of the dampening unit50. Moreover, both the elongated members30/30′ and the dampening unit50react to the load in a yielding manner and are mechanically arranged in series with respect to the body CA, as schematically shown inFIG.4. Therefore, the elongated members30/30′ and the dampening unit50can be considered two shock-absorbing stages arranged mechanically in series, which are indicated by the corresponding reference numbers for the sake of practicality. The use of the clamping devices1in each clamp100, or more generally in the clamp200, can be easily understood from the description above and does not require further explanation. However, it could be useful to specify that the body CA is clamped gradually and that from the first contact of the notched outer faces24of the laminar bodies20in each clamping device1a rotation occurs of the elongated bodies30and30′ around the respective axes A and A′, followed by the laminar bodies20entering again inside the respective interfaces22and23by a radial extent proportioned to the compliance characterising the plastic with which the respective interface22/23has been produced. The elongated members30/30′ of each clamping device1will therefore rotate by different opposite angles every time a clamping device1is radially pushed, in use, against the sheath M of the body CA. It is easy to understand that each individual laminar body20will be subjected to a radial displacement different than that of the adjacent bodies of the same elongated member or of the adjacent member, due to the local curvature of the body CA. It is easily understood that the combination of the rotation of the interfaces22/23, mounted on the elongated members30/30′, with the compliance of the same interfaces, due to the material with which they are constructed, allows the laminar bodies20to surround in a substantially matching manner the sheath M of each elongated body CA, independently of the diameter of the same sheath M. In this way, the load determined by the body CA is absorbed by each saddle1proportionally to the axial compliance thereof, given by the combination of the compliance of the elongated members30/31and of the dampening unit50, arranged and configured to operate in series, as shown in the diagram ofFIG.4. It is easily understood that this solution allows to increase the axial compliance of the clamping devices1by using a plurality of damping units arranged radially rather than longitudinally, to minimize the axial extension of the clamping devices1. Lastly, it is clearly apparent variants and modifications can be done to each clamp100, to the clamp200comprising a plurality thereof and to each of the respective clamping devices1, without however departing from the protective scope of the present invention. For example, according to the embodiment of the saddle1shown inFIGS.9to11, simplified for the sake of drawing economy, the dampening unit50may be of normal stress and may comprise a plurality of shock absorbers58arranged parallel to said given direction D. In particular, each shock absorber58, which is illustrated inFIGS.9to11through an axial-symmetrical body for the sake of practicality, is configured to operate along the given direction D, so that it can be defined as substantially linear and can be of the fluid-dynamic or mechanical type, without however limiting the protective scope of the present invention. In this regard, it should be specified that the support10is C-shaped at the back in order to house the base12. If deemed useful, at least one of the shock absorbers58may be provided with pressure sensors, position sensors or other sensors (where this specification has the sole purpose of providing an example and not limiting the possible choices), thus allowing to control at any time the current position of the support10with respect to the base12. In a clamp200provided with a plurality of layers of clamps100, and therefore with a plurality of clamping devices1arranged in a circle and in layers, the measurement of the axial displacement of each support10with respect to the respective base12can be useful for verifying the actual distribution of the overall axial load among the various “layers” of clamping devices100. Of course, it is useful to remember that each elongated body CA has a given tensile stiffness, to which an axial compliance corresponds that can be determined accordingly. Assuming that the body CA has absolute stiffness, and that it is clamped by using a plurality of clamping devices100arranged in series on more “layers” and connected together in an axially rigid manner through an appropriately constructed frame, the first clamping device1facing the load would be the only one to exert tensile strength up to break, if necessary, due to the lack of distribution of the load on the various layers of clamping devices1. Moreover, the compliance of each clamping device1can be modulated, given the same axial extension of the height of the respective clamp200, by combining several circumferential dampening stages: in particular both the compensation members40and the dampening unit50. This allows to limit the shear stress to be applied transversally on adjacent segments of the body CA, each interfacing one of the clamping devices100, and therefore to ensure both the integrity of the body CA and the proper operation of each clamping device1. In view of the description above, and in principle, in an ideal clamp200, the axial compliance of each clamping device1should decrease as you move away from the clamping device1facing the acting load. To this end, it would be useful to have available a clamping device whose axial compliance is adjustable at will, for example by using fluid dynamic actuators, whose compliance would be adjustable in real time following changes in the instantaneous acting load. In view of the description above, it is easy to understand that the clamping devices1described above and the clamp200incorporating them, whether it is a single-layer clamp or a multi-layer clamp, effectively solve the technical problem posed by the applicant in a simple and economical manner. | 15,568 |
11859736 | DESCRIPTION OF EMBODIMENTS Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. As shown inFIGS.1to3, an antistatic flexible hose A according to the embodiment of the present invention is a hose, a tube, or the like which is used in manufacturing facilities in the food and beverage industries, the chemical industry including medical supplies, the semiconductor industry, the cosmetics industry, the perfume industry, and the like. In particular, the antistatic flexible hose is a hose, a tube, or the like which not only prevents static buildup by static electricity created by conveyance of a powder, a granule, or the like but also exhibits superior pressure resistance performance. More specifically, the antistatic flexible hose A according to the embodiment of the present invention includes, as main constituent elements thereof, a hose body1having flexibility, a conductive layer2provided in an axial direction along an outer peripheral face1aof the hose body1, a conductive wire3provided in a spiral shape along the outer peripheral face1aof the hose body1and an outer surface2aof the conductive layer2, and a reinforcing member4provided in a spiral shape along the conductive wire3. The hose body1is a soft material or a semi-hard material made of a soft synthetic resin or a semi-hard synthetic resin such as vinyl chloride, an elastomer of such a synthetic resin, or other rubbers which is formed in a single layer structure, a plural layer structure, or a multiple layer structure. A single layer structure refers to a structure solely made of a single layer, a plural layer structure refers to a structure in which a plurality of layers are laminated so as to overlap with each other in a radial direction of the hose body1, and a multiple layer structure refers to a structure in which a large number of layers are laminated in the radial direction of the hose body1. As the component material of the hose body1, a transparent material or a translucent material is preferably used so that a fluid (not illustrated) which flows along an inner flow path Ap of the hose body1can be seen through from the outside of the hose body1. As a method for manufacturing the hose body1, layers are preferably created by extrusion molding, coextrusion molding, or the like. In addition, as shown inFIG.2, a braided blade5may be included between layers of the hose body1when necessary. The blade5is a reinforcing thread made of a synthetic resin fiber such as polyester, nylon (registered trademark), or aramid and is braided so as to be meshed or knit woven. The conductive layer2having electrical conductivity is formed on the outer peripheral face1aof the hose body1in a part of a circumferential direction of the hose body1in a band shape or a linear shape that extends in an axial direction of the hose body1. The conductive layer2is formed over an entire radial direction of a layer that is exposed on the outer peripheral face1ain the hose body1or formed partially only on the outside in the radial direction of the layer that is exposed on the outer peripheral face1ain the hose body1. Examples of a shape of the conductive layer2include a continuous shape that is disposed along an entire axial-direction length of the hose body1and an intermittent shape that is disposed at intervals of a predetermined length in the axial direction of the hose body1. As an example of disposing the conductive layer2on the outer peripheral face1aof the hose body1, preferably, a width in the circumferential direction of the hose body1is narrowed and a plurality of or only one the conductive layer2is formed at predetermined intervals in the circumferential direction so that a fluid in the inner flow path Ap can be sufficiently seen through the transparent or translucent hose body1. As a method for manufacturing the conductive layer2, for example, a conductive material containing highly conductive particulates such as particulates of a carbon material such as carbon black or metallic particulates are preferably extrusion-molded or coextrusion-molded with respect to a synthetic resin that acts as a base. In addition, as another example of the method for manufacturing the conductive layer2, the method for manufacturing can be changed to printing a conductive material or fixing a wire made of metal, a conductive thread, a conductive monofilament, or the like. The conductive wire3with a spiral shape is provided outside the hose body1and the conductive layer2along the outer peripheral face1aof the hose body1and the outer surface2aof the conductive layer2. The conductive wire3is formed in a linear shape using a conductive material having electrical conductivity such as a wire made of metal such as stainless steel, a conductive thread, or a conductive monofilament and wound so as to be tightened in the radial direction of the hose body1toward the outer peripheral face1aof the hose body1and the outer surface2aof the conductive layer2. Accordingly, the conductive wire3is attached by winding so as to be pressure-welded in the radial direction of the hose body1with respect to the outer peripheral face1aof the hose body1and the outer surface2aof the conductive layer2. As a component material of the conductive wire3, a metallic wire or the like is preferably used as a hard material with higher rigidity than the component material of the hose body1. As a method for manufacturing the conductive wire3, preferably, the conductive wire3is continuously wound and molded in a state where an elastic repulsive force is retained by winding the conductive wire3with a predetermined winding tension using a coil molder (not illustrated) or the like with respect to the hose body1and the conductive layer2having been extrusion-molded or coextrusion-molded. Furthermore, the reinforcing member4with a spiral shape is provided outside the hose body1and the conductive layer2along the conductive wire3so as to protrude from the outer peripheral face1aof the hose body1and the outer surface2aof the conductive layer2. Accordingly, the conductive layer2is disposed so as to be depressed between the reinforcing member4that spirally protrudes from the outer peripheral face1aof the hose body1and the outer surface2aof the conductive layer2. The reinforcing member4is formed in a thick line shape that is wider than an outer diameter of the conductive wire3using a soft material or a semi-hard material made of a soft synthetic resin, a semi-hard synthetic resin, an elastomer of such a synthetic resin, or other rubbers which has superior compatibility with the component material of the outer peripheral face1aof the hose body1and which is readily adherable. As the component material of the reinforcing member4, preferably, a material which is harder than the soft material that constitutes the hose body1and which is transparent or translucent is preferably used so that a fluid which flows along the inner flow path Ap of the hose body1can be seen through from the outside of the hose body1and the reinforcing member4. Furthermore, the reinforcing member4is disposed so as to sandwich the conductive wire3with the outer surface2aof the conductive layer2so that a surface of the conductive wire3is crimped to the outer surface2aof the conductive layer2. As a method for manufacturing the reinforcing member4, preferably, the reinforcing member4is laminated so as to overlap with the conductive wire3with respect to the hose body1and the conductive layer2having been continuously molded in the axial direction by extrusion molding or coextrusion molding. When an example (the first embodiment) of the hose body1, the conductive layer2, and the like are as shown inFIGS.1(a) and1(b), the conductive layer2with a continuous shape is formed over an entire axial-direction length of the hose body1with a plural layer structure. The illustrated hose body1has a two-layer structure in which an inner layer11which is made of semi-hard vinyl chloride or the like with superior abrasion resistance and of which an entire circumferential direction is transparent and a transparent outer layer12made of soft vinyl chloride or the like are laminated in the radial direction. The band-shaped conductive layer2is coextrusion-molded in a part in the circumferential direction of the outer layer12so as to be disposed exposed to an outer peripheral face12aof the outer layer12. When another example (a second embodiment) of the hose body1, the conductive layer2, and the like are as shown inFIGS.2(a) and2(b), the conductive layer2with a continuous shape is formed over an entire length of the hose body1with a multiple layer structure. The hose body1of the illustrated example has a four-layer structure in which an innermost layer13made of a fluororesin (ethylene-tetrafluoroethylene copolymer) or the like with superior abrasion resistance, gas permeability, and chemical resistance, an inner layer14made of a polyamide-based resin (modified nylon12) or the like, and an intermediate layer15and an outer layer16made of a polyurethane-based elastomer (thermoplastic polyurethane) or the like are laminated in a radial direction. The band-shaped conductive layer2is coextrusion-molded in a part in the circumferential direction of the outer layer16so as to be disposed exposed to an outer peripheral face16aof the outer layer16. A meshed blade5is provided along an outside surface of the intermediate layer15between the intermediate layer15and the outer layer16. Moreover, although not illustrated, as other modifications, the hose body1can be formed in a single layer structure in which the conductive layer2is formed over an entire radial direction or only on the outside in the radial direction or the hose body1may be changed to a three-layer structure or a structure with five layers or more. In addition, the shape of the conductive layer2can be changed to an intermittent shape from a continuous shape, a meshed or knit woven blade5can be provided between the inner layer11and the outer layer12in the first embodiment, or the blade5in the second embodiment can be changed to a knit woven blade5from the meshed blade5. When the shape of the conductive layer2is changed to an intermittent shape, the conductive layer2is disposed so as to straddle between pitches of the conductive wire3. Next, a method of use of the antistatic flexible hose A according to the embodiment of the present invention will be described. As an example of use of the antistatic flexible hose A, preferably, “a hose connection structure in which a hose having a conductive wire exposed on a hose surface is fitted into a grounded metallic pipe, a coil-shaped metallic grounding member is fitted to a connecting part of the metallic pipe and the hose, and the grounding member is brought into contact with the metallic pipe and the conductive wire on the hose surface” described in Japanese Patent No. 3690790 is used. In other words, in place of the “hose” described in Japanese Patent No. 3690790, an axial direction end part of the antistatic flexible hose A according to the first embodiment or the second embodiment is fitted into a grounded metallic pipe by grounding of a device main body, and a metallic grounding member is attached to a connecting part of the metallic pipe and the axial direction end part of the antistatic flexible hose A and tightened by a coil portion. Accordingly, the grounding member is kept in a contact state across the outer surface2aof the conductive layer2which is exposed between the spiral reinforcing member4on the surface of the antistatic flexible hose A and the metallic pipe, the conductive layer2is electrically connected to the metallic pipe via the grounding member, and the antistatic flexible hose A enters a grounded state. Therefore, static electricity generated in the antistatic flexible hose A is discharged via the conductive wire3→the conductive layer2→the grounding member→the metallic pipe→the device main body. In addition, when the device main body is not grounded, the device main body can be grounded via grounding by attaching the metallic grounding member to any point in the axial direction of the antistatic flexible hose A. Next, bending of the antistatic flexible hose A according to the embodiment of the present invention will be described. As shown inFIGS.3(a) and3(b), by bending a part in the axial direction of the antistatic flexible hose A, in the bent part, a bending direction outside part Ao extends in the axial direction and, at the same time, a bending direction inside part Ai partially protrudes to create a clearance wall Ac. Therefore, a part in the axial direction of the antistatic flexible hose A smoothly inflects while preventing a crush deformation of the inner flow path Ap that causes a cross-section thereof to change to an approximately elliptical cross-section and maintaining the circular cross-section shape of the inner flow path Ap. By comparison, in a case of a flexible hose without the reinforcing member4, although not illustrated, a crush deformation of the inner flow path Ap occurs and causes the cross-section to change to an approximately elliptical cross-section shape with the bending of the flexible hose, thereby increasing the likelihood of clogging of a fluid and causing shape retainability to decline. In doing so, depending on usage thereof, the conductive layer2of the antistatic flexible hose A may be disposed in the bending direction outside part Ao (extension side) in the bent part as shown inFIG.3(a)or may be disposed in the bending direction inside part Ai (clearance wall side) in the bent part as shown inFIG.3(b). The illustrated example represents the first embodiment. Since the second embodiment is similar to the first embodiment, an illustration thereof will be omitted. As shown inFIG.3(a), when the conductive layer2disposed in the bending direction outside part Ao is extended in the axial direction due to bending, a force is applied so as to separate the conductive layer2from the reinforcing member4and the conductive wire3. However, since the conductive wire3is tightened in the radial direction toward the outer surface2aof the conductive layer2, a crimping state to the conductive wire3is maintained so as to follow the conductive layer2. Conversely, as shown inFIG.3(b), when the conductive layer2disposed in the bending direction inside part Ai is caused to partially protrude to create the clearance wall Ac due to bending, a force is applied so as to cause the conductive layer2to approach the reinforcing member4and the conductive wire3. Therefore, a crimping state of the conductive layer2and the conductive wire3is maintained. With the antistatic flexible hose A according to the embodiment of the present invention described above, as shown inFIG.3(a), even when a force is applied so as to separate the conductive layer2from the reinforcing member4and the conductive wire3due to bending of the antistatic flexible hose A, since the conductive wire3is tightened in the radial direction toward the outer surface2aof the conductive layer2, a crimping state to the conductive wire3is maintained so as to follow the conductive layer2. Accordingly, a contact resistance of the conductive layer2and the conductive wire3is kept low independently of a length in the axial direction of the antistatic flexible hose A. In addition, the conductive layer2is disposed so as to be depressed between the reinforcing member4that spirally protrudes from the outer peripheral face1aof the hose body1and the outer surface2aof the conductive layer2. Therefore, even when the reinforcing member4comes into contact with a grounding face or the like, the conductive layer2remains contact-free. Furthermore, even when the conductive wire3is covered by the reinforcing member4and is not exposed and the reinforcing member4comes into contact with a grounding face or the like, the conductive wire3remains contact-free. Therefore, both prevention of an increase in contact resistance of the conductive layer2and the conductive wire3and prevention of breakage or peeling and separation of the conductive layer2and the conductive wire3with the bending of the flexible hose can be achieved. As a result, compared to a conventional configuration in which a spiral conductive wire that is wound along an outer peripheral face of an inner layer hose and an inner face of a conductive resin layer integrally molded to a part of an outer layer hose are brought into contact with each other, an electric resistance value can be lowered and stabilization can be achieved regardless of bending and without following a length of the antistatic flexible hose A. In addition, compared to a conventional configuration in which the conductive resin layer is disposed exposed on the outer peripheral face of the outer layer hose, since the conductive layer2does not come into direct contact with a grounding face or the like, a vibration, an impact, or the like with respect to the conductive layer2are reduced and the likelihood of an occurrence of cracks, breakage, peeling and separation, or the like are reduced, the antistatic flexible hose A can be reliably used even in the food and beverage industries, the medical industry, and the like where strict regulations are imposed on contamination by foreign substances. Furthermore, since the conductive wire3is protected by the reinforcing member4and does not come into direct contact with a grounding face, products, or the like, breakage, peeling and separation, and the like of the conductive wire3are less likely to occur and the antistatic flexible hose A can be reliably used even in the food and beverage industries, the medical industry, and the like where strict regulations are imposed on contamination by foreign substances. Moreover, even when the conductive wire3is made of a material susceptible to rust or oxidation such as a metal wire, a conductive thread, or the like, since the conductive wire3is protected by the reinforcing member4and does not come into direct contact with a fluid or the like, an occurrence of rust, oxidation, or the like can be prevented. In particular, the conductive wire3is preferably formed of a material that is harder than the component material of the hose body1. In this case, the conductive wire3not only functions as a grounding wire but also functions as a reinforcing material. Therefore, concomitantly using the hard conductive wire3and the reinforcing member4enables crush deformation of an entire hose with the bending thereof to be reliably prevented. As a result, shape retainability of the entire hose can be improved. In addition, although not illustrated, a reinforcing member (not illustrated) such as a wire can be wound so as to be tightened along a valley that is created between pitches of the spiral reinforcing member4and disposed in an exposed state. In this case, the shape retainability of the entire hose can be further improved. While the “hose connection structure” described in Japanese Patent No. 3690790 has been used as an example of use of the antistatic flexible hose A in the embodiment described above, examples of use of the antistatic flexible hose A are not limited thereto and the antistatic flexible hose A may have other structures as long as static buildup can be removed at an arbitrary location of the antistatic flexible hose A such as using a tightening band with another structure of which an installation location with respect to the antistatic flexible hose A is not specified instead of the grounding member according to Japanese Patent No. 3690790. REFERENCE SIGNS LIST A Antistatic flexible hose1Hose body1aOuter peripheral face2Conductive layer2aOuter surface3Conductive wire4Reinforcing member | 19,844 |
11859737 | DETAILED DESCRIPTION An example embodiment of a coupling10according to the invention is shown inFIGS.1and1A. Coupling10is for joining pipe elements and comprises first and second segments12and14positioned end to end surrounding a central space16for receiving the pipe elements. A spring assembly18joins a first end20of first segment12to a first end22of the second segment14. The spring assembly18biases the segments12and14away from one another toward or into an open, pre-assembled state shown. When in this open or pre-assembled state, pipe elements can be inserted into the central space16without disassembling the coupling10as described below. The example spring assembly18shown inFIGS.1and2comprises a first boss24projecting from the first end20of the first segment12, and a second boss26projecting from the second end22of the second segment14. The second boss26is positioned adjacent to the first boss24. Bosses24and26are cantilevers and thus are substantially responsible for the biasing force of the spring assembly18as described below. A first fulcrum28is positioned on the first boss24, the first fulcrum28contacting the second boss26and providing an axis30about which the segments12and14may pivot. In this example embodiment a second fulcrum32is positioned on the second boss26. The second fulcrum32contacts the first fulcrum28to further define the pivot axis30about which the segments12and14pivot. First and second fulcrums28and32are defined in this example embodiment by first and second lands34and36. The first and second lands34and36are respectively positioned on the first and second bosses24and26, the first land34being contiguous with the first fulcrum28, and the second land36being contiguous with the second fulcrum32(when present). At least the first land34is oriented angularly with respect to a plane38comprising the interface between the first and second segments12and14. In this example embodiment both the first and second lands34and36are angularly oriented with respective orientation angles40. A link42extends between the first and second bosses24and26. Link42captures the bosses, while permitting pivoting motion of the segments12and14. In this example the link42comprises a ring44which encircles the first and second bosses24and26. Ring44is retained on the bosses24and26by engagement with first and second heads46and48respectively projecting from the first and second bosses24and26. Ring44and the bosses24and26cooperate to provide the spring biasing action of the spring assembly18. The thickness50of the ring44, the distance52between the fulcrums28and32and the point where the bosses24and26engage the ring44, along with the area moment of inertia of the bosses, are parameters which will establish the spring constant of the spring assembly18and thus determine the amount of force necessary to close the coupling10and effect a joint. The angular orientation40of the lands34and36and the distance the fastener70has been tightened each act to set the maximum limit of separation between the segments12and14, and the inner diameter54of the ring44determines the minimum separation of the segments when supported by an undeformed spring assembly18as shown inFIGS.1and2. In one embodiment, the angular orientation40is such that, if the fastener70is not present (such as during the assembly of the coupling by the manufacturer) bosses24,26may be brought near enough together that the inner diameter54of ring44will clear heads46,48, allowing ring44to be easily assembled over bosses24,26. Subsequent assembly and tightening of fastener70to a pre-determined distance71(seeFIG.2) acts to separate heads46,48sufficient to retain ring44behind heads46and58as described above. The ring inner diameter54may be sized to hold the segments12and14in the open or pre-assembled state sufficient to permit insertion of pipe elements into the central space16, or the diameter54may be larger, and permit the segments12and14to be supported in the open or pre-assembled state by other elements of the coupling as described below. In this situation the segments12and14will have some angular free play as the segments are drawn toward one another to close the coupling, the spring assembly18not immediately coming into effect upon pivoting of the segments. Segments12and14are drawn toward one another by an adjustable attachment assembly56. Attachment assembly56joins the second end58of the first segment12to the second end60of the second segment14. Attachment assembly56is adapted to draw the segments12and14toward one another and into engagement with the pipe elements as described below. In this example the adjustable attachment assembly56comprises a first lug62attached to the second end58of the first segment12, and a second lug64attached to the second end60of the second segment14. Each lug62,64defines a respective hole66,68which receive a fastener70that extends between the lugs. In this example fastener70comprises a bolt72and a nut74, which, when tightened, draw the segments12and14toward one another against the biasing force of the spring assembly18. As shown in cross section inFIG.3, each segment12and14comprises first and second channels76and78respectively positioned on opposite sides80and82of each segment. The first and second channels76and78extend between the first and second ends20and58of the first segment12, and the first and second ends22and60of the second segment14(see alsoFIG.1). Channels76and78face the central space16. As shown in detail inFIG.4, each channel76,78(channel78in segment14being shown) is defined by sidewalls84and86positioned in spaced relation to one another. Each channel76,78furthermore has first and second floors88and90located between sidewalls84and86. Floors88and90face the central space16and are arcuate in shape as they extend between the ends and58and22and60of the segments12and14. As shown inFIG.4, first floor88is positioned closer to the side82of segment14and has a greater radius of curvature92than the second floor90, which has a radius of curvature94. As shown inFIG.3, the channels76and78and the arrangement of their floors88and90are symmetric about an axis96extending transversely through the coupling10. As further shown inFIGS.3and4, the channels76and78each receive a respective retainer98. Retainer98is shown in detail inFIG.5and comprises an arcuate band100having oppositely disposed ends102and104. Band100thus forms a “split ring” which, when compressed radially will deform to a smaller radius of curvature (seeFIG.7). In some embodiments, each band100is sized such that contact between bands100and the respective segments12and14within channels76and78allow one or both bands100to support segments12and14in spaced apart relation as shown inFIG.1. A plurality of teeth106are positioned along one edge108of band78. Teeth106project from band100toward the central space16. As shown inFIGS.3and4, teeth106are oriented angularly toward axis96with respect to a line110extending radially from an axis112arranged coaxially with the central space16. The angular orientation is advantageous for retaining pipe elements as described below. As shown inFIG.5, at least one, but in this example embodiment, a plurality of tabs114are positioned along an edge116oppositely disposed from edge108. As shown inFIG.4, the one or more tabs114are oriented substantially perpendicular to the line110and are offset from the band100toward axis112arranged coaxially with the central space16. This offset of tabs114permits them to overlie the second floor90, and the band100to overlie the first floor88, when retainers98are properly received within respective channels76and78as shown inFIGS.3and4. Proper assembly of the retainers98within the channels76and78permits pipe elements to be inserted into a pre-assembled coupling10as described below. However, as shown inFIG.6, the channels76and78(78shown) and the retainers98are sized such that if the coupling10is improperly assembled with the band100overlying the second floor90and the tab or tabs114overlying the first floor88, the retainer's radius of curvature is smaller and teeth106effectively prevent insertion of the pipe element into the central space16with the segments12and14in spaced apart relation in the pre-assembled state. This cooperation between the retainer98, its tabs114, teeth106, and the first and second floors88and90of channels76and78prevent improper assembly of a pipe joint using coupling10. If the pipe elements could be inserted with the retainer teeth106facing in the wrong direction (FIG.6) then the teeth will not be self-actuating against forces which would draw or push the pipe element out of the coupling. Thus the retainer would provide reduced mechanical restraint. As shown inFIG.3, segments12and14further comprise a third channel118. Channel118is positioned between the first and second channels76and78and faces the central space16. Channel118receives a ring seal120which ensures a fluid tight joint. Ring seal120is formed of a flexible, resilient material such as EPDM or other rubber compounds and has inner surfaces122sized to receive pipe elements when they are inserted into the central space16as described below. A pipe stop124is positioned between inner surfaces122. The pipe stop projects into the central space16and limits insertion of pipe elements by engaging the pipe elements when they are inserted into coupling10to the desired depth. Ring seal120also has an outer surface126that may be sized to engage and support the segments12and14in spaced apart relation as shown inFIGS.1and3. One or more of the bands100may also cooperate with the ring seal120to support the segments12and14in spaced apart relation. The separation of the segments12and14, when supported by the ring seal120and/or band or bands100, is sufficient to permit pipe elements to be inserted into the coupling when it is in its pre-assembled state (FIGS.1,2and3).FIG.3shows an example channel configuration wherein the second floors90are positioned between the first floors88and the third channel118. In this example the tabs114project toward the third channel118when the retainers98are properly oriented within the coupling10. As shown inFIG.1, coupling10further comprises a first aperture128in segment12. In this example embodiment aperture128is aligned with the first channel76and provides a line of sight130toward the central space16. In this example embodiment, aperture128is positioned at the interface132between segments12and14and is formed as a trough134in both segments12and14. The troughs134in each of the segments12and14are aligned so that when the segments are drawn into engagement they provide a view toward the central space16to permit visual confirmation that the retainer is present and that a pipe element is present within the central space and seated at least past the retainer. As shown inFIG.1A, a second aperture136is also positioned in at least one of the segments12and14. The second aperture136is aligned with the second channel78in this embodiment (seeFIG.3) and also provides a line of sight toward central space16. Again, in the example embodiment10illustrated, the second aperture136is positioned between the segments12and14. Aperture136is also formed by troughs134at the interface132between the segments12and14. The second aperture also permits visual confirmation that a pipe element is present within the central space16. As shown inFIGS.1and3, each segment12and14also comprises first and second arcuate surfaces138and140respectively positioned on sidewalls84and86. Arcuate surfaces138and140face the central space16and a plurality of projections142may be positioned on each arcuate surface138,140. Projections142are arranged in spaced relation to one another along the arcuate surfaces138and140and project toward the central space16. As described below, projections142engage the pipe elements and increase joint stiffness and accommodate a wider tolerance range on the pipe outer diameter. When projections142are forced into engagement with the pipe elements as the segments12and14are drawn toward one another they add stiffness to the joint between the coupling10and the pipe elements upon their engagement with the outer surfaces of the pipe elements. Additionally, the projections142allow the coupling10to accommodate a larger pipe outer diameter tolerance in combination with known manufacturing tolerances for coupling10. When the outer diameter of pipe elements is near the small end of the tolerance range the presence of the projections142ensures mechanical engagement between the coupling10and the pipe elements. However, when the pipe diameter is at the large end of the tolerance range the projections will tend to deform the outer surface of the pipe elements locally, and projections142may also deform. For couplings10used with plain end pipe elements this is particularly advantageous as plain end couplings are typically designed so that the arcuate surfaces138,140(seeFIG.3) do not engage the outer surfaces of the pipe elements. This arrangement ensures that the clamping force provided by the fastener70(seeFIG.2) is fully applied to the retainers98. Were the arcuate surfaces138,140of the coupling10to engage the pipe outer surface directly, the clamping force would be divided between contact of the arcuate surfaces with the pipe and contact between the retainers98and the pipe elements. Because the surface areas of projections142are small relative to the arcuate surfaces138,140, and contact the pipe element outer surface only at discrete points, only minimal clamping force from the fastener70needs to be diverted into contact between the projections142and the pipe elements to provide enhanced stiffness without compromising the axial retention provided by the retainers98. Projections142are advantageous in that they achieve greater rigidity even with the lesser clamping force available with the single fastener design of the coupling10. The single fastener70acts in conjunction with the spring assembly18to ensure that adequate clamping force is applied to the pipe elements. Operation of coupling10is illustrated inFIGS.1,3,7and8. With the coupling10in the pre-assembled state as shown inFIGS.1and3, pipe elements144and146are inserted into the central space16. The pipe elements clear the teeth106of retainers98, engage and the inner surfaces122of ring seal120, and engage the pipe stop124. Next, the fastener70is tightened (see alsoFIG.2) drawing the segments12and14toward one another. As shown inFIG.7the ring seal120and the teeth106are compressed between the segments12and14and the pipe elements144and146. Pivoting motion of the segments about fulcrums28and32(seeFIG.2) is resisted by the biasing force of the spring assembly18. As shown inFIG.8, the elements comprising the spring assembly, in this example, the bosses24and26and the ring44, deform in proportion to the spring force, with the ring44extending into an oval shape and the bosses24and26bending as cantilevers (deformed shapes shown in solid line, undeformed in broken line). Apertures128,136may be used to visually confirm that the pipe elements are present in the coupling10. FIG.9shows an exploded view, andFIG.9Ashows an assembled view, of a preassembled combination coupling and pipe element147according to the invention. The combination coupling and pipe element147comprises a coupling148and a first pipe element184, and is used to couple a second pipe element186to the first pipe element (seeFIGS.10and11). The second pipe element186may, for example, be part of a piping network (not shown), and the first pipe element184may be part of another assembly, such as a flexible hose for a fire suppression sprinkler, or an inlet or and outlet of a pump or a valve to cite a few examples. The coupling148comprises first and second segments150and152positioned end to end surrounding a central space154for receiving pipe elements. A spring assembly156and an adjustable attachment assembly158, as described above for coupling10, join the ends of the segments. Coupling148further comprises first and second shoulders160and162(see alsoFIG.10) positioned on opposite sides164,166of each segment150and152. Shoulders160and162extend lengthwise along the segments150and152and project toward the central space154. Shoulders160and162define a channel168which extends between the ends of the segments150and152and faces central space154. Channel168receives a ring seal170for a fluid tight joint. Ring seal170has an inner surface172sized to receive pipe elements (see alsoFIG.10) and an outer surface174which may be sized to support the segments150and152in the preassembled state, i.e., in spaced relation sufficient to insert the second pipe element186into the central space154without disassembling the combination147.FIG.9Ashows the coupling in the preassembled state with the segments150and152in spaced relation. As described above for coupling10, the spring assembly156may also be used to bias the segments150and152into the open, preassembled state shown inFIG.9A. Ring seal170may also comprise a pipe stop176positioned between the inner surfaces172. Pipe elements inserted into the central space engage the pipe stop176when properly seated (seeFIG.11). As shown inFIGS.9and10, each segment150and152further comprises a first arcuate surface178positioned on the first shoulder160and a second arcuate surface180positioned on the second shoulder162. Arcuate surfaces178and180face the central space154. A plurality of projections182may be positioned on the arcuate surfaces178and180. Projections182are arranged in spaced relation to one another along the arcuate surfaces178and180and project toward the central space154. Projections182engage the pipe elements and increase joint stiffness and accommodate a wider tolerance range on the pipe outer diameter. As shown inFIG.9A, the coupling148may have at least one aperture171in one of the segments150,152. In this example the aperture171comprises a trough173positioned at an interface between the first and second segments150and152. As shown inFIG.9, the first pipe element184comprises a rim188which projects outwardly from the first pipe element and extends circumferentially around. Rim188is positioned in spaced relation to an end190of the first pipe element184, and as shown inFIGS.9A and10, is captured within the central space154by engagement with the shoulder162. Rim188may be defined by a circumferential groove192in the first pipe element184, or a circumferential bead194which projects radially outwardly from the first pipe element184. In the example embodiment shown inFIG.9, the rim188is defined by both the groove192and the bead194. The preassembled combination coupling and pipe element147shown inFIG.9Ain its preassembled state is assembled as illustrated inFIGS.9B and9C. The first pipe element184is engaged with the ring seal170. The ring seal170is then positioned within the channel168of the first segment150while the rim188is engaged with the first shoulder160within what will become the central space154. Next the spring assembly156is formed by engaging the first end175of the first segment150with the first end177of the second segment152. In the example shown, engagement of the first ends175and177is effected by joining a first boss179projecting from the first end175of the first segment150with a second boss181projecting from the first end177of the second segment152and pivotably linking them together using a link183. In this example the link183comprises a ring185into which the bosses179and181are inserted, each boss having a respective head187,189which retain the bosses within the ring185when the segments are pivoted into the preassembled state. As shown inFIG.9C, the second boss181is contacted by a fulcrum191on the first boss179, and the first boss179is contacted by a fulcrum193on the second boss181. The bosses179and181joined by the ring185act as cantilever springs which bias the segments150and152away from one another and can also be used to support the segments in spaced apart relation, either alone or in combination with the ring seal170as described above. Next the second end195of the first segment150is attached to the second end197of the second segment152using the adjustable attachment assembly158. In this example embodiment the adjustable attachment assembly comprises a first lug201mounted on the second end195of the first segment150, a second lug203mounted on the second end197of the second segment152, and a fastener205extending between the first and second lugs. Working together with the spring assembly156(and/or the ring seal170), initial tightening of the fastener205holds the segments150and152in the preassembled state shown inFIGS.9A and9C. In this configuration the segments150,152are supported in spaced apart relation sufficient to permit the second pipe element186to be inserted into the central space154(seeFIGS.10-11) while also capturing the first pipe element184by engagement between the shoulder160and the rim188. As shown inFIG.9C, the projections182increase the ability of the segments150,152to retain the first pipe element184when the combination147is in the preassembled state. FIGS.10and11illustrate use of the combination147to join pipe elements184and186. As shown inFIG.10, with the combination147in the preassembled state the second pipe element186is inserted into the central space154. Upon insertion the second pipe element186engages with surface172on the ring seal170(the first pipe element184is similarly engaged with the ring seal). As shown inFIG.11, the segments are then drawn toward one another using the adjustable attachment assembly158. In this example the fastener205is tightened, drawing the segments150and152against the biasing force of the spring assembly156(seeFIG.9C) and compressing the ring seal170to form a fluid tight joint. If projections182are present they engage the pipe elements184,186, otherwise, the arcuate surfaces178and180engage the pipe elements.FIG.11shows the arcuate surface178engaging a groove192in the second pipe element186. FIG.12shows an embodiment of the preassembled combination147wherein the first arcuate surface178has a first radius of curvature207and the second arcuate surface180has a second radius of curvature209. In this example embodiment the second radius of curvature209is less than the first radius of curvature207. This configuration of radii is appropriate when rim188of the first pipe element is defined by a groove192because it permits the first pipe element184to be captured by coupling148when it is in the preassembled state, while allowing the second pipe element186to be inserted into the central space154without disassembling the coupling. The groove192in the first pipe element184may be deeper than the groove192in the second pipe element186to accommodate this embodiment. The use of the combination147having a single fastener205and a captured pipe element184provides significant advantage by increasing the stability of the coupling on the pipe elements through engagement between the coupling shoulder and the rim of the pipe element. The presence of the spring assembly and single fastener significantly inhibit the ability to manipulate the coupling by rocking it, making it much more difficult to separate the pipe element from the coupling. The single fastener also simplifies the tightening step, as only one fastener need be tightened, as opposed to two fasteners, which must be tightened in an alternating sequence to avoid damage to the ring seal. Couplings according to the invention are expected to improve the efficiency of installation and the reliability of joints formed. Further expected advantages include a lighter weight coupling which has a lower external profile and which is smaller for a given pipe size. Having only one fastener reduces the part count and contributes to reduced errors during assembly, as well as eliminating the need to tighten more than one fastener in an alternating sequence. FIGS.13and14show an example coupling250according to the invention. Coupling250comprises first and second segments252and254attached to one another surrounding a central space256. Attachment of segments252and254is effected by first and second attachment members258and260positioned at respective opposite ends262and264of segments252and254. In this example embodiment the first attachment member258comprises first and second lugs266and268, and a fastener270comprising a bolt272and a nut274(seeFIG.14). Lugs266and268are in facing relation to one another and extend from ends262of respective segments252and254. The lugs have holes276which receive a first fastener270, the fastener extending between the first and second lugs. Comprised of lugs266,268and fastener270, the first attachment member is adjustably tightenable for drawing the segments252and254toward one another to join pipe elements as described below. Further in this example embodiment, the second attachment member260comprises third and fourth lugs278and280, and a second fastener282comprising a bolt284and a nut286. Lugs278and280are in facing relation to one another and extend from ends264of respective segments252and254. The lugs have holes276which receive a second fastener282, the fastener extending between the third and fourth lugs. Comprised of lugs278,280and fastener282, the second attachment member is also adjustably tightenable for drawing the segments252and254toward one another to join pipe elements as described below. As shown in cross section inFIG.15each segment252and254comprises first and second channels288and290respectively positioned on opposite sides290and294of each segment. The first and second channels288and290extend between the ends262and264of segments252and254(seeFIG.13) and face the central space256. As shown in detail inFIG.16, each channel288,290(channel290in segment254being shown) is defined by sidewalls296and298positioned in spaced relation to one another. Each channel288,290furthermore has first and second floors304and306located between sidewalls296and298. Floors304and306face the central space256and are arcuate in shape as they extend between the ends262and264of the segments252and254. As shown inFIG.16, first floor304is positioned closer to the side294of segment254and has a greater radius of curvature308than the second floor306, which has a radius of curvature310. As shown inFIG.15, the channels288and290and the arrangement of their floors304and306are symmetric about the axis312extending transversely through the coupling250. As further shown inFIGS.15and16, the channels288and290each receive a respective retainer314. Retainer314is shown in detail inFIG.17and comprises an arcuate band316having oppositely disposed ends318and320. Band316is thus forms a “split ring” which, when compressed radially will deform to a smaller radius of curvature. In some embodiments, each band316is sized such that contact between bands316and the respective segments252and254within channels288and290allow one or both bands316to support segments252and254in spaced apart relation as shown inFIG.13. A plurality of teeth322are positioned along one edge324of band316. Teeth322project from band316toward the central space256. As shown inFIG.16, teeth322are oriented angularly toward axis312with respect to a radius326extending from the central space. The angular orientation is advantageous for retaining pipe elements as described below. As shown inFIG.17, a plurality of tabs328are positioned along an edge330oppositely disposed from edge324. As shown inFIG.16, tabs328are oriented substantially perpendicular to the radius326and are offset from the band316in the direction which teeth322project. This offset of tabs328permits the tabs to overlie the second floor306, and the band316to overlie the first floor304, when retainers314are properly received within respective channels288and290as shown inFIGS.15and16. Proper assembly of the retainers314within the channels288and290permits pipe elements to be inserted into a pre-assembled coupling250as described below. However, as shown inFIG.18, the channels288and290(only290shown) and the retainers314are sized such that if the coupling250is improperly assembled with the band316overlying the second floor306and the tabs328overlying the first floor304it is not possible to insert a pipe element into the coupling, also described below. As shown inFIG.15, segments252and254further comprise a third channel332. Channel332is positioned between the first and second channels288and290and faces the central space256. Channel332receives a ring seal334which ensures a fluid tight joint. Ring seal334is formed of a flexible, resilient material such as EPDM or other rubber compounds and has inner surfaces336sized to receive pipe elements when they are inserted into the central space256as described below. A pipe stop338is positioned between inner surfaces336. The pipe stop projects into the central space256and promotes insertion of pipe elements by engaging the pipe elements when they are inserted into coupling250to the desired depth. In some embodiments, ring seal334also has an outer surface340that is sized such that it may cooperate with each band316to engage and support the segments252and254in spaced apart relation as shown inFIG.13. The separation of the segments when supported by each band316and ring seal334is sufficient to permit pipe elements to be inserted into the coupling when it is in its pre-assembled state (FIG.13).FIG.15shows an example channel configuration wherein the second floors306are positioned between the first floors304and the third channel332. In this example the tabs328project toward the third channel when the retainers314are properly installed within the coupling250. As shown inFIGS.13and15, each segment252and254also comprises first and second arcuate surfaces300and302respectively positioned on sidewalls296and298. Arcuate surfaces300and302face the central space256and a plurality of projections305may be positioned on each arcuate surface300,302. Projections305are arranged in spaced relation to one another along the arcuate surfaces300and302and project toward the central space256. Projections305increase joint stiffness and allow a wider tolerance range on the pipe outer diameter as described below. Operation of the example coupling250is illustrated inFIGS.19and20. As shown inFIG.19, coupling250is provided in the pre-assembled state, with the segments252and254attached to one another end to end using the attachment member258(comprising lugs266and268and fastener270) and the attachment member260(comprising lugs278,280and fastener282). The segments252and254are held apart in spaced relation sufficient to permit insertion of pipe elements342and344into the central space256by the retainers314, or, in another embodiment, by a combination of the retainers314and the undeformed ring seal334. Whether the retainers314alone, or the retainers314in combination with the undeformed ring seal334hold the segments in spaced relation is dependent on the choice of material and geometry of retainers314and ring seal334. With reference toFIG.16, as pipe element344is inserted into central space256, the retainer314, being properly installed with band316overlying the first floor304and the tabs328overlying second floor306, has a radius of curvature which allows the pipe element to clear teeth322which project into the central space256when the coupling250is in the preassembled state. However, if, as shown inFIG.18, the retainer314is installed improperly, with the band316overlying the second floor306, the retainer's radius of curvature is smaller and teeth322effectively prevent insertion of the pipe element344into the central space256with the segments252and254in spaced apart relation in the pre-assembled state. This cooperation between the retainer314, its tabs328, teeth322, and the first and second floors304and306of channels288and290prevent improper assembly of a pipe joint using coupling250. If the pipe elements342and344could be inserted with the retainer teeth322facing in the wrong direction (FIG.18) then the teeth will not be self-actuating against forces which would draw or push the pipe element out of the coupling. Thus the retainer would not provide sufficient mechanical engagement preventing pipe element blowout when the joint is pressurized. Once both pipe elements342and344are inserted into the central space engaging the pipe stop338and respective inner surfaces336of ring seal334(FIG.20) the fasteners270and282are tightened. Tightening the fasteners270and282draws the segments252and254toward one another, and, as shown inFIG.20, the segments compress the ring seal334and the retainers314against the pipe elements. Compression of ring seal334forms a fluid tight seal and compression of retainer314forces teeth322into mechanical engagement with the outer surfaces of pipe elements342and344to form a secure joint. The advantage of the angular orientation of teeth322is readily apparent, as it causes the teeth to be self-actuating and resist axial forces which would draw or push the pipe elements out of engagement with the coupling250. Projections305are also forced into engagement with the pipe elements342and344as the segments252and254are drawn toward one another. The projections305add stiffness to the joint between the coupling250and the pipe elements342and344upon their engagement with the outer surfaces of the pipe elements. Additionally, the projections305accommodate a larger pipe outer diameter tolerance. When the outer diameter of pipe elements342and344is near the small end of the tolerance range the presence of the projections305ensures mechanical engagement between the coupling250and the pipe elements342and344. However, when the pipe diameter is at the large end of the tolerance range the projections will tend to deform the outer surface of the pipe elements locally. For couplings250used with plain end pipe elements this is particularly advantageous as plain end couplings are typically designed so that the arcuate surfaces300,302(seeFIG.15) do not engage the outer surfaces of the pipe elements. This arrangement ensures that the clamping force provided by the fasteners270and282(seeFIG.14) is fully applied to the retainers314. Were the arcuate surfaces300,302of the coupling250to engage the pipe outer surface directly, the clamping force would be divided between contact of the arcuate surfaces with the pipe and contact between the retainers314and the pipe elements. Because the surface areas of projections305are small relative to the arcuate surfaces300,302, and contact the pipe element outer surface only at discrete points, only minimal clamping force from the fasteners270and282need to be diverted into contact between the projections305and the pipe elements342and344to provide enhanced stiffness without compromising the axial retention provided by the retainers314. FIGS.21and22show an example coupling346according to the invention. Coupling346comprises first and second segments348and350attached to one another surrounding a central space352. Attachment of segments348and350is effected by first and second attachment members354and356positioned at respective opposite ends358and360of segments348and350. In this example embodiment the first attachment member354comprises first and second lugs362and364, and a fastener366comprising a bolt368and a nut370. Lugs362and364are in facing relation to one another and extend from ends358of respective segments348and350. The lugs have holes372which receive fastener366, the fastener extending between the first and second lugs. Comprised of lugs362,364and fastener366, the first attachment member is adjustably tightenable for drawing the segments348and350toward one another to join pipe elements as described below. As further shown inFIGS.21and22, the second attachment member356comprises a hinge374. In this example embodiment hinge374comprises first and second bosses376and378which project respectively from ends360of the segments348and350. As shown inFIGS.21and22, each boss376and378has a respective enlarged head380and382, as well as respective first and second lands384and386. Lands384and386are in facing relation with one another and are angularly oriented with respect to one another to permit pivoting action of the segments about the hinge374. Hinge374further comprises a ring388which surrounds the bosses376and378. Ring388is retained to the bosses by the heads380and382and the inner circumference of the ring provides the reaction surface against which the bosses376and378react when fastener366is tightened to draw the segments348ad350toward one another. The angular orientation of the lands384and386provide clearance enabling the heads380and382to be positioned within the ring388when the lands are in face to face contact during assembly of the coupling346. As shown in cross section inFIG.23each segment348and350comprises first and second sidewalls390and392respectively positioned on opposite sides394and396of each segment. The first and second sidewalls390and392extend between the ends358and360of segments348and350(seeFIG.21). As shown in detail inFIG.23, each sidewall390,392comprises a respective arcuate surface398and400facing the central space352. Each sidewall390,392furthermore has a plurality of projections402positioned on each arcuate surface398,400. Projections402are arranged in spaced relation to one another along the arcuate surfaces and project toward the central space352. As shown inFIG.23, segments348and350further comprise a channel404. Channel404is positioned between the first and second sidewalls390and392and faces the central space352. Channel404receives a ring seal406which ensures a fluid tight joint. Ring seal406is formed of a flexible, resilient material such as EPDM or other rubber compounds and has inner surfaces408sized to receive pipe elements when they are inserted into the central space352as described below. A pipe stop410is positioned between inner surfaces408. The pipe stop projects into the central space352and promotes insertion of pipe elements by engaging the pipe elements when they are inserted into coupling346to the desired depth. Ring seal406also has an outer surface412that is sized to engage and support the segments348and350in spaced apart relation as shown inFIG.21. The separation of the segments when supported by ring seal406is sufficient to permit pipe elements to be inserted into the coupling, clearing the projections402when the coupling346is in its pre-assembled state (FIG.21). Operation of the example coupling346is illustrated inFIGS.24and25. As shown inFIG.24, coupling346is provided in the pre-assembled state, with the segments348and350attached to one another end to end using the attachment members354and356, in this example fastener366, lugs362and364and hinge374. When undeformed, ring seal406holds the segments348and350in spaced apart relation sufficient to permit insertion of pipe elements414and416into the central space352as illustrated inFIG.24. It is advantageous that ring seal406has sufficient stiffness to support the segments348and350in spaced relation during shipping and handling and during installation. With reference toFIG.25, as pipe elements414and416are inserted into central space352, their outer surfaces engage the inner surfaces408of the ring seal406. The ends of the pipe elements engage the pipe stop410, and this engagement aligns the sidewalls390and392with respective circumferential grooves418and420in the pipe elements414and416. Once both pipe elements414and416are inserted into the central space engaging the pipe stop410and respective inner surfaces408, the fastener366is tightened, causing the segments348and350to pivot about hinge374(seeFIG.22). Tightening the fastener366draws the segments348and350toward one another, and, as shown inFIG.25, the segments compress the ring seal406and cause the projections402to engage the pipe elements414,416within their respective grooves418ad420. Projections402provide additional stiffness in bending, rotation and axially to the coupling346over designs without the projections. The projections also accommodate a wider tolerance range on pipe diameter, which is advantageous for small diameter pipe elements (3 inches or less). For example, when the diameter of grooves418and420is near the small end of the tolerance range the presence of the projections402ensures mechanical engagement between the coupling346and the pipe elements414and416. However, when the pipe diameter is at the large end of the tolerance range the projections will tend to deform the pipe elements locally within the grooves418and420. FIGS.26-28show another coupling embodiment422in the preassembled state having a captured pipe element424. Coupling422, shown inFIG.26, is similar in structure to coupling346(described above) and useful for items such as valves wherein the pipe element424comprises an integral part of the valve, for example an inlet and/or an outlet conduit of the valve. Such a valve would be provided with the coupling or couplings422attached at either or both ends and with the coupling in its preassembled state, allowing the valve to be rapidly integrated into a piping network by inserting the free ends of pipe elements of the network into the central space352of each coupling422opposite to the captured pipe element424and then tightening the fasteners366. The captured pipe element coupling422obviates the need to disassemble and reassemble the couplings and the valve. The valve or other component which uses the captured pipe element coupling422is not shown for clarity, but would be located at the free end424aof the pipe element424. FIG.27shows the captured pipe element424and coupling422in detail. Pipe element424is received within the central space352and has a groove426that receives sidewalls392on segments348and350, the other side of the coupling comprising sidewalls390being open for receiving a pipe element to which the valve or other item of which pipe element424is a component. A circumferential bead428is positioned contiguous with the groove426and has a larger diameter than the sealing surface430of the pipe element424. Sealing surface430engages a ring seal (not shown) positioned within the channel404and provides a fluid tight seal between the coupling and the pipe element. Bead428is received within a circumferential recess432in the sidewall392. The bead428, groove426and sidewall392are sized such that the bead and sidewall overlap when the segments348and350of coupling422are supported in spaced relation (for example by a ring seal in channel404, not shown) sufficient to permit a pipe element (without a bead) to be inserted into central space352from the side opposite to the captured pipe element424. Mechanical engagement between the bead428and the sidewall392thus capture the pipe element424when the coupling422is in the pre-assembled state shown inFIG.26. FIG.28shows another advantage of projections402on the arcuate surfaces400of sidewall392. Due to the angular separation of the segments348and350the degree of overlap between the sidewalls392and the bead428decreases with distance from the hinge374. Projections402extend toward the central space352and provide additional overlap with bead428and hence mechanical engagement at points farther from the hinge374, thereby ensuring that pipe element424remains captured by the segments348and350. | 43,359 |
11859738 | DETAILED DESCRIPTION Referring toFIG.1, a gas turbine engine is shown at1. The gas turbine engine1is of a type preferably provided for use in subsonic flight, and comprises in serial flow communication a fan2through which ambient air is propelled, a compressor section3for pressurizing the air, a combustor4in which the compressed air is mixed with fuel and ignited for generating an annular stream of hot combustion gases, and a turbine section5for extracting energy from the combustion gases. The fan2, the compressor section3, and the turbine section5are rotatable about a central axis R of the engine1. The engine1includes a fluid or hydraulic system6having one or more fluid lines7used to flow a fluid, such as lubricant, fuel, air, from a source8of the fluid to a component in need of the fluid. For instance, the fluid system may be a lubrication system operable to flow lubricant from a source of lubricant to a bearing cavity of the engine1for providing lubricant to bearings rotatably supporting a shaft9of the engine1. Alternatively, the fluid system6may be a fuel system for providing fuel from a fuel reservoir to fuel nozzles of the engine1. Alternatively, the fluid system6is an example of pneumatic system of the engine used for flowing air to an engine or aircraft component for purposes including cooling, actuation, feedback and environment control. Referring toFIGS.2-3, the fluid lines used in the fluid system have connecting end that are sealingly engaged to a port. Particularly, the fluid lines may be connected using a coupling assembly such as the one depicted at10. The coupling assembly10is used for securing a fluid line12to a component14of the gas turbine engine1. The fluid line12may be a fluid tube, which is substantially rigid, or a fluid hose, which may be flexible. The assembly10has a nipple16that is threadably engaged to the component14via suitable correspondingly mating threads16a,14adefined respectively by the nipple16and by an aperture of the component14. The assembly10has a ferrule18that defines a sealing engagement SE with the nipple16. The ferrule18is secured to the fluid line12, which may be a tube or a hose. The assembly10further has a coupling nut20that is used for biasing the ferrule18in sealing engagement with the nipple16. The ferrule18is shown as being secured to the fluid tube12via a weld joint18a. Any suitable joint may be used. Referring more particularly toFIG.3, both of the nipple16and the ferrule18define frustoconical faces16b,18b, which are sealing faces and that are in contact with one another. More specifically, to assemble the coupling assembly10, the coupling nut20and the nipple16are rotated one relative to the other about a central axis A, which may be substantially aligned with the line12, to deform the ferrule18such that the sealing engagement SE is created between the frustoconical faces16b,18bof the nipple16and ferrule18. In the embodiment shown, the coupling nut20has a head20cand a shank20sprotruding from the head20c. The head20cis engageable by a wrench for fastening the coupling nut20. Specifically, the head20cdefines faces20dthat are engageable by faces of the wrench. The shank20sdefines inner threads20athat are threadably engaged with corresponding outer threads16cof the nipple16so that rotation of the nipple16relative to the coupling nut20translates into a translation of the coupling nut20along the central axis A. The coupling nut20defines a shoulder20bthat extends circumferentially around the central axis A and that defines a passage20pvia which the fluid lines12is received. The shoulder20bof the coupling nut20is in abutment against a shoulder18cof the ferrule18. Therefore, rotating the coupling nut20about the central axis A results in the shoulder20bof the coupling nut20pushing against the shoulder18cof the ferrule18thereby biasing the frustoconical faces16b,18bof the nipple16and of the ferrule18against one another until the sealing engagement SE is created. As shown inFIG.4, a force field, which is illustrated by arrows F1, is therefore generated by the shoulder20bof the coupling nut20and applied on the shoulder18cof the ferrule18. This force field F1and the frustoconical shape of the faces18b,16bof the ferrule18and of the nipple16causes the ferrule18to deform until the shape of the face18bof the ferrule18mates with the face16bof the nipple16. This creates the sealing engagement SE between the ferrule18and the nipple16. More specifically, while fastening the coupling nut20on the nipple16, a distance between the frustoconical faces16b,18bdecreases and a contact begins to develop therebetween. Upon further fastening the coupling nut20, a sliding engagement between the frustoconical faces16b,18bis created and results in an elastic radial expansion of the ferrule18relative to the central axis A. This may have for effect of decreasing the area of contact between the frustoconical faces16b,18binto an uninterrupted, narrow, circular/elliptic contact area, which results in the sealing engagement SE therebetween, with increased unitary pressure at the contact area. The pressure at the sealing engagement SE must be superior to the combined loads including fluid pressure acting at the interface to prevent leakage. As shown inFIG.3, an external surface of the ferrule18may be frustoconical. This may prevent said external surface from contacting the coupling nut20during the radial expansion of the ferrule18. Referring toFIG.2, in some cases, the shoulder20bof the coupling nut20is defined by a thrust wire that circumferentially extends around the central axis A. Such a wire may be inserted into an aperture (not shown) and wrapped around the ferrule18on an inner side of the coupling nut20. The thrust wire may allow inserting the coupling nut20on the line12after the ferrule18is welded on the line12. After the coupling nut20is on the line12, the thrust wire may be inserted to lock the coupling nut20on the line12. Apertures20kdefined through some of the faces20dof the coupling nut20are used to receive a locking wire, also referred to as a safety cable, that is used to prevent the coupling nut20from unfastening. Referring toFIGS.2and5, the faces20dof the head20cof the coupling nut20are arranged in an hexagonal pattern such that a periphery of the head20chas a hexagonal shape when seen in a cross-section taken on a plane normal to the central axis A. The head20cis shown engaged by an open-ended wrench22inFIG.5. The open-ended wrench22has two faces22athat are in abutment against two opposed ones of faces20dof the head20cof the coupling nut20. The wrench22has an open end22bto allow access to the line12for engaging the wrench22to the head20c. Referring toFIGS.5and6, the two faces22aof the open-end wrench22are facing one another and parallel to one another; the two faces22abeing in abutment with two of the faces20dof the coupling nut20. This contact serves to transmit the rotation induced at the wrench to the nut. It has been observed by the inventors of the present application that rotating the open-ended wrench22creates local stress concentrations P (FIG.6) on the coupling nut20. These stress concentrations P have been found to locally deform the coupling nut20from being substantially circular to oval. Such a deformation may propagate to other components of the system (e.g., ferrule, nipple, line) and may affect the sealing engagement SE between the nipple16and the ferrule18. Moreover, it has been observed that such stress concentrations P may plastically deform the coupling nut20locally on the nut head. This has further been observed by the inventors of the present application to change the angle of the contact surface between the ferrule18and the nipple16, as the deformation progresses. In other words, the open-ended wrench22may not offer a uniform distribution of the force on the coupling nut20that may result in the phenomena described above. This may impact an efficiency of the seal created between the ferrule18and the nipple16. Moreover, the force applied to the wrench22, which is depicted by arrow F1onFIG.5, and the resulting force applied by the coupling nut20on the faces22aof the wrench22may cause the opposite faces22aof the wrench22to “open” and become non-parallel to one another. It has been observed that such a deformation of the open-ended wrench22may amplify the phenomena described above. Three types of wrenches are typically used to fasten the coupling nut20on the nipple16: an open-ended wrench22, a single hexagonal flare crowfoot wrench24(FIG.9), and a double hexagonal flare crowfoot wrench26(FIG.10). Each of those wrenches have faces22a,24a,26athat are in abutment against faces20dof the head20cof the coupling nut20. All of those wrenches22,24,26have an open end22b,24b,26bto be able to insert the fluid line12(FIG.2) therethrough. Hence, those wrenches22,24,26extend circumferentially around a portion of a circumference of the coupling nut20and leave a portion of said nut20free of interaction with the wrenches22,24,26. The double hexagonal flare crowfoot wrench26has more faces than the single hexagonal flare crowfoot wrench24. Referring toFIGS.7-8, a simulation was carried using the single hexagonal flare crowfoot wrench24, such as the one illustrated inFIG.7, that extends circumferentially around most of the coupling nut head20c. The single hexagonal flare crowfoot24has faces24ain the embodiment shown. Some of the faces24aare in abutment against the six faces20d(FIG.2) of the coupling nut20. As shown in the stress contours ofFIG.8, the stress is more uniformly distributed than when using the open-ended wrench22ofFIG.5. Using the single-hexagonal flare crowfoot24reduces the local stress peak and hence the magnitude of deformation of the coupling nut22compared to when using the open-ended wrench22. An evenly distributed load around the nut head20c, on contact points between the wrench and the coupling nut20, may result in less of the “ovalization” phenomenon described herein above. Coupling nuts in accordance with the present disclosure are described herein below. These coupling nuts have heads whose faces are arranged in patterns that may purposively prevent a user from using the open-ended wrench22that may amplify the ovalization risk described above. A plurality of possible patterns of faces are described below. However, it will be noted that many other suitable patterns are contemplated without departing from the scope of the present disclosure. For instance, any patterns defining faces circumferentially distributed about the central axis A and preventing the engagement of the open-ended wrench22ofFIG.5are contemplated. Specifically, those heads have edges at junction between faces. The faces and the edges of the heads of the present disclosure are arranged such that the faces22aof the open-ended wrench22ofFIG.5contact solely the edges while being free of surface contact with the faces of the coupling nut. If none of the faces of the coupling nut is in abutment against the faces22aof the open-ended wrench22ofFIG.5, then the open-ended wrench22will be unable to transfer a torque to the coupling nut and will, thus, be unable to deform the coupling nut as explained above. Such coupling nuts may be non-convex polygons, which may be axisymmetric. Referring now toFIGS.11and12, a coupling nut in accordance with another embodiment that is incompatible with the open-ended wrench22is shown at120. The nut120has a head120c; a top plan view of the head120cis shown inFIG.12. The head120cis the present embodiment a polygon, more specifically a non-convex polygon, that defines successively convexities and concavities disposed in alternation around a circumference of the head120c. The head120cis axisymmetric which allows a wrench to engage the head120cat more than one relative orientation. In the embodiment shown, the head120cof the coupling nut120has a pattern corresponding to two superposed hexagons. The head120cof the coupling nut120has 24 faces120dcircumferentially distributed around the central axis A and24edges120eeach located between two adjacent ones of the faces120d. In the embodiment shown, an angle between each two adjacent ones of the faces120dis about 120 degrees. The faces120dof the coupling nut120include torque-transmitting faces120f. The torque-transmitting faces120fare faces that are engaged by a tool for transmitting the force imparted to the tool to the faces of the coupling nut120and that result into rotation of said nut along arrow F1. In other words, the torque-transmitting faces120fof the faces120dare the faces that are compressed or pushed by the tool to induce rotation of the coupling nut120in one rotational direction. Of the 24 faces120d,12may be torque-transmitting faces120fat a time depending on rotational direction. Each of the torque-transmitting faces120fmay be located circumferentially between two non-torque-transmitting faces120g. In other words, the torque-transmitting faces120fmay be interspaced with the non-torque-transmitting faces120g. It will be appreciated that the torque-transmitting faces120fand the non-torque transmitting faces120gmay be interchanged depending of a direction of rotation of the coupling nut120. In other words, the faces120dthat are torque-transmitting faces120fin a first direction of rotation of the coupling nut120may become non-torque-transmitting faces120gin a second direction of rotation of the coupling nut120opposite the first direction of rotation and vice versa. Each of the torque-transmitting faces120ffaces a respective direction D that has a circumferential component relative to the central axis A. Particularly, the torque-transmitting faces120fare off-centered relative to the central axis A and have an offset to transmit a rotational load. In the embodiment shown, a projection120d1(boundaries of said projection being shown with dashed lines inFIG.12) of each of the faces120din the directions normal thereto are free of intersection with the central axis A. As shown inFIG.12, each of the projections120d1of each of the faces120dlands on an opposite one of the faces120dbeing parallel thereto. In the embodiment shown, the projection120d1of each of the faces120dmeets an associated one of the non-torque-transmitting faces120g. In the embodiment shown, the head120chas a baseline surface120c1that defines some of the faces120d. The baseline surface120c1has a shape corresponding to a convex polygon. In the depicted embodiment, the baseline surface120c1is a hexagon but other shapes are contemplated. Protrusions120pprotrude from the baseline surface120c1away from the central axis A. In the illustrated embodiment, each of faces120c2of the baseline surface120c1has one protrusion120pprotruding therefrom away from the central axis A. As will be explained below, these protrusions120plimit a user from engaging the open-ended wrench22to the head120cof the coupling nut120. The shape of the head of the coupling nut is therefore a convex polygon defining protrusions extending away from and beyond faces of the convex polygon. These protrusions prevent the engagement of the open-ended wrench22with the head of the coupling nut. In other words, because of these projections, the faces of the open-ended wrench22are unable to abut against the faces of the convex polygon in a sufficient way that allows torque to be transmitted to the coupling nut. If a user cannot use the open-ended wrench22, the ovalization risk described above is limited. In the embodiment shown, the coupling nut120defines a plurality of symmetry planes P1(only one shown with a dashed line inFIG.12) that contain the central axis A. Each of the symmetry planes P1extends from one of the edges120eto a diametrically opposed one of the edges120eand intersects the central axis A. In the illustrated embodiment, none of the faces120dare intersected by the symmetry planes P1. The torque-transmitting faces120fmay be free from intersection with the symmetry planes P1. Still referring toFIG.12, the edges120einclude a first subset120e1of the edges120eand a second subset120e2of the edges120e. The edges120eof the first subset120e1are contained within a first cylindrical surface boundary C1having a first radius R1. The edges120eof the second subset120e2are contained within a second cylindrical surface boundary C2having a second radius R2greater than the first radius R1. All of the faces120dare contained radially relative to the central axis A between the first radius R1and the second radius R2. All of the torque transmitting-faces120fare contained radially between the edges of the first subset and the edges of the second subset. The diameter of the cylindrical surface boundary C2is greater than the corresponding opening in the open-ended wrench22, which prevents engagement. In the embodiment shown, the coupling nut120presents two tabs120h, which may be diametrically opposed from one another. Each of the two tabs120hmay present an aperture120itherethrough. The tabs120hand apertures120imay be used for the typical purpose of securing a locking wire or safety cable (not shown) for limiting the coupling nut120from becoming unfastened from the nipple16(FIG.2) during use. Referring toFIGS.13and14, the features described above may prevent a user from using the open-ended wrench22shown inFIG.13and the single hexagonal flare crowfoot wrench24shown inFIG.14. Those tools, that is the open-ended wrench22and the single hexagonal flare crowfoot wrench24, each have two faces that are diametrically opposed to one another and that are parallel to one another. It may not be possible for a user to mate those tools22,24with the coupling nut120because geometrical interferences I may be created between the parallel faces of those tools22,24and diametrically opposed edges120eof the coupling nut120. The edges120emay be defined by the protrusions120p. In other words, the protrusions120pprevent the faces of the open-ended wrench22and the faces of the single hexagonal flare crowfoot wrench24from abutting the faces120dof the head120cof the coupling nut120. Hence, no torque is transmissible from these tools to the coupling nut120. If a user were unable to mate the tools22,24with the coupling nut120, he/she might be tempted to use a version of the same tool but of a greater dimension. In such case, it may be possible for the tool22,24to receive the coupling nut120, but there will be no transmission of torque possible because the parallel faces of the tools22,24will be abutting against edges120eof the coupling nut120. Hence, the faces of the tools22,24may be free of contact with any of the faces120dof the coupling nut120, which may result in the inability of the user to use those tools22,24to fasten the coupling nut120. Referring now toFIG.15, the commonly available double hexagonal flare crowfoot wrench26may be used for fastening the coupling nut120. Such a tool26has a wrenching interface W1having faces26acircumferentially distributed about the central axis A but for the opening26bthat is configured for receiving the fluid line12(FIG.2). In other words, the faces26aof the tool26match the faces120dof the coupling nut120. The wrenching interface W1defines edges26calternating with the faces26a. In the embodiment shown inFIG.15, each of the faces26aof the wrenching interface W1is in abutment against an associated one of the faces120dof the coupling nut120. Similarly to the coupling nut120, the faces26aof the wrenching interface W1include alternating torque-transmitting faces26fand non-torque-transmitting faces26g. In the embodiment shown, the wrenching interface W1defines one symmetry plane P2that intersects the opening26band that contains the central axis A. The symmetry plane P2may be free of intersection with the torque-transmitting faces26fof the wrenching interface W1. In the embodiment shown, projections of the torque-transmitting faces26fin directions normal to the torque-transmitting faces26fare free of intersection with the central axis A. Referring now toFIG.16, a coupling nut in accordance with another embodiment is shown generally at220. A cross-section of the coupling nut220taken on a plane normal to the central axis A may correspond to three superposed squares, indexed by 30 degrees one to another for an axisymmetric pattern. Angles T2between each two adjacent ones of faces220dof the coupling nut220may be about 90 degrees. This coupling nut220may present the same features as those described herein above with reference toFIG.12. A tool defining a wrenching interface corresponding to the coupling nut220may be used for fastening the coupling nut220. In the embodiment shown, the head220cof the coupling nut220has 24 faces220dcircumferentially distributed around the central axis A and24edges220eeach located between two adjacent ones of the faces220d. In the embodiment shown, the pattern of the faces220dof the head220chas a baseline surface220c1that defines some of the faces220d. The baseline surface220c1has a shape corresponding to a convex polygon. In the depicted embodiment, the baseline surface220c1is a square, but other shapes are contemplated. Protrusions220pprotrude from the baseline surface220c1away from the central axis A. In the illustrated embodiment, each of faces220c2of the baseline surface220c1has two protrusions220pprotruding therefrom away from the central axis A. As will be explained below, these protrusions220pintentionally prevent a user from engaging the open-ended wrench22to the head220cof the coupling nut220. In the embodiment shown, the coupling nut220defines a plurality of symmetry planes P3(only one shown with a dashed line inFIG.16) that contain the central axis A. Each of the symmetry planes P3extends from one of the edges220eto a diametrically opposed one of the edges220eand intersects the central axis A. In the illustrated embodiment, none of the faces220dare intersected by the symmetry planes P3. Still referring toFIG.16, the edges220einclude a first subset220e1of the edges220eand a second subset220e2of the edges220e. The edges220eof the first subset220e1are contained within a first cylindrical surface boundary C3having a first radius R3. The edges220eof the second subset220e2are contained within a second cylindrical surface boundary C4having a second radius R4different than the first radius R3. All of the faces220dare contained radially relative to the central axis A between the first radius and the second radius. Referring now toFIGS.17-18, a coupling nut in accordance with yet another embodiment is shown generally at320. The coupling nut320may define similar tabs320hand apertures320ias described above with reference toFIG.11. In the embodiment shown, the coupling nut320has a plurality of faces that defines a spline coupling having a plurality of teeth320tcircumferentially distributed around the central axis A. Each of the teeth320tdefines a torque-transmitting face320f, a non-torque-transmitting face320g, and an end face320j. It is understood that the torque-transmitting faces320fbecome the non-transmitting faces320gwhen the nut320is rotated in a counter clockwise direction. The faces of the head320cfurther includes inter-teeth faces320keach located between two adjacent ones of the teeth320t. In the embodiment shown, the torque-transmitting faces320fare facing a direction D that may be solely tangential relative to the central axis A. In other words, the direction D faced by the torque-transmitting faces320f(and by the non-torque transmitting faces320g) may be free of a radial component relative to the central axis A. The end faces320jmay face a direction that is solely radial relative to the central axis A and may be unable to transmit any torque regardless of the direction of rotation of the coupling nut320. In a particular embodiment, the more the tangential component of the torque transmitting face is predominant relative to the radial component, the greater the effective area for load distribution, and less likely the elastic and/or plastic ovalization described above is likely to happen. The coupling nut320may present analog features described above with reference toFIG.12that may allow the coupling nut320to deter a user from using an open-ended wrench20to fasten the coupling nut320. The coupling nut320may define an external periphery rendering torque transmission from the open-ended wrench20very difficult. A tool defining a wrenching interface mating with the teeth320aof the coupling nut320is part of the present disclosure. In the embodiment shown, the shape of the head320chas a baseline surface320c1that defines the inter-teeth faces320k. The baseline surface320c1is a circle. The teeth320tprotrude from the baseline surface320c1away from the central axis A. As for the protrusions described above, the teeth320tlimit a user from engaging the open-ended wrench22to the head320cof the coupling nut320. That is, if an open-ended wrench22were to engage the head320cof the coupling nut320, only edges320edefined at intersections between the faces320f,320g,320jof the teeth320twould be in contact with the faces of the wrench22and would be unable to transmit any torque to the coupling nut320. That is, none of the torque-transmitting faces320fwould be in abutment against the faces of the wrench22. The open-ended wrench22cannot engage with the teeth320tbecause a distance between the opposed faces of the open-ended wrench22would need to be equal or greater than an outer cylindrical surface boundary C5to avoid interference, and thus cannot transmit torque. The teeth320tare located radially inwardly of the outer cylindrical surface boundary C5. Still referring toFIG.18, in the embodiment shown, the edges320einclude a first subset of the edges320eand a second subset of the edges320e. The edges320eof the first subset are contained within a first cylindrical plane having a first radius. The edges320eof the second subset are contained within a second cylindrical plane having a second radius different than the first radius. All of the torque-transmitting faces320fare contained radially relative to the central axis A between the first radius and the second radius. Referring toFIGS.19-20, a tool in accordance with one embodiment is shown at126. The tool has a wrenching interface W2, which in the illustrated embodiment corresponds to a double-hexagon pattern. However, the wrenching interface W2of the tool126may be selected to correspond to any of the coupling nuts20,120,220,320described herein above, or any geometrically applicable pattern. In other words, a shape of the wrenching interface W2of the tool126may be seen as the negative of the shape of the coupling nut20,120,220,320. In some cases, the line12(FIG.2) on which the coupling assembly10(FIG.2) is to be located is in close proximity to another element preventing typical access with the aforementioned tools over the tube12or the nut shank20s, using the previously described thrust wire configuration. This other element may be, for instance, a connection between the line12and another line of a lubrication system of a gas turbine engine10, or a custom ferrule18in an elbow or tee configuration. Therefore, in those situations, it may be difficult to insert the tool around the line12or custom ferrule via its opening. In this particular configuration, when the traditional single-layer tool26is prevented from engagement, the tool126disclosed herein may be may be used. The tool126has a plurality of layers126a, which may be substantially identical to one another, acting simultaneous on the coupling nut head. Each of the layers126aof the tool126defines a tool drive provided in the form of an aperture126c. The aperture126cis square shaped here, but any other suitable shape is contemplated. The apertures126cof each of the layers126aare in register with one another once the layers126aare stacked on the nut. In the embodiment shown, the position of the opening126brequired for engagement over the tube12features an angular offset between layers126ato completely engage all nut head faces with the entire tool stack. Each of the layers126amay be, one after the other, engaged over the line12and slid into the driving engagement with the coupling nut. Once the entire tool stack of layers126aare in engagement with the coupling nut, the tool drive may be engaged with the tool drives126band the coupling nut may be torqued or un-torqued on its fitting (FIGS.2and3). As shown inFIG.20, the wrenching interface W2of each of the layers126ais circumferentially offset one relative to the other. That is, each of the layers126ais disposed around the coupling nut20ofFIG.2and each of the layers126amay engage a respective one of the three pairs of opposed faces20dof the coupling nut20. More than three layers126amay be used. Two layers may be used. As shown inFIG.20, once all of the layers126aare engaged on the coupling nut, a whole circumference of the coupling nut is surrounded by the tool126via its layers126a. This configuration in which the whole circumference of the coupling nut is surrounded by the tool126, and in which each of the faces of the coupling nut are engaged by the tool126, may further contribute in overcoming the ovalization problem described above. Referring toFIGS.21-22, a tool in accordance with one embodiment is shown at226. The tool226has a wrenching interface W2, which in the illustrated embodiment corresponds to a double-hexagon pattern. However, the wrenching interface W2of the tool226may be selected to correspond to any of the coupling nuts20,120,220,320described herein above. In other words, a shape of the wrenching interface W2of the tool226may be seen as the negative of the shape of the coupling nut. The tool226includes two legs226athat are pivotable one relative to the other about a pivot point J. This configuration may allow the ability to completely engage all nut head faces (20d,120f,220f,3200. As shown inFIG.21, for engaging the tool226to the coupling nut, the legs226aare pivoted away from one another to increase a dimension of an opening226bof the tool226for inserting the coupling nut. Then, the leg226amay be pivoted about a pivot point J via which the two legs226aare connected to one another to create the engagement with the coupling nut and torque may be applied on said nut. A locking mechanism may be used to maintain the leg226ain engagement with the coupling nut during the fastening operation. For instance, the locking mechanism may use a strap, pin, a cam mechanism. The tool drive may be used to lock the tool around the coupling nut. As shown inFIG.22, once the two legs226aare locked and engaged on the coupling nut, a whole circumference of the coupling nut is surrounded by the tool226via its two legs226a. This configuration in which the whole circumference of the coupling nut is surrounded by the tool226, and in which each of the faces of the coupling nut are engaged by the tool226, may further contribute in overcoming the ovalization problem described above. In the embodiment shown, each of the legs226adefines a tool drive226cprovided in the form of a square aperture. Once the legs226are both in engagement with the coupling nut to be fastened, the tool drives226cof the two legs226aare in register and the wrench may be engaged to the tool226via the two tool drives226cthereby locking the two legs226ain engagement against the coupling nut. Referring now toFIGS.23to25, a tool in accordance with yet another embodiment is shown at326. The tool has a wrenching interface W2, which in the illustrated embodiment corresponds to a double-hexagon pattern. However, the wrenching interface W2of the tool326may be selected to correspond to any of the coupling nuts20,120,220,320described herein above. In other words, a shape of the wrenching interface W2of the tool226may be seen as the negative of the shape of the coupling nut. The tool326includes two legs326a,326bthat are pivotably engaged to one another. In the embodiment shown, the two legs326a,326bare detachable from one another to allow a user to dispose a first leg326aof the tool326around a first portion of the coupling nut20,120,220,320and a second leg326bof the tool326around a second portion of the coupling nut20,120,220,320. Once the two legs326a,326bare wrapped around the coupling nut, the two legs326amay be pivotably connected to one another and pivoted toward one another to engage the coupling nut20,120,220,320until two tool drives326eof each of the legs326a,326bare in register as shown inFIG.25. At which point, the drive of the wrench may be inserted through the tool drive326eto lock the two legs326a,326bin engagement with the coupling nut during torqueing. Hence, in the embodiment shown, the two legs326a,326bare locked by the drive of the wrench inserted in the tool drives326e. As shown inFIG.23, the first leg326adefines an arcuate protrusion326dat a distal end thereof and the second leg326bdefines a shaft portion326cat a distal end of the second leg326b. An aperture is defined through the second leg326bbetween the shaft portion326cand a remainder of the second leg326b. As shown inFIG.24, the arcuate protrusion326dis sized to be received within the aperture and a pivotal engagement is defined between the arcuate protrusion326dand the aperture326c. By being so engaged, the two legs326a,326bare pivotable one relative to the other about an axis going through a pivot point J2that is created by the engagement of the arcuate protrusion326dand the shaft portion326cof the two legs326a,326b. As shown inFIG.25, once the two legs326a,326bare pivotably engaged to one another, the two legs326a,326bmay be pivoted toward one another until the tool drives326eof each of the legs326a,326bare in register. The wrench may therefore be engaged to the tool drives326eto lock the two legs326a,326bin engagement on the coupling nut. This configuration in which the whole circumference of the coupling nut is surrounded by the tool326, and in which each of the faces of the coupling nut are engaged by the tool326, may further contribute in overcoming the ovalization problem described above. It will be appreciated that many modifications may be made to the tools disclosed herein above. For instance, the legs may include two members pivotably connected to one another such that the two members are pivotable one relative to the other about a pivot axis. In other words, each of the legs may be arcuate legs having two or more members. It will be appreciated that the tools126,226,326disclosed herein above may be used to engage any suitable coupling nuts. These coupling nuts may have any number of faces engageable by the tools. For instance, the wrenching interface W2of the tools may be tailored to engage a coupling nut having a square head, a head having two flat faces connected by two arcuate portions, etc. The present disclosure relates to a tube nut20to be used in tube assemblies10, featuring a wrench driving interface geometry for the torqueing tools, called here forth a wrenching configuration (WC). The disclosure includes a set of specifically designed tools to drive the coupling nut20and apply the assembly torque, such as but not limited to, a double hexagonal flare crowfoot wrench mating with the selected tube nut. The referred tooling may include specifically designed crowfoots compatible with a thrust wire nut configuration, where a commercial flare crowfoot cannot be used due to lack of space and/or accessibility. An aspect of this disclosure is to change the geometry of the tube nut's wrenching configuration from hexagonal to other geometries that may better distribute the torqueing load along the tube nut's wrenching configuration than what is currently available in the industry, and for most, preventing the use of open-ended wrenches which exacerbates the deformation risk on all fluid system components10. In a particular embodiment, the design-inherited features linked to this disclosure may therefore enforce that the torqueing procedure be done with a specific tool only, in order to ensure a better load distribution transmitted from the tool to the tube coupling nut. Common industry-specified tube nuts have a wrenching configuration characterized by exclusively standardized size single hexagonal geometry (6 flats) that can mate with at least 3 different standard torqueing tools: a single hexagonal flare crowfoot24, a double hexagonal flare crowfoot26, or a two flats open wrench22. By opposition, a coupling nut in accordance with the present disclosure may feature a double hexagonal wrenching configuration that can solely mate with a double hexagonal flare crowfoot26. The other two tools, that is the hexagonal wrench22and the single hexagonal crowfoot24, may not be used because the geometry forming the wrenching configuration of the coupling nut would interfere geometrically when attempting engagement with the aforementioned tools. The tool inherently selected may be the tool that may provide the best load distribution from the torqueing procedure, from the tool to the tube nut, along the perimeter of its wrenching configuration. A better load distribution may prevent generating localized peak stresses and permanent deformation/ovalization on components of the fluid fitting assembly10(in particular at the sealing interface SE). The tube nuts can feature a variety of wrenching configurations (WC) through which the assembly torque is driven. These configurations may include but not be limited to, for instance, double hexagon, triple square, external spline, Bristol Spline, external spanner driving feature, face hole spanner and serrations. The mating assembly torqueing tools (crowfoot) may have the internal spline/geometry version of the above. The disclosure is intended to integrate other features into the coupling nuts to enable the mechanism of securing the assembly with positive locking devices, such as but not limited to, what is used in the single hexagonal nut, like typical safety cable and locking wire. Recesses in the points of the wrenching configuration may facilitate the drilling required to obtain the hole by offering a perpendicular and larger surface area, which may otherwise be limited on the proposed geometries. The disclosure is also intended to include provision to feature a thrust wire configuration of the same tube nuts, along with special tools specifically designed to drive the coupling nut and apply assembly torque in assembly locations characterized by restrictively constrained tool access typical to thrust wire coupling nut configurations. A thrust wire nut configuration affects mainly the internal diameter at the WC, where the thrust wire is fitted, so the design may be compatible with the present disclosure. The specially designed tools may be defined as wrenches having the driving interface compatible with all wrenching configurations (WC) of the proposed coupling nut individually, and characterized by mechanical features allowing to wrap around the coupling nut, enclosing completely or partially the driving feature when the fluid coupling assembly featuring a thrust wire configuration is fully engaged into the fluid fitting assembly. Tool design options to fully engage and disengage the tool in this scenario include (but are not limited to) a multi-stack thin crowfoot (inserted layer by layer), or a hinged crowfoot (that covers a proportion of the nut perimeter similar to a flare crowfoot, or more). The embodiments described in this document provide non-limiting examples of possible implementations of the present technology. Upon review of the present disclosure, a person of ordinary skill in the art will recognize that changes may be made to the embodiments described herein without departing from the scope of the present technology. Yet further modifications could be implemented by a person of ordinary skill in the art in view of the present disclosure, which modifications would be within the scope of the present technology. | 40,063 |
11859739 | DETAILED DESCRIPTION FIG.1shows the interface between a connector2and a cylindrical fluid transfer conduit4that extends parallel to a central axis C. The connector2comprises a cylindrical hub portion6, which also extends parallel to the central axis C, and a flange portion8, which extends from an end of the hub portion6in a direction perpendicular to the central axis C. The flange portion8further comprises a through-hole10, by which the connector2may be secured to another structure, e.g. an aircraft wing rib. The hub portion6encloses a connection portion12of the fluid transfer conduit4. An elastomeric O-ring14is located between the hub portion6and the connection portion12, retained between an inner wall of the hub portion6and an outer wall of the fluid transfer conduit4. The O-ring14is confined by two retaining ridges16which extend radially outwards from the connection portion10of the fluid transfer conduit4. The O-ring14provides a seal between the connector2and the conduit4, such that fluid may flow along the conduit4and into the connector2without escaping. In addition, the configuration of O-ring14between the connection portion12and the hub portion6allows the fluid transfer conduit4to move a small distance in the direction of the central axis C relative to the connector2without compromising the seal. This enables a structure to which the connector2is secured to move or flex a small amount without imparting large stresses on the conduit4(as would be the case if the connector2was rigidly attached to the conduit4). Instead, the conduit4“floats” on the O-ring14such that it can slide longitudinally a small distance without breaking the seal. For example, the structure to which the connector2is attached may be an aircraft wing rib, which is designed to move a small amount during flight as the wing flexes due to aerodynamic load and/or temperature fluctuations. The fluid transfer conduit4may comprise a fuel pipe located within the wing which must therefore be able to cope with the wing flex during flight. FIG.2is a schematic perspective view of a composite connector102according to an example of the present disclosure. The connector102comprises a cylindrical hub portion106which extends parallel to a central axis C and a flange portion108which extends perpendicularly from an end of the hub portion106. The flange portion108comprises four through-holes114which allow the connector102to be fixed to a further structure (e.g. an internal rib of an aircraft wing). The hub portion106comprises polymer resin matrix reinforced with continuous hoop-wound (circumferentially-orientated) fiber110. The hoop-wound fiber110provides the hub portion106with high hoop strength such that the hub portion can resist large internal pressures. It also makes the hub portion106very stiff, such that large internal pressures cause negligible hoop expansion. The flange portion108comprises the same polymer resin matrix with its own continuous fiber reinforcement112(only shown partially for clarity). The composite connector102is manufactured using a pre-form net and a tubular pre-form.FIG.3shows an example of one such pre-form net300. The pre-form net300comprises an annular disc302defining a central hole303. The annular disc302is formed from fiber reinforcement304(although only a small portion of the total fiber reinforcement present is depicted inFIG.3to aid clarity), which has been stitched onto a non-structural support layer306made of a fiber veil (e.g. using a polyester or nylon thread, not shown). The support layer306holds the fiber reinforcement304in a desired position and orientation. The pre-form net300further comprises four through-holes308spaced around the annular disc302which will become fixing points in the flange portion of the finished connector, allowing the connector to be fixed securely to a further structure. The fiber reinforcement304extends both radially and circumferentially in the annular disc302, providing the finished connector with resistance to torques and bending loads. The fiber reinforcement304partially encircles the through-holes308(and may completely encircle the through-holes one or more times) to increase their strength and thus the strength of a connection between the finished connector and a further structure. An alternative pre-form net400is shown inFIG.4which comprises four flange lobes402arranged around and defining a central hole403. Continuous fiber reinforcement404runs between each of the flange lobes402(only partially shown for clarity). The fiber reinforcement404is stitched onto a non-structural support layer406comprising a fiber veil to hold the fiber reinforcement404in a desired position and orientation. The pre-form net400further comprises four through-holes408spaced around the annular disc402, in this example one through-hole408in each lobe402. The through holes408will become fixing points in the flange portion of the finished connector. The lobed pre-form net400may produce a finished connector with lower weight than the annular pre-form net300. As with the pre-form net300shown inFIG.3, the fiber reinforcement404extends both radially and circumferentially in the flange lobes402, providing the finished connector with resistance to torques and bending loads. The fiber reinforcement404encircles the through-holes408(possibly several times) to increase their strength. FIG.5shows a further alternative pre-form net500, comprising an annular disc502which surrounds a central tabbed section505. Continuous fiber reinforcement504extends around the annular disc502and into the central tabbed section505. The fiber reinforcement504is stitched onto a support layer506comprising a fiber veil to hold the fiber reinforcement504in a desired position and orientation. The pre-form net500further comprises four through-holes508spaced around the annular disc502. The through holes508will become fixing points in the flange portion of the finished connector (as seen inFIG.6). The tabbed section505comprises a plurality of radially extending tabs507, which may be formed by stitching the fiber reinforcement504to the support layer506in which tabs have already been cut, or by cutting tabs into the pre-form net500after the fiber reinforcement504has been stitched to the support layer506. The pre-form net500is flat while the fiber reinforcement504is stitched onto the support layer506, but the tabs507may then be folded out to extend perpendicularly from the annular disc502. As shown inFIG.6, when the pre-form net500is used to form a composite connector (described in more detail below), the folded-out tabs507are arranged to extend around an outer surface of a fiber-reinforced tubular pre-form600. It is shown schematically how the tubular pre-form600comprises continuous circumferentially-oriented fiber reinforcement604, e.g. hoop fiber reinforcement. The tabs serve to increase the area over which the fiber reinforcement504of the pre-form net500contacts the tubular pre-form600and its fiber reinforcement604, when compared with the contact area possible with alternative pre-form nets, such as those shown inFIGS.3and4. With these pre-form nets300,400, the tubular pre-form600may contact the pre-form net300,400only around the inner edge of the central hole303,403. Increasing the contact area between the fiber reinforcement504of the pre-form net500and the tubular pre-form600strengthens the connection between the flange portion and the hub portion in the resultant connector, increasing its strength and, in particular, its resistance to bending loads. As shown inFIG.7, manufacturing a composite connector according to the present disclosure comprises placing the pre-form net300(for example) into a mould700with a tubular pre-form310. The tubular pre-form310comprises continuous circumferential fiber reinforcement312and has an outer diameter which matches the diameter of the central hole303. The tubular pre-form310may be formed in a preceding manufacturing step by filament winding dry fiber onto a mandrel, with the mandrel being removed or left in situ when the tubular pre-form310is assembled with the pre-form net300in the mould700. The mould700into which the pre-form net300and the tubular pre-form310are placed comprises a first portion702and a second portion704. The first and second portions702,204are shaped such that when they are brought together they define an annular cavity, into which the pre-form net300is placed, and a tubular cavity, into which the tubular pre-form310is placed. Both the annular and tubular cavities are symmetrical about a central axis C. Although not shown inFIG.7, a mandrel on which the tubular pre-form310has been formed may also be placed into the mould700and may even form part of first or second portions702,704of the mould700. When placed in the mould700, the tubular pre-form310extends into the central hole303of the pre-form net300(as seen inFIG.3) such that any gap between the fiber reinforcement304,312of the pre-form net300and the tubular pre-form310is minimised. In this example, thermosetting polymer resin is pumped into the annular and tubular cavities through one or more input channels (not shown) and penetrates into and around the fiber reinforcement304,312of both the pre-form net300and the tubular pre-form310. Of course the support layer306is stitched to the fiber reinforcement304in the pre-form net300and becomes encapsulated as well. The mould700holds both the pre-form net300and the tubular pre-form310in position during this process. Heat is applied to the mould700to cure the resin and form a composite connector comprising a flange portion (formed from the pre-form net300) and a hub portion (formed from the tubular pre-form310). The finished composite connector may then be removed from the mould700.FIG.2provides an example of the resultant connector102. | 9,849 |
11859740 | Corresponding reference characters indicate corresponding parts throughout the drawings. DETAILED DESCRIPTION OF THE DISCLOSURE Referring toFIG.1of the drawings, a flange joint assembly suitable for use in conveying flammable liquid, such as from a liquid-reactor and/or within liquid-conveying conduit system is generally indicated at reference numeral10. In this illustrated embodiment, the flange joint assembly10comprises a flanged fitting, generally indicated at12; an expansion joint fitting, generally indicated at14; an annular gasket, generally indicated at15, disposed and sandwiched between the flanged fitting and the expansion joint fitting; and a flange coupler assembly, generally indicated at16, coupling together the flanged fitting, the expansion joint fitting and the annular gasket. It is understood that flanged fitting12of the present disclosure may be used separate from and independent of the illustrated expansion joint fitting14and/or the illustrated annular gasket15; the expansion joint fitting14may be used separate from and independent of the illustrated flanged fitting12and/or the illustrated annular gasket15; and the annular gasket15may be used separate and independent of the illustrated flanged fitting12and/or the illustrated expansion joint fitting14. For example, as explained in more detail below, the flanged fitting12may be coupled to other types of conduits, other than the illustrated expansion joint fitting14, including other types of expansion joint fittings, flanged piping, flanged components, etc. (as represented schematically inFIG.3). The expansion joint fitting14may be coupled to other types of flanged fittings, other than the illustrated flanged fitting12, including other types of nozzles, or piping, etc. The annular gasket15may be coupled between other types of fittings, or piping, etc., other than the illustrated flanged fitting12and expansion joint fitting14. The flanged fitting12has a longitudinal axis LA1, opposite upstream and downstream longitudinal ends (broadly, first and second longitudinal ends), and a passage20extending longitudinally within the flanged fitting and through the upstream and downstream longitudinal ends thereof. As used herein when describing the flanged fitting12and its components and structures, the longitudinal axis of the flanged fitting is used as the point of reference for the terms “axially,” “radially,” “inner,” “outer,” and like qualifiers. The illustrated flanged fitting12is configured as a nozzle, such as a nozzle for a reactor vessel. In other examples, the flanged fitting12may comprise other types of fittings, including piping or other conduits for conveying liquids, or other types of fitting components, including covers, agitators, mechanical seals, baffles, valves, etc. for use in a liquid system. The flanged fitting12comprises a conduit, generally indicated at22, and an annular flange, generally indicated at24, at a downstream longitudinal end of the flanged fitting. The conduit22comprises a conduit body22a(e.g., nozzle neck; pipe), and the annular flange24comprises an annular flange body24aat a downstream longitudinal end of the conduit body. Together, the conduit body22aand the annular flange body24aform a fitting body of the flanged fitting12. The fitting body may be formed as a one-piece, monolithically formed component, or the conduit body22aand the annular flange body24amay be formed separately and secured to one another. The fitting body may be fire-rated. As used herein, “fire-rated” means a component or structure is formed from material that meets the standard set forth in NFPA 30, and may include carbon steel, nickel alloys, reactive metals, and combinations. The fitting body may be comprised of (e.g., be formed from) a metal material, such as carbon steel or other types of metal. In the illustrated embodiment shown inFIGS.1-4, the fitting body may be formed as a suitable stub end for an ASME Class 150 or 300 joint flange. An internal liner26lines an interior surface of the fitting body, including the conduit body22aand the annular flange body24a. In one example, the liner26acts as a corrosion-resistance barrier to inhibit liquid in the flanged fitting12from contacting and corroding the material (e.g., metal) of the fitting body. In one or more examples, the liner26may comprise (e.g., be formed from) a non-metal material, such as glass, graphite, silicon carbide, ceramic, or other non-metal material. In one example, the liner26may uniformly cover the entire interior surfaces of the conduit body22aand the annular flange body24a. The liner26may have a uniform thickness of up to about 100 mm or other thicknesses. As explained below, the fitting body is modified to ensure the flange joint assembly10does not fail when subjected to a fire test temperature between 1400° F.-1800° F. (761° C.-980° C.) for a period of 30 minutes, according to the API Specification 6FB, Titled “Specification for Fire Test for End Connections.” That is, the fitting body is suitable for passing the test set forth in API Specification 6FB. For reasons explained below, as shown inFIGS.2-4, the annular flange24of the flanged fitting12also comprises an annular flange extension28extending around the outer diameter portion of the annular flange body24aand may be formed (e.g., forged and/or machined) as a one-piece, monolithically formed integral part of the annular flange body24a. The annular flange extension28increases the diameter of the annular flange24of the flanged fitting12beyond standard ASME Class 150 or 300 raised face dimensions without interfering with the flanged fitting12bolting63and fastener openings56and220. The annular flange extension28may be fire-rated. For example, the annular flange extension may be comprised of a (e.g., be formed from) a metal material, such as carbon steel or other types of metal that match the annular flange body24a. In one example, as shown inFIG.4, the annular flange extension28may have a radial width W1of about ⅜″ (9.525 mm) to increase the diameter of the annular flange24by ¾″ (1.905 cm). In other embodiments, the annular flange extension28may be formed separately and secured to the flange body24aof an ASME Class 150 or 300 standard raised face configuration flanged fitting by welding or in other suitable ways. The annular flange24of the flanged fitting12further comprises an annular insert or inlay30adjacent the outer radial end of the annular flange24. The annular inlay30is positioned downstream of the annular flange extension28such that a radially outer annular portion of the annular inlay30overlies (as viewed from the downstream longitudinal end of the flanged fitting) and abuts the annular flange extension. The annular inlay30may have an axial thickness T1of about ¼″ (6.35 mm). Moreover, the radially outer surface of the annular inlay30is generally flush with the radially outer surface of the annular flange extension28. The annular inlay30extends radially inward relative to the longitudinal axis LA1of the flanged fitting12and into an annular recess34of the annular flange body24asuch that a radially outer annular portion of the liner26of the annular flange24overlies (as viewed from the downstream longitudinal end of the flanged fitting) and abuts a downstream surface of a radially inner annular portion of the annular inlay. In other words, the radially outer annular portion of the liner26of the annular flange24generally abuts and is positioned downstream of the radially inner annular portion of the annular inlay30. The annular inlay30may be formed and secured from a welding method (i.e. weld overlay—thickness build-up through welding passes with final machining) to the annular flange body24awithin the annular recess34and forms a one-piece, monolithically formed annular flange body24a. In one example, as shown inFIG.4, the annular inlay30may extend radially inward from the radially outer end of the liner26a distance d1, which may be about ¼″ (6.35 mm), to inhibit crevice corrosion that can propagate underneath the liner and lead to cracking and/or failure of the liner. In other embodiments, the annular inlay30may be formed separately (e.g., forged and/or machined) and secured to the annular flange body24awithin the annular recess34using a welding method or in other suitable ways. The radially outer annular portion of the annular inlay30extends more radially outward than the radially outer annular portion of the liner26relative to the longitudinal axis LA1of the flange fitting12. For example, as shown inFIG.4, the annular inlay30may extend radially outward from the radially outer end of the liner26a distance d2, which may be about ⅜″ (9.525 mm). In the illustrated embodiment, the radially inner annular portion of the annular inlay30has an annular recess36at its downstream longitudinal end surface in which the radially outer annular portion of the liner26is received such that the downstream longitudinal end surface of the annular inlay at its radially outer portion is generally flush with the downstream end surface of the liner at the radially outer portion of the liner. Thus, the glass liner26lines a radially inner annular portion of the annular downstream end face of the annular fitting flange24, and a radially outer annular portion of the annular downstream end face of the annular fitting flange is free from the glass liner. Together, the downstream surface of the radially outer portion of the annular inlay30and the downstream surface of the liner26on the flange24define a gasket abutment face at the downstream longitudinal end of the flanged fitting12. The annular gasket abutment face is generally planar and lies in a plane generally perpendicular to the longitudinal axis LA1of the flanged fitting12. The downstream longitudinal surface of the radially outer annular portion of the annular inlay30partially defining the gasket abutment face may include a roughened finish, e.g., a phonographic finish (broadly, a serrated surface), to enhance and/or facilitate seating of the annular gasket15on the gasket abutment surface. For example, the downstream surface of the radially outer annular portion of the annular inlay30may include a phonographic finish of about 125 to about 250 root mean square (RMS) micro inches. For reasons explained below, the annular inlay30may be fire-rated. For example, the annular inlay30may comprise (e.g., be formed from) metal, such as a nickel alloy (e.g., Alloy 625, Alloy 600, Alloy C-276/C-22/C-2000, Hastelloy® G-30/G-35/BC-1, Inconel® 686, Monel® 400, Alloy 825, Alloy 200, AL-6XN®, or 904L SS), or a reactive metal (e.g., titanium Gr. 2/Gr. 7, zirconium 702, tantalum, tantalum with 2.5% tungsten), or combinations thereof, including alloys thereof. In one example, the annular inlay30is formed from Alloy 625. In one method of making the flanged fitting12, a one piece, monolithically formed flanged fitting including the annular flange extension is provided (e.g., forged and/or machined) as the fitting body. The fitting body is machined to form the annular recess34in the body. The annular inlay30is formed and secured from a welding method (e.g., weld overlay—thickness build-up through welding passes with final machining) to the annular flange body24awithin the annular recess34and forms a one-piece, monolithically formed annular flange body24a. The recess36of the inlay30is machined. The liner26(e.g., glass) is then applied to the interior surface of the flanged fitting body. The flanged fitting12may be formed in other suitable ways where the annular flange extension28and the annular inlay30are formed separately or a combination of monolithically formed parts and separate components and secured using a welding method or in other suitable ways. Referring toFIGS.5and6, the annular gasket15comprises opposing first and second annular gasket layers, generally indicated at40a,40b, respectively, (e.g., longitudinally upstream and downstream annular gasket layers), and an inner annular substrate42sandwiched between the first and second annular gasket layers. As used herein when describing the annular gasket15and its components and structures, an axis A1of the annular gasket is used as the point of reference for the terms “axially,” “radially,” “inner,” “outer,” and like qualifiers. Each annular gasket layer40a,40bcomprises a radially inner annular gasket segment44and a radially outer annular gasket segment46secured to a radially outer end of and circumferentially surrounding the radially inner annular gasket segment. The radially inner annular gasket segment44of the upstream annular gasket layer40agenerally opposes, abuts and seats against the liner26of the annular flange24. The radially inner annular gasket segment44of the downstream gasket layer40bis configured to generally oppose, abut and seat against an annular flange or other component of the other component (e.g., the expansion joint fitting14) of the flange joint assembly10. The radially inner annular gasket segment44is sized and shaped to extend from the radially outer end of the liner26on the annular flange24toward longitudinal axis of the flanged fitting12when the joint flange assembly10is assembled. In one example, the radially outer ends of the radially inner annular gasket segments44and the radially outer end of the liner26of the annular flange24are spaced at an equal radial distance from the longitudinal axis LA1of the flanged fitting12such that the two radially outer ends are generally aligned axially. The radially inner annular gasket segment44of the upstream annular gasket layer40aaccommodates imperfections in the liner26, provides a chemical seal, and protects and inhibits breakage of the non-metal liner, which may be glass or other frangible material. The radially inner annular gasket segments44of the upstream and downstream annular gasket layers40a,40bmay comprise (e.g., be formed from) a fluoropolymer, such as polytetrafluoroethylene (PTFE), including expanded PTFE (ePTFE). An example of suitable ePTFE is sold under the trademark GORE-TEX® and manufactured by W. L. Gore & Associates. The radially inner annular gasket segments44of the upstream and downstream layers40a,40bmay comprise (e.g., be formed from) other types of materials, including other types of polymers. Together, the radially inner annular gasket segment44of the upstream annular gasket layer40aand the liner26(e.g., glass liner) of the annular flange24form a liquid-tight seal. The radially outer annular gasket segment46of the upstream annular gasket layer40agenerally opposes, abuts and seats against the annular inlay30of the annular flange24. The radially outer annular gasket segment46of the downstream annular gasket layer40bis configured to generally oppose, abut and seat against an annular flange or other component of the other component (e.g., the expansion joint fitting14) of the flange joint assembly10. The radially outer annular gasket segment46is sized and shaped to radially extend from the radially outer end of the annular inlay30on the annular flange24toward the longitudinal axis LA1of the flanged fitting12when the joint flange assembly10is assembled. In one example, the radially outer ends of the radially outer annular gasket segments46are generally flush with the radially outer end of the annular inlay30. The phonographic finish of the downstream surface of the radially outer annular portion of the annular inlay30facilitates seating of the radially outer annular gasket segment46of the upstream gasket layer40aon the annular inlay and inhibits movement of the gasket15relative to the annular inlay and the flanged fitting12. The layers40a,40bof the radially outer gasket segment46provide a fire-rated seal at the outer radial end of the annular flange24. The radially outer annular gasket segments46of the upstream and downstream layers40a,40bmay comprise (e.g., be formed from) graphite, such as flexible graphite. The radially outer annular gasket segments46of the upstream and downstream layers40a,40bmay be fire-rated. An example of a suitable radially outer annular gasket segment46of flexible graphite is sold under the trademark GRAFOIL® gasket and manufactured by GrafTech International. The radially outer annular gasket segments46may comprise (e.g., be formed from) other types of materials, including other types of fire-rated materials. Together, the radially outer annular gasket segment46of the upstream gasket layer40aand the annular inlay30of the annular flange24form a fire-rated seal. The inner annular substrate42of the annular gasket15extends along an entire radial width of the gasket from the inner radial end to the outer radial end thereof. The annular substrate is provided for blow-out resistance to inhibit the annular gasket layers40a,40bfrom being unseated radially and/or forced radially out of its position between the annular flange24and the second conduit (e.g., the expansion joint fitting). In the illustrated embodiment, the annular substrate42is corrugated radially along its radial width to enhance friction between the annular substrate the annular gasket layers40a,40b. The annular substrate42may be fire-rated. For example, the annular substrate42may comprise (e.g., be formed from) metal, such as, a nickel alloy (e.g., Alloy 625, Alloy 600, Alloy C-276/C-22/C-2000, Hastelloy® G-30/G-35/BC-1, Inconel® 686, Monel® 400, Alloy 825, Alloy 200, AL-6XN®, or 904L SS), or a reactive metal (e.g., titanium Gr. 2/Gr. 7, zirconium 702, tantalum, tantalum with 2.5% tungsten), or combinations thereof, including alloys thereof. In one example, the annular substrate42is formed from tantalum. The annular substrate42may comprise (e.g., be formed from) other types of materials, including other types of fire-rated materials. In the illustrated embodiment, as shown inFIG.6, a combined, uncompressed axial thickness T2of the gasket layers40a,40band the annular substrate42at the radially inner annular gasket segment44is greater than the combined, uncompressed axial thickness T3of the layers and the annular substrate42at the radially outer annular gasket segment46. When sandwiched between the flanged fitting12and the second flanged conduit (e.g., expansion joint fitting14), such as shown inFIG.3, the axial thickness of the gasket15may be substantially uniform along the radial width. As such, the gasket layers40a,40bat the radially inner annular gasket segment44(e.g., ePTFE layers) are compressed more than the gasket layers at the radially outer annular gasket segment46(e.g., flexible graphite layers). Such a configuration may be advantageous where the layers40a,40bat the radially inner annular gasket segment44(e.g., ePTFE layers) need to be compressed more than the gasket layers at the radially outer annular gasket segment46(e.g., flexible graphite layers) to provide a suitable seal with the liner26at the annular flange24. As explained above, the flange coupler assembly16is used to couple the flanged fitting12and the annular gasket15to a second conduit, e.g., the expansion joint fitting14. In the illustrated embodiment, the flange coupler assembly16comprises an annular coupling flange50(e.g., a split flange or lap flange) configured to engage a upstream end surface of the annular flange of the flanged fitting12. As used herein when describing the first annular coupling flange50and its components and structures, an axis A2of the flange coupler assembly is used as the point of reference for the terms “axially,” “radially,” “inner,” “outer,” and like qualifiers. A downstream face of the first annular coupling flange50defines an annular flange recess52at a radially inner portion thereof extending around the axis A2of the flange coupler assembly16in which a portion of the annular flange24of the flanged fitting12, including a portion of the radially outer end thereof, is received. The annular coupling flange50defines a plurality of fastener openings56spaced apart around the axis A2of the flange coupler assembly16and extending through the upstream and downstream faces of the first annular coupling flange. The fastener openings56are axially alignable with fastener openings in an opposing annular coupling flange, for example. (The illustrated opposing annular coupling flange is discussed in more detail below when discussing the expansion joint fitting14.) The first annular coupling flange50may comprise (e.g., be formed from) a metal material, such a carbon steel or other types of metal. The flange coupler assembly16suitably facilitates a liquid-tight and fire-rated seal at the gasket15interfaces and does not exceed compressive force that would crush the gasket layers40a,40band/or crack the liner26(e.g., glass liner). The gasket15ensures the flange joint assembly10does not fail when subjected to a fire test temperature between 1400° F.-1800° F. (761° C.-980° C.) for a period of 30 minutes, according to the API Specification 6FB, Titled “Specification for Fire Test for End Connections.” That is, the gasket15is suitable for passing the test set forth in API Specification 6FB. The radially outer annular gasket segment46and the annular inlay30form an annular fire-rated seal to inhibit spreading of fire from outside the flange joint assembly10to the inside, and from inside the flange joint assembly to outside due to one or more of spalling and/or melting of the liner26(e.g., glass liner) and/or melting of the radially inner annular gasket segment44(e.g., ePTFE material) of the annular gasket15. This fire-rated seal is due to each of the radially outer annular gasket segments46, the annular substrate42, and the annular inlay30, which are fire-rated, being radially outward of the radially inner annular gasket segment44and the liner26(e.g., glass liner), each of which are not formed from material meeting NFPA 30. In one embodiment, where the annular inlay30is a nickel alloy (e.g. Alloy 625) or reactive metal, the inlay has high temperature capability to reduce sensitization of the inlay30in a glass furnace when applying the glass liner26, for example, so that corrosion resistance is not reduced. High corrosion resistance may reduce corrosion of the fire-rated seal, such as during maintenance of the flange joint assembly10. The inlay30may be of other materials. In addition to forming a fire-rated seal, the annular gasket15creates a liquid-tight seal at the interface of the liner26(e.g., glass liner) and the radially inner annular gasket segment44(e.g., ePTFE). Moreover, the annular insert30provides blow-out resistance to inhibit the gasket15from being displaced from between the flange joint assembly10(e.g., unseated) if pressure rises within the flange joint assembly, such as due to an internal fire. In one particular embodiment, the annular insert also maintains the fire rating of the fire-rated seal at the radially outer annular gasket segment46and maintains the fire rating of the gasket15as a whole. For example, the annular insert30may be fire-rated. For example, the annular insert30may comprise (e.g., be formed from) metal, such as nickel alloy, reactive metal. In one or more embodiments, the radially outer annular gasket segment46also eliminates electrical grounding issues and development of static build-up where each of the layers40a,40band the annular substrate42at the radially outer annular gasket segments46are electrically conductive. This arrangement will dissipate any static charge or electrical energy from equipment to the conduit system without the need for electrical jumpers which is a specific requirement in NFPA 30, Section 6.5.4, Titled “Static Electricity.” The flanged fitting10, including the annular gasket15, may be coupled to another component (e.g., liquid-conveying component) having a flange design suitable for the joint assembly to pass the test in API Specification 6FB. In addition to the illustrated expansion joint fitting14, described below, non-limiting examples of flange designs suitable for components to be coupled with the flanged fitting, including the annular gasket15, include, but are not limited to: 1) flat faced metallic weld-neck or slip-on flange with phonographic finish or spiral serrated surface across the special raised face diameter equal to the diameter of the annular flange24of the flanged fitting10; 2) lap joint flange with metallic stub-end raised face diameter equal to diameter of the annular flange24of the flanged fitting10; 3) metal lined (e.g., tantalum) flange with metal liner raised face diameter equal to diameter of the annular flange24of the flanged fitting10; and 4) glass-lined carbon steel flange similar or identical to the annular flange of the flanged fitting10. The components for coupling with the flanged fitting10may have other flange designs. Referring toFIG.7, another embodiment of a flange joint assembly is generally indicated at110. This flange joint assembly110is the similar to the first flange joint assembly10, with differences between described hereinafter. Identical components are indicated by the same reference numbers. Unlike the first flange joint assembly10, the present flange joint assembly110includes flanged fittings112that are suitable for being coupled together or to other fittings using a flange clamp(s)168rather than a coupling flange component, as with the first embodiment. To this end, an annular flange extension128of the flanged fitting112has a rounded end170that project axially from the annular flange body24a. The rounded upstream end170accommodates the flange clamp(s). As an example, the flanged fittings112may be used as or incorporated on one or more of manways, dome covers, nozzles, nozzle covers, piping, other trim/equipment connections, etc. The flanged fittings112may be manufactured in substantially the same way as the first flange fitting12. Referring toFIGS.1and9, the illustrated expansion joint fitting14defines a liquid flow passage208extending along a longitudinal axis LA2of the expansion joint fitting. The expansion joint fitting14comprises first and second annular coupling flanges210,212, respectively, (e.g., upstream and downstream coupling flanges) spaced apart from one another along the longitudinal axis LA2of the expansion joint fitting; and concentric radially inner and outer bellows, generally indicated at216,218, respectively, extending axially between and interconnecting the upstream and downstream coupling flanges. As used herein when describing the expansion joint fitting14and its components and structures, the longitudinal axis LA2of the expansion joint fitting is used as the point of reference for the terms “axially,” “radially,” “inner,” “outer,” and like qualifiers. The radially inner and outer bellows216,218are radially spaced apart from one another to define an annular plenum219therebetween extending axially along the expansion joint fitting14. Each of the upstream and downstream annular coupling flanges210,212defines a plurality of fastener openings220spaced apart around the longitudinal axis LA2of the expansion joint fitting14and extending through the upstream and downstream faces of the corresponding annular coupling flange. The fastener openings220are axially alignable with fastener openings (e.g., openings56,FIG.2) in an opposing annular coupling flange (e.g., coupling flange50), as shown inFIG.1, for example. Each of the annular coupling flanges210,212may comprise (e.g., be formed from) a metal material, such a carbon steel or other types of metal. For reasons explained below, in the illustrated embodiment (FIG.9) a radial width W2of one or more of the annular coupling flanges210,212may be greater than a radial width of the annular coupling flange50of the illustrated flanged fitting12. The radially inner bellows216includes an annular corrugated body224and opposite upstream and downstream longitudinal end portions respectively, secured to the respective upstream and downstream annular coupling flanges210,212, respectively. The upstream longitudinal end portion of the radially inner bellows216includes an axial segment226aextending along and secured to the interior annular surface of the upstream coupling flange210, and an annular radial segment228aextending radially outward from the axial segment radially along and secured to a upstream end face of the upstream annular coupling flange210. The downstream longitudinal end portion of the radially inner bellows216includes an axial segment226bextending along and secured to the interior annular surface of the downstream coupling flange212, and an annular radial segment228bextending radially outward from the axial segment radially along and secured to a downstream end face of the upstream annular coupling flange210. The annular radial segments228a,228bdefine respective first and second annular gasket abutment faces of the expansion joint14. The radially inner bellows216may be fire-dated. The radially inner bellows216may comprise (e.g., be formed from), metal such as nickel alloy (e.g., Alloy 625, Alloy 600, Alloy C-276/C-22/C-2000, Hastelloy® G-30/G-35/BC-1, Inconel® 686, Monel® 400, Alloy 825, Alloy 200, AL-6XN®, or 904L SS), or a reactive metal (e.g., titanium Gr. 2/Gr. 7, zirconium 702, tantalum, tantalum with 2.5% tungsten), or combinations thereof, including alloys thereof. In one example, the radially inner bellows216is multi-layered. For example, the radially inner bellows216may include a radially innermost layer comprising a first type of material (e.g., a reactive metal or nickel alloy), and one or more radially outer layers, each comprising a material different from the innermost layer (e.g., a reactive metal or nickel alloy). In one example, the radially innermost layer of the radially inner bellows216, which defines the liquid-conveying passage208of the expansion joint fitting, may comprise tantalum, or another type of reactive metal. In this same example, the one or more radially outer layers (e.g., two, three, or more layers) may comprise Alloy 625, or another type of nickel alloy. Each of the layers of the radially inner bellows216may have a thickness of about 0.5 mm. The respective downstream and upstream longitudinal end portions of the radially inner bellows216may be secured to the corresponding annular coupling flanges210,212, such as by spot welding, seal welding, or in other ways. The radially outer bellows218includes a corrugated body and is coupled to the upstream and downstream annular coupling flanges210,212by corresponding upstream and downstream annular mounting brackets234,236, respectively, mounted on the respective upstream and downstream annular coupling flanges. The upstream annular mounting bracket234on the upstream annular coupling flange210is disposed radially outward of the radially inner bellows216and projects axially (i.e., downstream) toward the downstream annular coupling flange212. The downstream annular mounting bracket236on the downstream annular coupling flange212is disposed radially outward of the radially inner bellows216and projects axially (i.e., upstream) toward the upstream annular coupling flange210. The annular mounting brackets234,236may be welded to the corresponding upstream and downstream annular coupling flanges210,212, or may be secured thereto in other ways. The radially outer bellows218may be fire-rated and may comprise (e.g., be formed from) metal, such as, but not limited to, nickel alloy (e.g., Alloy 625, Alloy 600, Alloy C-276/C-22/C-2000, Hastelloy® G-30/G-35/BC-1, Inconel® 686, Monel® 400, Alloy 825, Alloy 200, AL-6XN®, or 904L SS), or a reactive metal (e.g., titanium Gr. 2/Gr. 7, zirconium 702, tantalum, tantalum with 2.5% tungsten), or combinations thereof, including alloys thereof. In one example, the radially outer bellows218is multi-layered. For example, each of the layers of the radially outer bellows218may comprise (e.g., be formed from) nickel alloy, such as Alloy 625, or another type of nickel alloy. Each of the layers of the radially outer bellows218may have a thickness of about 0.5 mm. The respective downstream and upstream longitudinal end portions of the radially outer bellows218may be secured to the corresponding annular mounting brackets234,236, such as by welding or in other ways. The expansion joint fitting14further includes an inlet port244and an outlet port246, each of which is in fluid communication with the annular plenum219. In the illustrated embodiment, the inlet port244is mounted on the downstream annular mounting bracket236and extends radially outward therefrom, and the outlet port246is mounted on the upstream annular mounting bracket234and extending radially outward therefrom. It is understood that the locations of the ports244,246may be reversed in other embodiments. In use, a purge gas (e.g., an inert gas, such as, but not limited to, nitrogen) from a gas source250is delivered into the annular plenum219. The gas source250may include a compressor or gas cylinder for pressurizing the gas. The purge gas flows axially (e.g., upstream) through the annular plenum219and exits the annular plenum through the outlet port246. In the illustrated embodiment, the axial flow of purge gas (as indicated by arrows G) through the annular plenum219is in an axial direction (e.g., upstream) that is opposite the axial direction (e.g., downstream) of the flow of liquid through the expansion joint fitting14(as indicated by arrows labeled L). In other embodiments, the axial flow of purge gas may be in the same direction as the flow of liquid. In one embodiment, the purged gas that has exited the annular plenum219may be analyzed to determine if liquid in the expansion joint fitting14is leaking through the radially inner bellows216, which may indicate failure of the expansion joint fitting. In particular, if liquid or gas (i.e., fluid) is leaking into the annular plenum219, at least some amount of the liquid or gas will be entrained in the flowing purge gas and carried outside the annular plenum through the outlet port246. The exited purge gas may be analyzed continuously or periodically to detect any potential failure of the expansion joint fitting14. For example, the exited purge gas may flow through a detector or analyzer254suitable for detecting the flammable liquid or gas or other foreign substances entrained in the purge gas. The purge gas may be in a closed loop system, whereby any foreign substance in the purge gas is filtered via a filter system before being re-delivered into the annular plenum219. In one embodiment, one or more leak detection openings260are formed in the radially inner bellows216adjacent the inlet port244when the inner bellows216is multi-layered. The leak detection openings260penetrate only the outer layers of the inner bellows216in this example and fluidly connect the liquid flow passage208to the annular plenum219so that leak detection can be more expedient due to failure of the inner layer of the inner bellows216which can be a different material of construction (MOC) from the outer layers of the inner bellows216. This will provide a leak detection alert that there is a corrosion or failure issue with the inner layer of the multi-layer inner bellows216. In one example, one or more leak detection openings may have a diameter of about 3 mm. In the illustrated embodiment, the expansion joint fitting14is coupled to the flanged fitting12and the gasket15so that the joint assembly10is liquid-tight and passes the test set forth in API Specification 6FB. In this example, the annular coupling flange50of the flanged fitting12is secured to the upstream annular coupling flange210of the expansion joint fitting14with the fasteners extending through the corresponding aligned fastener openings56,220. As coupled, the downstream face of the gasket15abuts and seats on an upstream face of the annular radial segment228aof the radially inner bellows216to form a liquid-tight and fire-rated seal. In particular, the annular radial segment228aabuts and seats on both the radially outer annular gasket segment46to form the fire-rated seal, and the radially inner annular gasket segment44to form the liquid-tight seal. The illustrated expansion joint fitting14provides secondary protection should a leak form in the radially inner bellows216. That is, radially outer bellows218provides a secondary barrier so that any liquid or gas (i.e., fluid) leaking into the annular plenum219is contained therein to inhibit leaking of the liquid or gas externally of the expansion joint fitting14. As also set forth above, the expansion joint fitting14may facilitate leak detection of liquid or gas leaking into the annular plenum. Liquid or gas in the annular plenum219may be entrained in the purge gas flowing through the annular plenum. This liquid or gas may be detected by the detector or analyzer254to indicate the possibility of a leak. Moreover, the purge gas may facilitate removal of the leaked liquid or gas from the annular plenum219to further inhibit any leaking of liquid or gas outside the expansion joint fitting14. The expansion joint fitting14, including the annular gasket15, may be coupled to another component (e.g., liquid-conveying component) having a flange design so that the joint assembly passes the test in API Specification 6FB. In addition to the illustrated flanged fitting10, described below, non-limiting examples of flange designs suitable for components to be coupled with the expansion joint fitting14, including the annular gasket15, include, but are not limited to: 1) flat faced metallic weld-neck or slip-on flange with phonographic finish or spiral serrated surface across the special raised face diameter equal to one or both of the diameters of the annular radial segments228a,228bof the inner bellows216of the expansion joint fitting14; 2) lap joint flange with metallic stub-end raised face diameter equal to one or both of the diameters of the annular radial segments228a,228bof the inner bellows216of the expansion joint fitting14; 3) metal lined (e.g., tantalum) flange with metal liner raised face diameter equal to one or both of the diameters of the annular radial segments228a,228bof the inner bellows216of the expansion joint fitting14, such as flange310with metal liner326(e.g., tantalum) illustrated inFIG.10; and 4) glass-lined carbon steel flange similar or identical to the annular flange of the flanged fitting10. The components for coupling with the expansion joint fitting14may have other flange designs. Modifications and variations of the disclosed embodiments are possible without departing from the scope of the invention defined in the appended claims. When introducing elements of the present invention or the embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. As various changes could be made in the above constructions, products, and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | 39,315 |
11859741 | DETAILED DESCRIPTION Unless indicated otherwise, identical or functionally identical elements are provided with the same reference signs in the figures. It should furthermore be noted that the illustrations in the figures are not necessarily true to scale. FIG.1shows a schematic perspective view of an embodiment of a corrugated hose arrangement1.FIG.2shows a schematic lateral view of the corrugated hose arrangement1, andFIG.3shows a schematic front view of the corrugated hose arrangement1. Below, reference is simultaneously made toFIGS.1to3. The corrugated hose arrangement1comprises a corrugated hose2and a coupling apparatus3fastened to the corrugated hose2. The coupling apparatus3may also be referred to as a coupling or connection apparatus or even as a connector or connecting apparatus. By means of the coupling apparatus3, the corrugated hose2can be connected to other components, such as plugs, hoses, or the like. The corrugated hose2is a continuous product and can have any length. The corrugated hose arrangement1is preferably used in the field of motor vehicle technology. For example, the corrugated hose arrangement1can be used as fuel line, windshield washer line, headlamp cleaner line, sensor cleaner line, or the like. The corrugated hose arrangement1can, however, also be used in any other field. For example, the corrugated hose arrangement1can be used in building technology or for machine tools. A center axis or axis of symmetry M is assigned to the corrugated hose arrangement1. The corrugated hose arrangement1preferably has a rotationally symmetrical structure with respect to the axis of symmetry M. A longitudinal direction L is furthermore assigned to the corrugated hose arrangement1. The longitudinal direction L is oriented in parallel to the axis of symmetry M or corresponds thereto. The longitudinal direction L may also be referred to as the axial direction of the corrugated hose arrangement1. The longitudinal direction L in the orientation ofFIG.2is oriented from top to bottom. The longitudinal direction L may however also be oriented reversely. A radial direction R is furthermore assigned to the corrugated hose arrangement1and is oriented away from the axis of symmetry M. The radial direction R is positioned orthogonally to the axis of symmetry M. The corrugated hose arrangement1moreover has a circumferential direction UR, which may be oriented clockwise or counterclockwise. AsFIG.3shows, the circumferential direction UR is oriented clockwise. The circumferential direction UR is oriented around the axis of symmetry M. The circumferential direction UR may also be referred to as the peripheral direction of the corrugated hose arrangement1. FIG.4shows a schematic view of an embodiment of the corrugated hose2.FIG.5shows the detailed view V according toFIG.4.FIG.6shows a schematic sectional view of the corrugated hose2. Below, reference is simultaneously made toFIGS.4to6. The corrugated hose2is manufactured from a plastic material. The plastic material may, for example, be polyoxymethylene (POM), polypropylene (PP), or another suitable plastic material. The corrugated hose2may also be referred to as a corrugated pipe or is a corrugated pipe. The corrugated hose2is preferably produced by means of an extrusion method. The corrugated hose2may also be manufactured from different plastic materials. In this case, the corrugated hose2may, for example, be produced by means of a multi-component extrusion method and/or by means of a multi-layer extrusion method. When the corrugated hose2is produced in a multi-layer extrusion method, it has a wall structure in layers. The layers may have different plastic materials. The multi-layer extrusion method is thus an embodiment of a multi-component extrusion method. The corrugated hose2is a one-piece component, in particular a component made of a single piece of material. “One-piece” or “single piece” in this respect means that the corrugated hose2is not constructed of a plurality of individual elements or components but of one continuous unit. However, this does not rule out that the corrugated hose is constructed of different plastic materials. In this case, the corrugated hose2may, for example, be produced by means of a multi-component extrusion method and/or by means of a multi-layer extrusion method. “Single piece of material” herein means that the corrugated hose2is manufactured continuously from the same plastic material. At the ends, the corrugated hose2comprises a first end portion2A and a second end portion2B. The corrugated hose2is preferably a fluid line or media line. The fluid or medium may, for example, be a gas, water, fuel, oil, or any other liquid. For example, the corrugated hose2may be an air line or a gas line. The corrugated hose2may thus itself be a fluid carrier. The corrugated hose2may however also be suitable for receiving a multitude of cables or lines. In this case, the corrugated hose2is suitable as cable sheathing. The cables may, for example, be single-phase cables, multi-phase cables, coaxial cables, or the like. The lines may be fluid lines, such as gasoline lines, diesel lines, kerosene lines, hydraulic lines, or pneumatic lines. The corrugated hose2has a rotationally symmetrical structure with respect to the axis of symmetry M. The corrugated hose2may be curved. However, as viewed along the longitudinal direction L, the corrugated hose2is preferably stiff and in particular not foldable or telescopic. This means that the corrugated hose2is non-foldable or non-telescopic along the longitudinal direction L. The terms “non-foldable” or “non-telescopic” are in particular to be understood as meaning that the corrugated hose2, in particular due to the material and/or due to the geometry, cannot be extended or compressed or can at least only be minimally extended and compressed along the longitudinal direction L. This means that the corrugated hose2preferably has a high axial stiffness along the longitudinal direction L or along the axis of symmetry M. The corrugated hose2comprises a wall4, which extends completely around the axis of symmetry M in the circumferential direction UR (FIG.6) and toward which the radial direction R points. The wall4encloses an internal space I of the corrugated hose2. The internal space I is separated by means of the corrugated hose2, in particular by means of the wall4, from an environment U thereof. The circumferential direction UR not shown inFIGS.4to6is oriented along the wall4. The corrugated hose2comprises a corrugation5that is molded onto the wall4and has wave crests6and wave valleys7alternating in the longitudinal direction L. The wave valleys6and wave crests7are arranged such that one wave valley7is respectively arranged between two wave crests6and one wave crest6is respectively arranged between two wave valleys7. The corrugation5may have a sinusoidal profile as shown inFIGS.4to6. Alternatively, the corrugation5may however also have a rectangular profile. The wave crests6and the wave valleys7are provided on the corrugated hose2both on the outside, i.e., facing the environment U, and on the inside, i.e., facing the internal space I. For example, the wave crests6and the wave valleys7can be molded onto the corrugated hose2by means of a so-called corrugator after extrusion of the corrugated hose2. AsFIG.5shows, the wave crests6are connected to the wave valleys7by means of wave flanks8,9. Two wave flanks8,9are assigned to each wave crest6and each wave valley7. The wave flanks8,9preferably extend orthogonally to the axis of symmetry M. The wave flanks8,9may however also be inclined relative to the axis of symmetry M. The wave flanks8,9are part of the corrugation5. Each wave valley7comprises a rib10that extends circumferentially around the corrugated hose2and is in particular arranged centrally between two adjacent wave crests6. The rib10may completely extend circumferentially around the corrugated hose2. The rib10may however also be interrupted circumferentially. Transition regions11,12, which are designed as fillets, between the rib10and the wave flanks8,9function as bending points during bending of the corrugated hose2. The wave flanks8,9transition into the rib10by means of the transition regions11,12. The rib10extends on the outside of the corrugated hose2into the environment U and away from the internal space I. The rib10is curved arcuately, in particular circular-arcuately, into the environment U. On the inside, i.e., facing the internal space I, the wave valleys7are cylindrical, in particular circular cylindrical. This means that the wave valleys7facing the internal space I have no or at least only a minimal curvature. The corrugated hose2has an outer diameter or diameter d6at the wave crests6and an outer diameter or diameter d7at the wave valleys7, wherein the diameter d6is greater than the diameter d7. The corrugation5also has a wave height W. The wave height W is defined as a distance between the wave crests6and the wave valleys7as viewed in the radial direction R. The wave height W is in particular half the difference of the diameters d6, d7. The wave height W is in particular defined as a distance of a respective wave valley7, in particular of an outer contour of the corresponding rib10of the wave valley7, from the wave crest6, in particular from an outer contour of the wave crest6, as viewed in the radial direction R. The corrugated hose2moreover comprises connection ribs13,14extending along the longitudinal direction L. The connection ribs13,14are respectively arranged between two adjacent wave crests6in a wave valley7and connect wave flanks8,9assigned to the adjacent wave crests6to one another. In particular, a first connection rib13and a second connection rib14are assigned to each wave valley7. The connection ribs13,14respectively transition by means of fillets15,16into the wave flanks8,9or into the wave crests6. The connection ribs13,14are hollow so that the connection ribs13,14can function as a fluid connection between two adjacent wave crests6. As a result, liquid remaining in the wave crests6can be prevented or at least reduced. This means that dead zones in the corrugated hose2are reduced. The ribs10are interrupted at the connection ribs13,14. The connection ribs13,14comprise an outer face17, which is cylindrical, in particular circular cylindrical. The outer face17is thus curved, in particular curved circular-cylindrically. This means that the outer faces17of all connection ribs13,14lie on a cylinder, in particular on a circular cylinder. The connection ribs13,14in this case preferably all have the same height as viewed in the radial direction R. The circular cylinder has a rotationally symmetrical structure with respect to the axis of symmetry M. The connection ribs13,14may however also have different heights with respect to the radial direction R so that the outer faces17do not lie on a circular cylinder but on different circular cylinders. The connection ribs13,14transition into the wave valleys7by means of fillets18,19. The outer faces17may however also be planar or flat and not have a cylindrical curvature. In this case, the connection ribs13,14are preferably cuboidal or cubical. The first connection rib13and the second connection rib14of each wave valley7are arranged at an offset of a first circumferential angle of 180° to one another in the circumferential direction UR. This means that the first connection rib13and the second connection rib14of each wave valley7are arranged opposite one another. The connection ribs13,14of two adjacent wave valleys7are in turn arranged at an offset to one another in the circumferential direction UR. The connection ribs13,14of two adjacent wave valleys7are in particular arranged at an offset of a second circumferential angle of 90° to one another along the circumferential direction UR. The connection ribs13,14are thus arranged such that the connection ribs13,14in each wave valley7are arranged at an offset of the first circumferential angle of 180° to one another, and that the connection ribs13,14of adjacent wave valleys7are arranged at an offset of the second circumferential angle of 90° to one another. In that the connection ribs13,14of two adjacent wave valleys7are arranged at an offset of the second circumferential angle of 90° to one another, the flexibility of the corrugated hose2is not negatively or only insignificantly negatively influenced by the connection ribs13,14. This means that the flexibility of the corrugated hose2is retained. Very narrow rates of bending can thus be achieved. The flexibility of the corrugated hose2thus does not differ or differs only insignificantly from a corrugated hose without such connection ribs13,14. The connection ribs13,14have a height H as viewed in the radial direction R. The height H is defined as a distance of a respective wave valley7, in particular from an outer contour of the corresponding rib10, to the respective outer face17of the connection rib13,14as viewed in the radial direction R. Particularly preferably, the height H is less than the wave height W. For example, the height H may be half the wave height W. The height H may however also be equal to the wave height W. All connection ribs13,14may have the same height H. The connection ribs13,14may however also have different heights H. In that the connection ribs13,14are provided, a longitudinal elongation of the corrugated hose2in the longitudinal direction L can be minimized by the action of the operating pressure of the fluid or medium to be conveyed. In particular, a minimum longitudinal elongation of the corrugated hose2can be achieved. However, due to the offset arrangement of the connection ribs13,14of adjacent wave valleys7, the flexibility of the corrugated hose2is only restricted a little so that very narrow bending radii are possible. Moreover, by the provision of connection ribs13,14, which can serve as fluid connection between adjacent wave crests6, the production of dead zones in the internal space I of the corrugated hose2can be reliably reduced. Let us now return to the coupling apparatus3according toFIGS.1to3. The coupling apparatus3comprises a receptacle part20shown inFIGS.7and8. The receptacle part20is suitable for receiving the corrugated hose2, in particular one of the end portions2A,2B of the corrugated hose2. The receptacle part20has a rotationally symmetrical structure with respect to the axis of symmetry M. The receptacle part20is manufactured from a plastic material. For example, the receptacle part20may be manufactured from POM, PP, or another suitable plastic material. The receptacle part20may also be manufactured from different plastic materials. In particular, the receptacle part20is a plastic injection-molded component. The receptacle part20may also be a plastic multi-component injection-molded component. The receptacle part20may however also be manufactured from a metallic material, such as an aluminum alloy or a steel alloy. The receptacle part20comprises a tubular coupling portion21having a collar22extending annularly around the axis of symmetry M. The coupling portion21is hollow and is completely perforated by an aperture23. By means of the coupling portion21, the receptacle part20can, for example, be connected to a plug, a hose, or the like. For this purpose, the latter can be pushed onto the coupling portion21. The collar22prevents the plug or hose from sliding from the coupling portion21. The coupling portion21is shown inFIGS.7and8as the “male variant.” This means that the coupling portion21can be inserted into another component. The coupling portion21may however also be designed as the “female variant” (not shown). In this case, a component can be inserted into the coupling portion21. The coupling portion21is adjoined in one piece, in particular in a single piece of material, by a receptacle portion24. The receptacle portion24is likewise hollow. The receptacle portion24comprises a receptacle region25perforating the receptacle portion24and having a diameter d25. The diameter d25may taper in the direction of the coupling portion21. The receptacle region25is connected to the aperture23. The receptacle region25preferably comprises a cylindrical first cavity26and a second cavity27, which adjoins the cylindrical first cavity26and is conical or frustoconical. The receptacle region25transitions into a chamfer25A. The chamfer25A is preferably not part of the receptacle region25. The coupling portion24is adjoined in one piece, in particular in a single piece of material, by a tubular base body28. A grip region29is molded onto the base body28and can be gripped by a tool, e.g., by an open-end wrench. The grip region29may, for example, be an outer hexagon. Alternatively, the grip region29may also be an outer square or the like. On the upper side, a first latching hook30and a second latching hook31extend out of the base body28, in particular out of the grip region29. The number of latching hooks30,31is arbitrary. The latching hooks30,31are preferably designed as snap hooks or may be referred to as such. The latching hooks30,31are resiliently deformable and can be bent outward in the radial direction R away from the axis of symmetry M. The latching hooks30,31are arranged at an offset of 180° to one another in the circumferential direction UR. In particular, the latching hooks30,31are positioned opposite one another. The base body28is hollow. An engaging portion32extends through the base body28in the direction of the receptacle region25. The chamfer25A is arranged between the receptacle region25and the engaging portion25and connects them to one another. The engaging portion32thus transitions into the receptacle region25via the chamfer25A. The engaging portion32may also be designed in the form of an internal thread. The engaging portion32may, for example, have two to five thread turns. The engaging portion32may however also be part of a bayonet closure. In this case, the engaging portion32is not an internal thread. Besides the receptacle part20, the coupling apparatus3comprises a locking part33shown inFIGS.9and10. The locking part33is manufactured from a plastic material. For example, the locking part33may be manufactured from POM, PP, or another suitable plastic material. The locking part33may also be manufactured from different plastic materials. The locking part33is preferably a plastic injection-molded component. The locking part33may also be a plastic multi-component injection-molded component. The locking part33may however also be manufactured from a metallic material, such as an aluminum alloy or a steel alloy. The locking part33likewise has a rotationally symmetrical structure with respect to the axis of symmetry M. The locking part33is hollow and comprises a base body34, on the outside of which a mating engaging portion35in the form of an external thread is provided. The mating engaging portion35may also be part of the previously mentioned bayonet closure. In this case, the mating engaging portion35is not an external thread. The mating engaging portion35is suitable for interlockingly engaging in the engaging portion32of the receptacle part20. An interlocking connection is established by at least two connection partners, here the engaging portion32and the mating engaging portion35, engaging in or behind one another. This means that the locking part33may be screwed into the receptacle part20. In doing so, the locking part33moves along the longitudinal direction L or along the axis of symmetry M into the receptacle part20. As previously mentioned, the engaging portion32and the mating engaging portion35may also interact in a different way, e.g., in the form of a bayonet closure. Two latching lugs or latching ribs36,37extending annularly around the axis of symmetry M are provided on the base body34. The latching ribs36,37have a wedge-shaped cross-section. The latching ribs36,37are positioned at a distance from one another as viewed in the longitudinal direction L. In particular, a first latching rib36and a second latching rib37are provided, which are arranged at an axial distance from one another along the longitudinal direction L or along the axis of symmetry M. The latching hooks30,31of the receptacle part20are configured to interlockingly engage in or snap into the latching ribs36,37. In doing so, the two latching hooks30,31latch either into the first latching rib36or into the second latching rib37. A grip region38is furthermore molded onto the base body34. The latching ribs36,37are positioned between the mating engaging portion35and the grip region38as viewed along the longitudinal direction L. The grip region38may, for example, be an outer hexagon. Alternatively, the grip region38may also be an outer square or the like. The grip region38may have the same wrench width as the grip region29. The grip regions29,38may however also have different wrench widths. The base body34comprises a conical or funnel-shaped insertion opening39, which has a rotationally symmetrical structure with respect to the axis of symmetry M. The insertion opening39extends through the entire base body34, i.e., through the grip region38and the latching ribs36,37. The insertion opening39is suitable for receiving the corrugated hose2, in particular one of the end portions2A,2B of the corrugated hose2. In the orientation ofFIGS.9and10, a plurality of engaging elements40to43extend on the underside out of the base body34. The number of engaging elements40to43is arbitrary. For example, four engaging elements40to43are provided. The engaging elements40to43are preferably snap hooks, which are configured to interlockingly engage in the wave valleys7of the corrugated hose2. The engaging elements40to43are resiliently deformable and deformed outward in the radial direction R away from the axis of symmetry M when the corrugated hose2is pushed into the locking part33. The engaging elements40to43are arranged regularly or irregularly distributed about the axis of symmetry M and thus form a tubular geometry having an outer diameter or diameter d40. The diameter d40is smaller than the diameter d25so that the engaging elements40to43can be received in the receptacle region25of the receptacle part20. Due to the tubular geometry, the engaging elements40to43are thus designed as cylinder segments, in particular circular cylinder segments, as viewed along the circumferential direction UR. Between the engaging elements40to43, intermediate spaces44to47are provided. The engaging elements40to43and the intermediate spaces44to47are alternately arranged as viewed along the circumferential direction UR. The intermediate spaces44to47may be as wide as, wider than, or narrower than the engaging elements40to43as viewed along the circumferential direction UR. AsFIG.10shows, the engaging elements40to43extend into the mating engaging portion35as viewed along the longitudinal direction L. This means that the mating engaging portion35extends completely around the engaging elements40to43as viewed in the radial direction R. Between the mating engaging portion35and the engaging elements40to43, an annular gap48is provided. The gap48extends completely around the axis of symmetry M. The insertion opening39is adjoined by a cylindrical aperture49, which, like the insertion opening39, extends through the base body34. The insertion opening39is thus connected to the aperture49. The corrugated hose2can be guided on or in the aperture49. The aperture49is interrupted by a plurality of flat portions50to52as viewed along the circumferential direction UR. Such a flat portion50to52is assigned to each engaging element40to43. The flat portions50to52transition into the engaging elements40to43at constrictions53to55. The constrictions53to55serve as bending regions or hinges for the engaging elements40to43. The constrictions53to55are in particular film hinges. The coupling apparatus3moreover comprises a sealing part56shown inFIGS.11and12. The sealing part56is a plastic or rubber component. For example, the sealing part56may be manufactured from a thermoplastic elastomer (TPE), in particular from a thermoplastic polyurethane (TPU), an ethylene-propylene-diene rubber (EPDM), or the like. The sealing part56is preferably a plastic injection-molded component. The sealing part56has a rotationally symmetrical structure with respect to the axis of symmetry M. The sealing part56can be received in the receptacle region25of the receptacle part20. Alternatively, the sealing part56may be injection-molded directly onto the receptacle region25of the receptacle part20in a plastic multi-component injection-molding method. The sealing part56comprises a tubular base body57. The base body57is hollow and comprises a receptacle region58for receiving the corrugated hose2, in particular one of the end portions2A,2B of the corrugated hose2. The receptacle region58has a diameter d58that may be equal to the diameter d6of the corrugated hose2. The diameter d58may however also be slightly greater or slightly smaller than the diameter d6of the corrugated hose2. The diameter d58is particularly preferably slightly smaller than the diameter d6. A circumferential chamfer59may be provided on the receptacle region58. The chamfer59facilitates the insertion of the corrugated hose2into the sealing part56. The base body57has an outer diameter or diameter d57. The diameter d57is slightly greater than the diameter d25of the receptacle region25of the receptacle part20. A rib60extending annularly around the axis of symmetry M is provided on the outside of the base body57. The rib60is curved arcuately, in particular circular-arcuately. On the face side, the base body57is closed at least in sections by means of a cover portion61. The cover portion61comprises an aperture62having a diameter d62. The diameter d62is smaller than the diameter d7of the corrugated hose2so that the corrugated hose2cannot be pushed through the aperture62. The functionality of the coupling apparatus3is explained below with reference toFIGS.13to17. First, the coupling apparatus3is assembled. For this purpose, the sealing part56is first received in the receptacle part20. In doing so, the sealing part56is pressed into the receptacle region25of the receptacle part20. Both the partially conical profile of the receptacle region25and the circumferential rib60of the sealing part56ensure that the sealing part56is pressed into the receptacle region25in the radial direction R. As previously mentioned, the sealing part56may also be injection-molded directly onto the receptacle part20in a multi-component injection-molding method. Subsequently, the locking part33is rotated relative to the receptacle part20. This rotational movement may but does not have to comprise screwing the locking part33into the receptacle part20. In this case, a screwing movement is realized between the locking part33and the receptacle part20. The locking part33is received at least in sections in the receptacle part20. Instead of a screw connection, another connection, such as a bayonet closure, may however also be provided. The engaging portion32of the receptacle part20and the mating engaging portion35of the locking part33interlockingly engage in one another. During the rotational movement of the locking part33relative to the receptacle part20, the engaging portion32and the mating engaging portion35interact such that the rotational movement is converted into an axial movement of the locking part33along the longitudinal direction L or along the axis of symmetry M. The engaging portion32and the mating engaging portion35thus form a gear device63of the coupling apparatus3. The gear device63may be any type of gears that are suitable to convert the rotational movement of the locking part33in relation to the receptacle part20into an axial movement or linear movement of the locking part33along the longitudinal direction L and relative to the receptacle part20. It is in particular sufficient if the gear device63converts the rotational movement of the locking part33in relation to the receptacle part20into an axial movement or linear movement of the engaging elements40to43along the longitudinal direction L or along the axis of symmetry M. During the rotational movement of the locking part33in relation to the receptacle part20, the locking part33is moved along the longitudinal direction L or along the axis of symmetry M in relation to the receptacle part20until the latching hooks30,31glide over the first latching rib36and latch or snap into it. In doing so, the latching hooks30,31are resiliently deformed outward along the radial direction R away from the axis of symmetry M. The rotational movement of the locking part33relative to the receptacle part20may comprise screwing the locking part33into the receptacle part20. This is however not necessarily required. Any other connection between the locking part33and the receptacle part20that moves the receptacle part20along the longitudinal direction L or along the axis of symmetry M into the locking part33may be used. The locking part33is thus fixed on the receptacle part20. The receptacle part20and the locking part33are captively connected to one another. Furthermore, in that the sealing part56is pressed into the receptacle part20, it is also captively connected thereto. The coupling apparatus3is now in a preassembled state or unlocked state Z1shown inFIG.13. The locking part33can be separated from the receptacle part20again only if the latching hooks30,31are deformed outward in the radial direction R away from the first latching rib36so that they no longer interlockingly engage in or behind the first latching rib36. At the same time, the locking part33is again moved out of the receptacle part20. This may but does not have to comprise unscrewing the locking part33from the receptacle part20. Subsequently, as shown inFIGS.14and15, the corrugated hose2, in particular one of the end portions2A,2B of the corrugated hose2, is inserted into the coupling apparatus3. In doing so, the conical insertion opening39of the locking part33serves as guide for the corrugated hose2. The corrugated hose2may be cut both in a wave valley7and in a wave crest6. The respective end portion2A,2B is pushed through the engaging elements40to43. In doing so, the engaging elements40to43are resiliently deformed outward in the radial direction R away from the axis of symmetry M. The engaging elements40to43glide off on the corrugation5. The corrugated hose2is pushed into the sealing part56. The chamfer59of the sealing part56helps to insert the corrugated hose2into the latter. The corrugated hose2is pushed into the coupling apparatus3until the corrugated hose2, in particular one of its end portions2A,2B, is pushed against the cover portion61of the sealing part56. The corrugated hose2is then sealed on the face side in a fluid-tight manner with respect to the sealing part56. The sealing part56can be elastically deformed. The engaging elements40to43all come to lie together in a common wave valley7(FIG.15) of the corrugated hose2. The coupling apparatus3is still in the unlocked state Z1. In the unlocked state Z1, the engaging elements40to43are positioned outside of the receptacle region25of the receptacle part20as viewed along the longitudinal direction L. The engaging elements40to43in the unlocked state Z1may be positioned at least partially within the chamfer25A. However, the engaging elements40to43in the unlocked state Z1may also be positioned completely outside of the chamfer25A. In order to bring the coupling apparatus3from the unlocked state Z1into a final assembled state or locked state Z2shown inFIGS.16and17, the locking part33is moved further into the receptacle part20as viewed along the longitudinal direction L. This takes place by means of a rotation of the locking part33in relation to the receptacle part20. For example, the locking part33may be screwed into the receptacle part20during this rotational movement. In doing so, the latching hooks30,31glide over the second latching rib37and snap or latch into it. At the same time, the engaging elements40to43are moved into the receptacle region25so that a movement of the engaging elements40to43in the radial direction R away from the corrugated hose2is blocked. The corrugated hose2can thus no longer be pulled out of the coupling apparatus3. A respective end face64(FIG.17) of the engaging elements40to43rests on one of the wave flanks8,9of that wave valley7in which the engaging elements40to43engage, and pushes it along the longitudinal direction L against the cover portion61of the sealing part56, whereby the latter is elastically deformed. This ensures that the corrugated hose2is safely pressed into the sealing part56. The end face64is preferably oriented orthogonally to the axis of symmetry M or orthogonally to the longitudinal direction L. The end face64may however also be inclined relative to the axis of symmetry M. The corrugated hose2is thus locked in the coupling apparatus3on the one hand, and the corrugated hose2is pushed into the sealing part56on the other hand. This produces a high contact pressure on the sealing part56, in particular on the cover portion61thereof. This ensures fluid-tight sealing of the corrugated hose2with respect to the coupling apparatus3. Against an unintentional release of the locking part33from the receptacle part20, they are locked by means of the latching hooks30,31and the second latching rib37. Furthermore, by means of the coupling apparatus3, a reliable fixing of corrugated hoses2having a small wave height W is also reliably possible. The corrugated hose2can be separated from the coupling apparatus3only if the latching hooks30,31are brought out of engagement with the second latching rib37by means of resilient deformation. For this purpose, the latching hooks30,31are bent outward along the radial direction R away from the axis of symmetry M. Subsequently, the locking part33is moved out of, in particular unscrewed from, the receptacle part20until the latching hooks engage behind the first latching rib36. The engaging elements40to43are now arranged outside of the receptacle region25. The corrugated hose2can now be pulled out of the coupling apparatus3, wherein the engaging elements40to43are resiliently deformed and deformed outward along the radial direction R away from the corrugated hose2. The coupling apparatus3can thus again be brought from the locked state Z2into the unlocked state Z1. For the assembly and disassembly of the corrugated hose arrangement1, no assembly tools are advantageously required. Although the present invention was described based on exemplary embodiments, it can be modified in various ways. LIST OF REFERENCE CHARACTERS 1Corrugated hose arrangement2Corrugated hose2A End portion2B End portion3Coupling apparatus4Wall5Corrugation6Wave crest7Wave valley8Wave flank9Wave flank10Rib11Transition region12Transition region13Connection rib14Connection rib15Fillet16Fillet17Outer surface18Fillet19Fillet20Receptacle part21Coupling portion22Collar23Aperture24Receptacle portion25Receptacle region25A Chamfer26Cavity27Cavity28Base body29Grip region30Latching hook31Latching hook32Engaging portion33Locking part34Base body35Mating engaging portion36Latching rib37Latching rib38Grip region39Insertion opening40Engaging element41Engaging element42Engaging element43Engaging element44Intermediate space45Intermediate space46Intermediate space47Intermediate space48Gap49Aperture50Flat portion51Flat portion52Flat portion53Constriction54Constriction55Constriction56Sealing part57Base body58Receptacle region59Chamfer60Rib61Cover portion62Aperture63Gear device64End faced6Diameterd7Diameterd25Diameterd40Diameterd57Diameterd62DiameterH HeightI Internal spaceL Longitudinal directionM Axis of symmetryR Radial directionU EnvironmentUR Circumferential directionW Wave heightZ1StateZ2State | 35,989 |
11859742 | DETAILED DESCRIPTION While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail, embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. The disclosed wire basket bracket enables a cable cleat assembly to be safely and securely mounted to a wire basket with minimal tools and can accommodate a variety of cable attachment products. Further, the wire basket bracket may be connected to a cable cleat and used with power cable installations where high voltage cable installations are implemented. The combination of the wire basket and a cable cleat assembly holds the cables in place during a short-circuit event to prevent damage to people and property. Turning to the figures,FIG.1depicts an example of a clamp bottom102of one example of a wire basket bracket. The clamp bottom102is shaped as a U-shaped configuration. The clamp bottom102includes a base103that is planar and rectangularly shaped. A first sidewall106resides along a longitudinal edge111of the base103and a second sidewall108resides along the other longitudinal edge113of the base103. The first sidewall106and second sidewall108are planar and extend from the base103at a right angle and include an interior side107and an exterior side109. The clamp bottom102has a first end110and a second end112. The first end110of the clamp bottom102includes a wire basket slot114in each of the first sidewall106and second sidewall108. The wire basket slots114are configured as a U-shaped cutout within the first sidewall106and second sidewall108. The wire basket slots114are configured to accept a cross-wire of a wire basket. A through hole116resides in the base103at approximately the middle of the base103. The through hole116maybe a rectangular opening as depicted or may also be circular. The through hole116is configured to accept a carriage bolt to extend therethrough. The clamp bottom102includes latch reliefs118near the second end112of the clamp bottom102. Latch relief118resides within each of the first sidewall106and second sidewall108and extends at least a portion into the base103. The latch reliefs118are slots disposed within the sidewalls106,108and a portion of the base103. The latch reliefs118are configured to allow for the second end112of the clamp bottom102to deflect and deform at the latch reliefs118during installation. Adjacent the latch reliefs118are latch slots119in each of the first sidewall106and second sidewall108at the second end112of the clamp bottom102. The latch slots119are configured as J-shaped cutouts within the first sidewall106and second sidewall108. Each of the latch slots119in the first sidewall106and second sidewall108include a hook121with an end portion123. The hook121is configured to engage a cross-wire of a wire basket. FIG.2depicts a clamp top104of the wire basket bracket100. The clamp top104is shaped as a U-shaped configuration similar to the clamp bottom102, with a first end132and a second end134. The clamp top104includes a base105that is planar and rectangularly shaped. A first sidewall120resides along a longitudinal edge124of the base105and a second sidewall122resides along the other longitudinal edge126of the base105of the clamp top104. The first sidewall120and second sidewall122extend from the base105at a right angle and include an interior side129and an exterior side131. Each of the first sidewall120and the second sidewall122each include an interference bead133along the exterior side131. The interference beads133are located on each of the first sidewall120and second sidewall122along a longitudinal axis at approximately a center of the respective sidewalls120,122. The interference beads133are formed as a rib in the sidewalls120,122and protrudes out from the exterior side131from a planar portion of the sidewalls120,122. Each of the first sidewall120and second sidewall122includes a cross-wire notch136,138at each of the first end132and second end134. The first cross-wire notch136is roughly C-shaped. The first cross-wire notch136is configured to engage with a cross-wire of a wire basket. The second cross-wire notch138is also roughly C-shaped, just as the first cross-wire notch136. The second cross-wire notch138is configured to engage with another cross-wire of a wire basket. A through hole135resides in the base105at approximately the middle of the base105of the clamp top104. The through hole135maybe a rectangular opening as depicted or may also be circular. The through hole135is configured to accept a carriage bolt to extend therethrough. FIG.3depicts the clamp bottom102in an initial installation position with a wire basket150. The wire basket150generally includes cross-wires, or crossmembers, with a first plurality of cross-wires disposed parallel to each other and a second plurality of cross-wires disposed parallel to each other, but perpendicular to the first plurality. This configuration creates a grid of cross-wires. As depicted, a first cross-wire152and second cross-wire154are parallel to each other, but perpendicular to a third cross-wire156and fourth cross-wire158, that are parallel to each other. The grid connection typically forms a rectangular opening159between the cross-wires152,154,156, &158. In the initial installation position, a first cross-wire152of the wire basket150resides within the wire basket slots114of the first sidewall106and second sidewall108of the clamp bottom102. The first end110of the clamp bottom102is supported by the first cross-wire152of the wire basket150. FIG.4depicts the clamp bottom102in a second installation position. In the second installation position, the latch slots119at the second end112of the clamp bottom102are engaged with the second cross-wire154of the wire basket150. The second end112of the clamp bottom102is supported by the second cross-wire154of the wire basket150. To orient the clamp bottom102from the first position to the second position as depicted inFIG.4, the clamp bottom102is pivoted up about the engagement of the wire basket slots114and first cross-wire152. As the clamp bottom102is pivoted up, the end123of the latch slots119of the first sidewall106and second sidewall108contact the second cross-wire154. As the clamp bottom102is further pivoted up, the latch slots119deflect inward in a direction of the first end112via the latch reliefs118. The latch slots119and second end112defect inwards until the end portion123of the hook121clears the second cross-wire154. When the second cross-wire154has cleared the end portion123of the hook121, the latch slots119are engaged with the second cross-wire154. The clamp bottom102is now attached to the wire basket150. FIGS.5and6depict the clamp bottom102and clamp top104mated and installed to the wire basket150. The clamp bottom102and clamp top104are configured to mate in a clam shell fashion, to form the wire basket bracket100. The clamp top104resides within the clamp bottom102. That is, the exterior side131of the sidewalls120,122of the clamp top104are disposed between the interior side107of the sidewalls106,108of the clamp bottom102. The distance between the exterior side131of the first sidewall120and the exterior side131of the second sidewall122of the clamp top104is configured to be less than the distance between the interior side107of the first sidewall106and the interior side107of the second sidewall108of the clamp bottom102to allow for the clamp top104to mate between the sidewalls106,108of the clamp bottom102. The distance between the interference beads133(FIG.6) of the first sidewall120and second sidewall122of the clamp top are configured to be slightly larger than the distance between interior side107of the sidewalls106,108of the clamp bottom102. When the clamp top104is in the mated configuration with the clamp bottom102, the first sidewall120and second sidewall122of the clamp top104are deflected inwards by the interior sides107first sidewall106and second sidewall108of the clamp bottom102. The clamp top104is held together to the clamp bottom102in compression. As depicted inFIG.5, the first cross-wire notch136and second cross-wire notch138of the clamp top104are engaged with the first cross-wire152and second cross-wire154, respectively, of the wire basket150. The clamp top104is thereby aligned with the clamp bottom102, as are the through hole116of the clamp bottom102and the through hole135of the clamp top104. FIG.7depicts an example cable cleat assembly170connected to the wire basket bracket100that is, in turn, connected to a wire basket150. The cable cleat assembly170being the cable cleat assembly170disclosed in FIGS. 4-9 of U.S. patent application Ser. No. 16/252,962. In this example, the cable cleat assembly170is fastened to the wire basket bracket100through a carriage bolt162. Any other acceptable fastener may also be used. The threaded shaft of the carriage bolt162extends from the head of the carriage bolt162through the through hole135(not seen) of the clamp top104and through the through hole116(not seen) of the clamp bottom102. A nut (not depicted) is then fastened to the end of the threaded shaft of the carriage bolt162. FIG.8depicts another example of a cable management assembly180including a cushion sleeve182and strap cleat184. The cushion sleeve182and strap cleat184are connected to the wire basket bracket100that is in turn connected to a wire basket150. In this example, the cushion sleeve182rests on the wire basket bracket100. Three power cables186reside within the cushion sleeve182. The strap cleat184extends around the cushion sleeve182and the wire basket bracket100to secure both the power cables186installed within cushion sleeve182and wire basket bracket100to the wire basket150. FIGS.9-15depict an alternative example wire basket bracket200of the present invention.FIG.9is an exploded perspective view of a wire basket bracket200and the cable cleat assembly170described above inFIG.7. As depicted inFIG.9, the wire basket bracket200includes a bracket frame202and a locking plate204. The bracket frame202is shaped as a U-shaped configuration, with a first end210and a second end212. The bracket frame202includes a base203that is planar and rectangularly shaped. A first sidewall206resides along a first longitudinal edge211of the base203and a second sidewall208resides along a second longitudinal edge213of the base203. The first sidewall206and second sidewall208are planar and disposed from the base203at a right angle. The first sidewall206and second sidewall208each include an interior side207and an exterior side209. The bracket frame202includes two cross-wire notches214in each of the first sidewall206and second sidewall208. The cross-wire notches214are configured as a U-shaped cutout within the first sidewall206and second sidewall208. The cross-wire notches214are configured to accept a cross-wire of a wire basket. The two cross-wire notches214in each of the sidewalls206,208include one cross-wire notch214adjacent the first end210and one cross-wire notch214adjacent the second end212. The cross-wire notches214on the first side wall206and second sidewall208are spaced from each other at a distance configured to engage two adjacent and parallel wire basket cross-wires. A through hole215resides in the base203at approximately the middle of the base203. The through hole215maybe a circular opening as depicted. The through hole215is configured to accept a carriage bolt262to extend therethrough. Also depicted inFIG.9, the locking plate204is shaped as a U-shaped configuration. The locking plate204includes a base205that is planar and rectangularly shaped. The locking plate204has a first end216and a second end218. The distance from the first end216to the second end218of the locking plate204is approximately the same as the distance from the first end210and second end212of the bracket frame202. Each of the bracket fame202and the locking plate204are configured to span a distance greater than a pair of adjacent cross-wires. A first sidewall220resides along a first longitudinal edge224of the base205and a second sidewall222resides along the second longitudinal edge226of the base205. As depicted, the longitudinal edges224,226are radiused edges that extend between the base205and the sidewalls220,222. The first sidewall220and second sidewall222are planar and disposed from the base205at a right angle. The first sidewall220and second sidewall222each include an interior side228and an exterior side230. A through hole232resides in the base205of the locking plate204at approximately the middle of the base205. The through hole232is rectangularly shaped and is configured to accept a square shoulder264of the carriage bolt262. The square shoulder264is configured to fit within the square through hole232of the locking plate204. The end of the carriage bolt262includes a threaded shaft266for a nut164to attach thereto. In this configuration, rotation of the cable cleat assembly170rotates the locking plate204through the rotation of the carriage bolt262being acted on by the cable cleat assembly170, and the carriage bolt262acting on the locking plate204. FIG.10depicts a perspective view of an assembled wire basket bracket200and cable cleat assembly170. The bracket frame202is attached to the locking plate204via the carriage bolt162(not seen). In this configuration, the longitudinal edges211,213of the bracket frame202are disposed approximately 90-degrees from the longitudinal edges224,226of the locking plate204.FIG.11depicts a side view of the assembled wire basket bracket200. The longitudinal edges211,213of the bracket frame202are parallel with the longitudinal edges224,226of the locking plate204. The cross-wire notches214are engaged with a first cross-wire152and second cross-wire154of a wire basket150. In this configuration, the first cross-wire152and second cross-wire154are locked between the bracket frame202and the locking plate204. The wire basket bracket200is secured in place with the bracket frame202and locking plate204in this configuration. FIG.12depicts the assembled wire basket bracket200and cable cleat assembly170in an initial installation position. In the initial installation position, the assembled wire basket bracket200and cable cleat assembly170are positioned above first cross-wire152, second cross-wire154, a third cross-wire156, and fourth cross-wire158of the wire basket150. The longitudinal axis of the cable cleat assembly170and the locking plate204are aligned, and the longitudinal axis of bracket frame202is disposed 90-degrees relative to the cable cleat assembly170and the locking plate204. An arrow161indicates the movement of the wire basket bracket into the opening159of the wire basket150towards a second installation position. FIG.13depicts the second installation position of the wire basket bracket200and cable cleat assembly170. In the second installation position, the longitudinal axis of the cable cleat assembly170and the locking plate204are aligned, and the longitudinal axis of bracket frame202is disposed 90-degrees relative to the cable cleat assembly170and the locking plate204. The cross-wire notches are engaged with a first cross-wire152and second cross-wire154of a wire basket150. The wire basket bracket200and cable cleat assembly170are supported by the first cross-wire152and second cross-wire154. FIG.14depicts an installed position of the wire basket bracket200and cable cleat assembly170. In the installed position, the longitudinal edges211,213of the bracket frame202are parallel with the longitudinal edges224,226of the locking plate204. The cross-wire notches214are engaged with a first cross-wire152and second cross-wire154of a wire basket150. In this configuration, the first cross-wire152and second cross-wire154are locked between the bracket frame202and the locking plate204. The wire basket bracket200is secured in place with the bracket frame202and locking plate204in this configuration.FIG.15depicts the wire basket bracket200and cable cleat assembly170ofFIG.14with three power cables190(two visible, one hidden from view) installed within. FIGS.16-22depict a further example wire basket bracket300of the present invention.FIG.16is an exploded perspective of the wire basket bracket300, including a bracket frame302and a locking slide304. The bracket frame302is generally shaped in a U-shaped configuration including an interior329within. The bracket frame302includes a first end310and a second end312. The bracket frame302includes a base303that is planar and rectangularly shaped. Adjacent the first end310of the bracket frame302within the base303are a series of detents317,319. A first detent317is directly adjacent the first end310and a second detent319is adjacent the first detent317. Each of the detents317,319include a detent tab321that resides within an opening333in the base. The detent tab321of the first detent317is angled downward such that the detent tab321projects into the interior329of the bracket frame302. The detent tab321of the second detent319is planar with the base303. A through hole332resides in the base303of the bracket frame302at approximately the middle of the base303. The through hole332is configured to accept a carriage bolt to mount a cable cleat assembly to the wire basket bracket300. The bracket frame302further includes a first sidewall306residing along a first longitudinal edge311of the base303and a second sidewall308residing along the second longitudinal edge313of the base303. The first sidewall306and second sidewall308are planar and disposed from the base303at a right angle. The first sidewall306and second sidewall308each include an interior side307and an exterior side309. Each of the first sidewall306and second sidewall308each include a retaining flange347. The retaining flange347resides near the bottom of each of the first sidewall306and second sidewall308. The retaining flange347being further described below in connection withFIG.17. The first end310of the bracket frame302includes a wire basket slot314in each of the first sidewall306and second sidewall308. The wire basket slots314are configured as U-shaped cutouts within the first sidewall306and second sidewall308. The wire basket slots314are configured to accept a cross-wire of a wire basket. Adjacent a second end312of the bracket frame302is a slot315. The slot315forms an opening in the base303; longitudinal edges311,313; and sidewalls306,308. The slot315is configured to accept a cross-wire of a wire basket. As indicated above,FIG.16further depicts the locking slide304. The locking slide304includes a first end316and a second end318. The locking slide304includes a base305that is planar and rectangularly shaped. A through hole334resides in the base305adjacent the second end318of the base305. The through hole334maybe a circular opening as depicted. The through hole334is configured to accept a carriage bolt262to extend therethrough. A first sidewall320resides along a portion of a first longitudinal edge324of the base305and a second sidewall322resides along the second longitudinal edge326of the base305. The first sidewall320and second sidewall322are planar and disposed from the base305at a right angle. The first sidewall320and second sidewall322each include an interior side328and an exterior side330. The first sidewall320and second sidewall322each include a leading edge338. The leading edge338is inset from the first end316and extends from the respective longitudinal edges324,326to a bottom335of the sidewalls320,322. Located at a second end318of the locking slide304on each of the first sidewall320and second sidewall322is a stop340. The stop340is a rectangular extension from the bottom135of each of the sidewalls320,322. FIG.16further depicts a backwall342of the locking slide304. The backwall342extends from a back edge344of the base305. The backwall342extends from the base305at a right angle. A portion of a detent catch346located within the back edge344and a portion is located within the base305. The detent catch346is an opening in the back edge344and base305that is configured to accept the detent tab321of first detent317or second detent319. FIG.17depicts the wire basket bracket300with the bracket frame302mated with the locking slide304in a first mated position. The locking slide304resides within the bracket frame302. That is, the exterior side331of the sidewalls320,322of the locking slide304are disposed between the interior side307of the sidewalls306,308of the bracket frame302. The distance between the exterior side331of the first sidewall320and the exterior side331of the second sidewall320of the locking slide304is configured to be less than the distance between the interior side307of the first sidewall306and the interior side307of the second sidewall308of the bracket frame302to allow for the locking slide304to mate between the sidewalls306,308of the bracket frame302. FIG.17further depicts the retaining flange347of the first sidewall320and second sidewall322. The retaining flange347includes ledges348that extend into the interior329at a right angle to the sidewalls320,322and parallel to the base303. The ledges348are offset from the base303at a slightly larger dimension than the height of the sidewalls320,322of the locking slide304to allow the locking slide304to slidably mate with the bracket frame302. In the first mated position, the first detent317is engaged with the detent catch346. In the first mated position, the detent catch346acts on the detent tab321of the first detent317to prevent the locking slide304from being removed from the first mated position. FIG.18depicts the bracket frame302in an initial install position. In the initial installation position, the first cross-wire152of the wire basket150resides within the wire basket slots314of the first sidewall306and second sidewall308of the bracket frame302. The first end310of the bracket frame302is supported by the first cross-wire152of the wire basket150.FIG.19depicts the bracket frame302in a second installation position. In the second installation position, the second cross-wire154of the wire basket150is inserted into the slot315adjacent the second end312of the bracket frame302. To orient the bracket frame302from the first position to the second position as depicted inFIG.19, the bracket frame302is pivoted up about the engagement of the wire basket slot314and first cross-wire152. As the bracket frame302is pivoted up, the second cross-wire154enters the slot315for engagement. The bracket frame302continues pivoting until the second cross-wire154reaches the bottom of the slot315. FIGS.20and21depict the bracket frame302and locking slide304mated and installed to the wire basket150in a second mated position.FIG.20depicts a bottom prospective of the wire basket bracket300. In the second mated position, the locking slide304is slid as far into the bracket frame302as the locking slide can travel before engagement of the stops340with the retaining flanges347.FIG.20depicts the stops340engaged with the retaining flanges347of the first sidewall306and second sidewall308, stopping any further forward movement by the locking slide304. The through hole332of the bracket frame302is aligned with the through hole334of the locking slide304. FIGS.20and21depict the second end318of the locking slide304disposed between the second cross-wire154and the base303of the bracket frame302. The orientation of the locking slide304is disposed between the second cross-wire154and the base303of the bracket frame302. This orientation locks the wire basket bracket300to the wire basket150and prevents the second cross-wire154from being removed from the slot315of the bracket frame302. The second detent319is positioned over the detent catch346. The detent tab321of the second detent319may then be depressed into the interior329of the bracket frame302to prevent reward movement of the locking slide304. FIG.22depicts an installed position of the wire basket bracket300with a cable cleat assembly170as described above attached thereto. | 24,211 |
11859743 | DETAILED DESCRIPTION Features, advantages, and embodiments of the present disclosure are set forth or apparent from a consideration of the following detailed description, drawings, and claims. Moreover, it is to be understood that the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the disclosure as claimed. Various embodiments are discussed in detail below. While specific embodiments are discussed, this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without departing from the spirit and scope of the present disclosure. Reference will now be made in detail to present embodiments of the disclosed subject matter, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the disclosed subject matter. As used herein, the terms “first,” “second,” “third,” “fourth,” and “exemplary” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. Further, to more clearly and concisely describe and point out the subject matter, the following definitions are provided for specific terms, which are used throughout the following description and the appended claims, unless specifically denoted otherwise with respect to a particular embodiment. The term “tube spacing and fastening system” as used in the context refers to a group of interacting or interrelated elements that act according to a set of rules to form a unified whole deployed to spatially separate tubes or its equivalents, such as pipes, rods, bars or any tubular structure and at the same time, to fasten them together. The detailed description uses numerical and letter designations to refer to features of tube spacing and fastening systems in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar tube spacing and fastening systems. As used herein, the numerals “20,” “40,” “60,” and “80” may be used interchangeably to distinguish one system from another and are not intended to signify location or importance of the individual systems. The term “spacer element” as used in the context refers to a device or piece used to create or maintain a desired amount of space between two or more objects. The detailed description uses numerical and letter designations to refer to features of spacer elements in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar spacer elements. As used herein, the numerals “22,” “42,” “62,” and “82” may be used interchangeably to distinguish one spacer element from another and are not intended to signify location or importance of the individual spacer elements. The term “core part” as used in the context refers to a central and foundational portion of a spacer element, usually distinct from the enveloping portions by a difference in nature or structure or function. The detailed description uses numerical and letter designations to refer to features of core parts in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar core parts. As used herein, the numerals “29,” “45,” and “86” may be used interchangeably to distinguish one core part from another and are not intended to signify location or importance of the individual core parts. The term “fastening element” as used in the context refers to a device or component that structurally joins or affixes two or more objects together. In general, fasteners are used to create non-permanent joints, that is, joints that can be removed or dismantled without damaging the joining components. The detailed description uses numerical and letter designations to refer to features of fastening elements in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar fastening elements. As used herein, the numerals “23,” “46,” “72,” and “92” may be used interchangeably to distinguish one fastening element from another and are not intended to signify location or importance of the individual fastening elements. The term “raised slot edge” as used in the context refers to elevated sides of a narrow, elongated depression, groove, notch, slit, or aperture, especially a narrow opening on a spacer element for receiving or admitting something of a planar dimension such as a fastening strap or band. The detailed description uses numerical and letter designations to refer to features of raised slot edges in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar raised slot edges. As used herein, the numerals “54,” and “68” may be used interchangeably to distinguish one raised slot edge from another and are not intended to signify location or importance of the individual raised slot edges. The term “top end” as used in the context refers to the highest or uppermost point, portion, or surface of a spacer element. The detailed description uses numerical and letter designations to refer to features of top ends in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar top ends. As used herein, the numerals “37,” and “65” may be used interchangeably to distinguish one top end from another and are not intended to signify location or importance of the individual top ends. Similarly, the term “bottom end” as used in the context refers to the lowest or lowermost point, portion, or surface of a spacer element. The detailed description uses numerical and letter designations to refer to features of bottom ends in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar bottom ends. As used herein, the numerals “38,” and “66” may be used interchangeably to distinguish one bottom end from another and are not intended to signify location or importance of the individual bottom ends. The term “top tray slot” as used in the context refers to a narrow, elongated depression, groove, notch, slit, or aperture, especially a narrow opening on top of a spacer element for receiving or admitting something of a planar dimension such as a fastening strap or a band. The detailed description uses numerical and letter designations to refer to features of top tray slots in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar top tray slots. As used herein, the numerals “52,” and “67” may be used interchangeably to distinguish one top tray slot from another and are not intended to signify location or importance of the individual top tray slots. The term “tube outer surface” as used in the context refers to an outermost or uppermost or exterior boundary or layer or area of a tube. The detailed description uses numerical and letter designations to refer to features of tube outer surfaces in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar tube outer surfaces. As used herein, the numerals “26,” “47,” “73,” and “93” may be used interchangeably to distinguish one tube outer surface from another and are not intended to signify location or importance of the individual tube outer surfaces. The tube spacing and fastening system of the present disclosure provides for coupling multiple tubular structures together. The tube spacing and fastening system of the present disclosure couples or connects multiple tubular structures together without brazes or welds. In some examples, the tube spacing and fastening system may include a spacer element and a fastening band for coupling the multiple tubular structures. The spacer element functionally addresses an engineering contradiction of holding the tubular structures together and, at the same time, spatially separating them from another. The fastening band extends around the outer surfaces of the tubular structures and fastens them to the spacer element, loosely below a predetermined temperature range and conversely, tightly above the predetermined temperature range. The spacer element is also configured to distribute stress in each of the plurality of tubular structures in relation to the spacer element. Surface features may be present on the spacer. Further, the tube spacing and fastening system of the present disclosure may allow for coupling of multiple tubular structures in a manner that reduces, prevents, or eliminates high stress concentrations. Gas turbine engine installations include tubes or conduits carrying fuel, oil, hydraulic fluids ore pressurized air. The tubes or conduits are usually bundled together to carry the fluid within or across several compartments and components (such as fan, compressor, turbine) of the engine under a nacelle or to discharge the fluid overboard. Tube or pipe assemblies deployed in engineering assemblies found in aircraft engines, heat exchangers, and nuclear power structures typically bundle the tubes using spacers. The spacers may be permanently joined to the tube bundle, for example, with brazed or welded blocks and tabs. For example, a typical tube assembly of exemplary tubular structures may include, in a non-limiting manner, tubes, pipes, rods, bars, or combinations thereof. In one instance, an exemplary tube assembly may include a bank of exemplary tubes permanently joined (e.g., brazed or welded) in a clamp forming a clamp-tube assembly. In one instance, an exemplary tube assembly may include a bank of exemplary tubes permanently joined (e.g., brazed or welded) in a spacer forming a permanently joined spacer-tube assembly. FIG.1Ashows a schematic, perspective view of a tube spacing and fastening system for tubular structures, such as tubes, pipes, rods and bars, according to an embodiment of the present disclosure, typically found in engineering assemblies associated with aircraft engines. Referring toFIG.1A, a bank of exemplary tubes12is assembled in a tube spacing and fastening system20. The tube spacing and fastening system20may include a spacer element22configured to engage the exemplary tubes12and spatially separate one exemplary tube12afrom another exemplary tube12b. The spacer element22may spatially separate the exemplary tubes12and distribute stress in the tube spacing and fastening system20. Further, a fastening element23is configured to extend around at least a portion of an outer surface26of the exemplary tubes12and the fastening element23is configured to extend around at least a portion of the outer surface26of the exemplary tubular structures12, and to fasten the exemplary tubes12to the spacer element22in an adaptively spaced configuration. In one instance, the adaptively spaced configuration may include a first length of the fastening element23below a predetermined temperature range and a second length of the fastening element23above the predetermined temperature range, such that the first length is different from the second length. Further, in another instance, the adaptively spaced configuration may include a first configuration, wherein the exemplary tubes12are movably spaced around the spacer element22and a second configuration, wherein the exemplary tubes12are immovably spaced around the spacer element22. FIG.1Bshows an enlarged schematic, perspective front view of the spacer element22as in the tube spacing and fastening system20for exemplary tubes12ofFIG.1A.FIG.1Cshows an enlarged schematic, perspective back view of the spacer element22for the tube spacing and fastening system20ofFIG.1A. Referring toFIGS.1B and1C, the spacer element22may include two opposing faces, a first cradle bracket27and a second cradle bracket28, separated by a core part29positioned in the center of the spacer element22and in between the first cradle bracket27and the second cradle bracket28. The first cradle bracket27, the second cradle bracket28, and/or the core part29may be concave or may be any shape configured to complement the shape of the exemplary tubes12. In one instance, the core part29may be a double-concave core part. The spacer element22may be a spacer block and may be a solid block. The first cradle bracket27and the second cradle bracket28may be formed in the body of the spacer element22. With continued reference toFIGS.1B and1C, a first contact surface30may engage the corresponding first exemplary tube12a(FIG.1A) at the first cradle bracket27and a second contact surface31may engage the corresponding second exemplary tube12b(FIG.1A) at the second cradle bracket28. The first contact surface30, the second contact surface31, or both, may include a number of exemplary surface features32, such as, for example, but not limited to, indentations or protrusions. Going into more detail, the spacer element22employs the first cradle bracket27configured to engage the first exemplary tube12a(FIG.1A) and the second cradle bracket28configured to engage the second exemplary tube12b(FIG.1A). The core part29spatially separates the first cradle bracket27from the second cradle bracket28, and, thereby, spatially separates the first exemplary tube12aengaged in the first cradle bracket27and the second exemplary tube12bengaged in the second cradle bracket28. The spacer element22further includes a first recess33on one side, carved between the first cradle bracket27and a first corresponding surface35of the core part29. In a similar manner, the spacer element22further includes a second recess34on the other side, carved between the second cradle bracket28and a second corresponding surface36of the core part29. The first recess33is configured to accommodate a first part24(FIG.1A) of the fastening element23and the second recess34is configured to accommodate a second part25(FIG.1A) of the fastening element23. Each of the first recess33and the second recess34includes a projected lip49(FIGS.1B and1C) and a seat51(FIGS.1B and1C) that, together, keep the fastening element23within the respective recess33and34and prevent from slipping out of the recess, under stress. Continuing to refer toFIGS.1B and1C, the first cradle bracket27, the second cradle bracket28, and the core part29may join at a top end37of the spacer element22and at a bottom end38of the spacer element22. In an embodiment of the current disclosure, the fastening element23may be a wrap-around band made of a shape memory alloy (SMA). Without being held to any particular theory, it is currently believed that the scientific effect of exemplary shape-memory alloys is based on the phenomenon of continuous appearance and disappearance of the martensite phase with falling temperatures and rising temperatures. This thermoelastic behavior is the result of the transformation from a parent austenite phase, stable at an elevated temperature, to the martensite phase. Specifically, when a pre-deformed, shape memory alloy specimen is heated to the temperature of the parent austenite phase, a complete recovery of the deformation takes place. Complete recovery in this process is limited by the fact that strain must not exceed a critical value which ranges, for example, from 3% to 4% for copper shape-memory effect alloys to 6% to 8% for nickel-titanium shape-memory alloys. The shape-memory effect, as embodied by the fastening element23as an SMA band, is a spontaneous, reproducible, and reversible shape change associated with heating and cooling throughout an overall transformation temperature range. Further, it is possible to condition or ‘train’ a shape-memory alloy to have a shape-memory effect by repeating the cooling and heating process a number of times. The reversible shape change could be, for example, lengthening and shortening as the trained shape-memory alloy sample is cycled between two transitional temperatures. Referring toFIG.1A, when the fastening element23is a shape memory alloy band, the fastening element23of the current disclosure may have an overall transition temperature range above atmospheric temperature and below a temperature such that the shape memory alloy band may assume a first configuration (length) for tightly supporting the exemplary tubes12at a temperature above the overall transition temperature and may assume a second configuration (length) for loosely engaging the exemplary tubes12below the overall transition temperature. Thus, for the exemplary tubes12to engage with the spacer element22, the shape memory alloy band may generate high radial compressive force that swages the underlying exemplary tubes12. In operation, when the fastening element23is a shape memory alloy (SMA) band, the band is configured to be oversized in a cooled, martensitic state and, then, during operation, the band is warmed up to a smaller, contracted size to generate an elastic radial compressive force and thereby engage the exemplary tubes12with the spacer element22. Further, referring toFIG.1A, the shape memory alloy (SMA) band, in one embodiment of the current disclosure, generates high radial compressive force and swages (compresses or shrinks) underlying tube surfaces to locally yield at the static metal-to-metal joints by swaging a number of surface features (protrusions or indentations or teeth or dimples or ridges) configured on the contact surfaces and, at the same time, remain in continued contact with the spacer element22. Any shape-memory alloy may be used in the present disclosure as long as it demonstrates an adequate shape-memory effect. In one embodiment of the current disclosure, the shape-memory alloys include nickel-titanium alloys, in weight ratios selected to deform at a temperature above a desired transition temperature. Further, the chemical composition and transition temperature for the shape memory mental (SMA) are further selected to be appropriate for the desired tube spacing and fastening system operating temperature between ambient and about 1000° F. Thus, exemplary shape memory alloy (SMA) bands for the fastening element23ofFIG.1Autilize their shape-memory characteristic and corresponding configured and memorized length to provide a temperature-sensitive length change and, thereby, a significant degree of adaptive spacing of the exemplary tubes12during operation. Specifically, when the exemplary tubes12tubes are at their operating temperature above the transition temperature of the shape memory alloy (SMA) bands, typical shape memory alloy (SMA) bands transform to their memorized shorter length, providing a tight and reduced spacing and lateral loading on the exemplary tubes12. Referring toFIGS.1A,1B, and1C, the shape memory alloy (SMA) band for the fastening element23of the current disclosure may engage the first cradle bracket27and the second cradle bracket28and the outer surfaces26of the exemplary tubes12upon heating above the parent austenite transition temperature range to a high temperature, tight configuration of the shape-memory alloy. Conversely, once cooled below the martensite transition temperature range, typical shape memory alloy (SMA) bands convert to their low temperature configuration and is in an expanded length or stretched length or oversized length corresponding to the lower temperatures. Typically, such high temperature configurations are associated with operational conditions when the exemplary tubes12need to be in compact, tight and immovable contact. Further low temperature configurations are associated with maintenance or shutdown of the engineering spacing and fastening system and the shape memory alloy (SMA) band enable assume a loose configuration enabling a slidable or movable disengagement of the exemplary tubes12from their respective cradle brackets and the spacer element22. The shape memory alloy (SMA) bands and their shape-memory effect thus inherently provide adaptive spacing for the exemplary tubes12, in relation to each other and to the spacer element22to which they are fastened. The stress distribution effect of the shape memory alloy (SMA) bands may be further enhanced by adopting a stress-adaptive configuration of the spacer element22and related parts and components. For example, contact surfaces where two or more parts engage and/or interact with each other (e.g., the first contact surface30and/or the second contact surface31) may include a stress-adaptive configuration (e.g., surface features configured to reduce contact stress between parts). In another embodiment of the disclosure, one, or more, or all, of the joints39in spacer element22are filleted for optimal stress distribution at the corners where the fastening element23engages with the spacer element22. In other words, a first exemplary joint39abetween the first cradle bracket27and the top end37, a second exemplary joint39bbetween the second cradle bracket28and the top end37, a third exemplary joint39cbetween the first cradle bracket27and the bottom end38, and a fourth exemplary joint39dbetween the second cradle bracket28and the bottom end38are all filleted joints. Referring toFIGS.1A,1B, and1C, the exemplary tubes12have diameter in the range of 0.75 to 1.0 inches and wall thickness in the range of 0.020 to 0.035 inches. The width of the spacer element22is of the order of 0.5 inches and the thickness of the shape memory alloy (SMA) band is in the range of 0.020 to 0.063 inches. Continuing to refer toFIGS.1B and1C, additional stress distribution configurations may include specially contouring the first contact surface30and the second contact surface31between the exemplary tubes12and the first cradle bracket27and the second cradle bracket28. Accordingly, instead of full surface contact between a stiffer block (e.g., spacer element22) and a thin-walled tube (e.g., exemplary tubes12), which generates higher edge contact stress, the spacer element22may include exemplary surface features32. The exemplary surface features32may be protrusions (also known as ‘beads’) in one instance and may be indentations (also known as ‘dimples’) in another instance. In yet another instance, the surface features32may be any combination of protrusions and indentations. The exemplary surface features32can be of different shapes with varying cross sections such as spherical-circular (as shown inFIGS.1B and1C), or elliptical, or square, or trapezoidal, or triangular, or any combination of these. Thus, the exemplary surface features32may create a low stress field at discrete points of contact on the exemplary tubes12. Specifically, the first exemplary tube12ajoins the first cradle bracket27at the first contact surface30and the second exemplary tube12bjoins the second cradle bracket28at the second contact surface31, and either the first contact surface30, or the second contact surface31, or both include the exemplary surface features32that may include protrusions and/or indentations, which may provide effective stress optimization configuration. Thus, referring toFIGS.1A,1B, and1C, the metal-to-metal contacts at the ‘thick-walled’ first cradle bracket27and the ‘thick-walled’ second cradle bracket28may result in high stresses, so the exemplary surface features32(protrusions/indentations) may be included in a non-limiting manner. In other words, the exemplary surface features32(protrusions/indentations) may be omitted in another instance, if desired. FIG.2Ashows a schematic, perspective view of a tube spacing and fastening system40for the exemplary tubes12, according to an embodiment of the present disclosure. Referring toFIG.2A, the tube spacing and fastening system40includes a spacer element42with two opposing faces shaped as a first cradle bracket43and a second cradle bracket44separated by a core part45. In an embodiment of the current disclosure, outer surfaces of the first cradle bracket43and the second cradle bracket44may be marked with exemplary surface features including protrusions/indentations (not visible, such as described with respect toFIGS.1B and1C). Continuing to refer toFIG.2A, a fastening element46is extended around at least part of an outer surface47of each of the exemplary tubes12in the tube spacing and fastening system40to fasten the exemplary tubes12to the spacer element42. In one instance, the fastening element46may be a shape memory alloy (SMA) band. FIG.2Bshows an enlarged schematic, perspective view of the spacer element42as in the tube spacing and fastening system40for the exemplary tubes12ofFIG.2A, according to an embodiment of the present disclosure. Continuing to refer toFIG.2B, the spacer element42is configured as a solid block that includes a seating slot or groove52to accommodate the fastening element46, embodied as a shape memory alloy (SMA) band. The fastening element46, embodied as a shape memory alloy (SMA) band, typically extends around the spacer element42and the exemplary tubes12. Further, the seating slot or groove52may include raised edges54on the spacer element42to provide a secure or snug seating arrangement for the fastening element46, embodied as a shape memory alloy (SMA) band within the seating slot or groove52. Continuing to refer toFIG.2B, additional stress distribution configurations may include specially contouring the contact surfaces between the exemplary tubes12and the first cradle bracket43and the second cradle bracket44. Accordingly, instead of full surface contact between a stiffer block (e.g., the spacer element42) and a thin-walled tube (e.g., the exemplary tubes12), which generate higher edge contact stress, the spacer element42may include exemplary surface features (not shown). The exemplary surface features may be protrusions (also known as ‘beads’) in one instance and may be indentations (also known as ‘dimples’) in another instance. In yet another instance the surface features may be any combination of protrusions and indentations. Thus, the exemplary surface features may create a low stress field at discrete points of contact on the exemplary tubes12. Specifically, the first exemplary tube12ajoins the first cradle bracket43at a corresponding first contact surface (not shown) and the second exemplary tube12bjoins the second cradle bracket44at a corresponding second contact surface (not shown), and either the first contact surface or the second contact surface or both include exemplary surface features that may include protrusions and/or indentations, which may provide effective stress distribution configuration. Thus, referring toFIGS.2A and2B, the metal-to-metal contacts at the ‘thick-walled’ first cradle bracket43and the ‘thick-walled’ second cradle bracket44may result in high stresses, so exemplary surface features (protrusions/indentations) may be included, in a non-limiting manner. In other words, the exemplary surface features (protrusions/indentations) may be omitted in another instance, as desired. FIG.3Ashows a schematic, perspective view of a tube spacing and fastening system60for the exemplary tubes12, according to an embodiment of the present disclosure. Referring toFIG.3A, the bank of exemplary tubes12are assembled in a tube spacing and fastening system60. Tube spacing and fastening system60includes a spacer element62with two opposing faces shaped as a first thin-walled bracket63and a second thin-walled bracket64. In one embodiment of the disclosure, outer surfaces of the first thin-walled bracket63and second thin-walled bracket64are marked with protrusions and/or indentations (not shown), such as described with respect toFIGS.1B and1C. The thin-walled bracket64and the thin-walled bracket63may function as cradles, such as described with respect toFIGS.1A to2B, such that the tube spacing and fastening system60ofFIGS.3A and3Bincludes a plurality of cradles (e.g., thin-walled bracket64and thin-walled bracket63). FIG.3Bshows an enlarged schematic, perspective view of the spacer element62as part of the tube spacing and fastening system60for the exemplary tubes12ofFIG.3A, according to an embodiment of the present disclosure. Continuing to refer toFIG.3B, the spacer element62has a top end65, a bottom end66, and a top tray slot67with a raised slot edges68. Further, referring toFIG.3AandFIG.3B, a fastening element72, embodied as a shape memory alloy (SMA) band, is extended around outer surfaces73of the exemplary tubes12in the tube spacing and fastening system60to fasten them to the spacer element62. The tube spacing and fastening system60may include the spacer element62with two opposing faces shaped as the first thin-walled bracket63and the second thin-walled bracket64. In another embodiment of the disclosure, the first thin-walled bracket63is configured to engage the first exemplary tube12aand the second thin-walled bracket64is configured to engage the second exemplary tube12b. The first thin-walled bracket63and the second thin-walled bracket64join each other at the top end65on top of the spacer element62and further at the bottom end66of the spacer element62. Further, the first thin-walled bracket63and the second thin-walled bracket64are spatially separated by a hollow space in between the first thin-walled bracket63and the second thin-walled bracket64. Continuing to refer toFIGS.3A and3B, additional stress distribution configurations may include specially contouring the contact surfaces between the exemplary tubes12and the first thin-walled bracket63and the second thin-walled bracket64. Accordingly, instead of full surface contact between a stiffer block (e.g., the spacer element62) and a thin-walled tube (e.g., the exemplary tubes12), which generate higher edge contact stress, the spacer element62may include exemplary surface features (not shown). The exemplary surface features may be protrusions (also known as ‘beads’) in one instance and may be indentations (also known as ‘dimples’) in another instance. In yet another instance, the surface features may be any combination of protrusions and indentations. Thus, the exemplary surface features may create a low stress field at discrete points of contact on the exemplary tubes12. Specifically, the first exemplary tube12ajoins the first thin-walled bracket63at a corresponding first contact surface (not shown) and the second exemplary tube12bjoins the second thin-walled bracket64at a corresponding second contact surface (not shown), and either the first contact surface, or the second contact surface, or both, include exemplary surface features that may include protrusions and/or indentations, which may provide effective stress distribution configuration. Thus, referring toFIGS.3A and3B, the metal-to-metal contacts at the first thin-walled bracket63and the second thin-walled bracket64may not result in high stresses, so the exemplary surface features32may not be included in a non-limiting manner. In another instance, however, the exemplary surface features32may be included and formed as protrusions/indentations, as desired, in order to reduce existing stress. FIG.4is a schematic, perspective view of a tube spacing and fastening system80for the exemplary tubes12in accordance with an embodiment of the current disclosure. Referring toFIG.5, the tube spacing and fastening system80includes a spacer element82. The spacer element82may be any predetermined formation, such as a star formation, or cross formation, or any combination thereof. The spacer element82may include one or more radial arms84arranged in a star formation. Further, each of the radial arms84joins at its respective base with a core part86. The radial arms84and the core part86may be integral and unitary or may be separate parts coupled or connected together. In the non-limiting example ofFIG.4, there are four exemplary radial arms84extending from the core part86, but, in other embodiments, there may be fewer or more than four radial arms84. The number of radial arms84may be selected based on the number of the exemplary tubes12desired to be coupled together. With continued reference toFIG.4, an exemplary pair of adjacent radial arms84aand84b(two adjacent radial arms) and the core part86joining at their respective base, may form an exemplary cradle bracket88, to engage a corresponding tubular structure, embodied as an outer surface93of the exemplary tubes12. Accordingly, in the example ofFIG.5, four cradle brackets88may be formed to accommodate four exemplary tubes—a first exemplary tube12a, a second exemplary tube12b, a third exemplary tube12cand a fourth exemplary tube12d. The tube spacing and fastening system80may include the spacer element82constructed in a star formation, or a cross formation, or any combination thereof, with the exemplary radial arms84extending outward from the core part86. In an embodiment, outer surfaces of the radial arms84(e.g., the surfaces forming the cradle bracket88) may be marked with surface features including protrusions/indentations (not shown), such as described with respect toFIGS.1B,1C,2B,3B, and6A to6C. Continuing to refer toFIG.4, a fastening element92, embodied as a shape memory alloy (SMA) band may be extended around the outer surfaces93of each of the exemplary tubes12in the tube spacing and fastening system80to fasten them to an exemplary star formation, or a cross formation, or any combination thereof, of the spacer element82. FIG.5is a schematic, perspective view of a tube spacing and fastening system100for the exemplary tubes12in accordance with an embodiment of the current disclosure. Referring toFIG.6, the tube spacing and fastening system100includes a spacer element182. The spacer element182includes three exemplary radial arms184a,184b, and184carranged in a star formation. Each of the radial arms184a,184b, and184cjoins at its respective base with a core part186. The radial arms184a,184b, and184cand the core part186can be integral and unitary or can be separate parts coupled or connected together. With continued reference toFIG.5, an exemplary pair of adjacent radial arms184band184c(two adjacent radial arms) and the core part186joining at their respective base, form an exemplary cradle bracket188, to engage a corresponding tubular structure, embodied as an outer surface193of the exemplary tubes12. Accordingly, in the example ofFIG.5, three cradle brackets188are formed to accommodate three exemplary tubes—the first exemplary tube12a, the second exemplary tube12b, and the third exemplary tube12c. The outer surfaces of the radial arms184a,184b, and184c(e.g., the surfaces forming the cradle bracket188) are marked with surface features including protrusions/indentations (not shown), such as described with respect toFIGS.1B,1C,2B,3B, and6A to6C. Continuing to refer toFIG.5, a fastening element192, embodied as a shape memory alloy (SMA) band is extended around the outer surfaces193of each of the exemplary tubes12a,12band12cto fasten them to the spacer element182. FIGS.6A to6Cshow exemplary surface features32, which may be provided in any or all of the spacer elements described herein, such as, for example, the spacer element22(FIG.1C), the spacer element42(FIG.2A), the spacer element62(FIG.3A), the spacer element82(FIG.4), and the spacer element182(FIG.5). The exemplary surface features32may be prismatic surface features32a(FIG.6A), elongated rectangular surface features32b(FIG.6B), or rounded, semi-spherical surface features32c(FIG.6C). Other shapes are also contemplated, such as, for example, cubes or other polygonal shapes, elliptical, square, trapezoidal, triangular, elongated curved shapes, continuous shapes, discrete shapes, etc. Any combination of the surface features shown and/or the surface features described may be provided on the spacer elements of the present disclosure. The surface features32may be protrusions, indentations, or combinations thereof. More than one shape of surface features32may be provided on a single bracket surface of a spacer element. More thane one shape of surface features32may be provided on different bracket surfaces of a single spacer element. The surface features32described herein may be formed with additive manufacturing, electrical discharge texturing, or electroforming. Referring toFIG.1AtoFIG.6C, the spacer element22, the spacer element42, the spacer element62, the spacer element82, and the spacer element182may be additively manufactured. Further, specifically, the spacer element22, the spacer element42, the spacer element62, the spacer element82, and the spacer element182may be optionally contoured with dimples/ridges/beads through additive manufacturing economically. In other embodiments of the disclosure, other manufacturing methods, such as traditional subtractive manufacturing may be employed to produce the parts from typical machined blocks. As for spacing and fastening system material, the spacer elements22,42,62, and82are made of steel, Inconel®, or other suitable metals, such as nitinol (Ni—Ti) that meet high temperature applications as well as provide inherent elasticity to retain extending strength needed for braze-free and weld-free joints. Any of the spacer blocks, fastening elements, and spacing and fastening systems described herein may be combined with all or portions of the other spacer blocks, fastening elements, and spacing and fastening systems described herein. Although a single spacing and fastening system is shown for the exemplary tubes12, more may be provided along the length of the exemplary tubes12. In such a manner, the tube spacing and fastening systems of the present disclosure may include a plurality of spacer blocks and fastening elements. The number may be selected based on the desired coupling and securement of the exemplary tubes12. FIG.7is a block diagram of a method200of spacing and fastening tubular structures in accordance with one embodiment of the current disclosure. Referring toFIG.7, the method200of spacing and fastening tubular structures, such as the exemplary tubes12, includes in step202, providing a spacer element, in step204, engaging a plurality of tubular structures to the spacer element, in step206, spatially separating the plurality of tubular structures from one another, and in step208, distributing stress in the plurality of tubular structures. The method200further includes, in step212, extending a fastening element around at least a portion of an outer surface of the plurality of tubular structures and in step214, fastening the plurality of tubular structures to the spacer element in an adaptively spaced configuration. In another embodiment of the current disclosure, the method200of spacing and fastening tubes further includes non-permanently engaging a first exemplary tube12ato a first cradle bracket (FIGS.1B and1C,27;FIG.2A,43;FIG.3A,63;FIG.4,88;FIG.5,188), engaging a second exemplary tube12bto a second cradle bracket (FIGS.1B and1C,28; FIG.2A,44;FIG.3A,64;FIG.4,88;FIG.5,188) such that the first exemplary tube12aand the second exemplary tube12bare spatially separated. In one aspect of the disclosure, the tube spacing and fastening systems of the present disclosure use appropriate fastening elements to space and fasten the tubes and/or pipes with their structural integrity intact and without any cutting or shearing of the tubes and/or pipes. The spacing and fastening elements, as described in the embodiments of the current disclosure, thereby, improve on several critical operational performance factors including high stress concentration (Kt) at tube joints, difficulty in controlling uniformness of quality (owing to voids, limited braze/weld witness feature, and lack of coverage), low high-cycle fatigue (HCF) capability of material flux, geometric stress concentration, and rapid transition from flexible tube surfaces to stiff constraining elements. Although described as engaging the exemplary tubes12, the connection provided by the spacer element and the fastening element may be permanent in one instance. In other instances, the connection provided by the spacer element and fastening element to engage the exemplary tubes12may be non-permanent. In some embodiments, the spacer element and the fastening element may be retrofit onto the exemplary tubes12. The spacer element and the fastening element may be capable of being serviceable or replaceable, in the manufacturing plant or in the field. The tube spacing and fastening systems of the present disclosure may include shape memory alloy (SMA) bands as a fastening element that provides an advantage over permanently joined spacing and fastening system configurations that sometime hold the tubes too tenaciously during tube reconstitution and/or tend to score the tubes during installation. The tube spacing and fastening systems of the present disclosure provide a non-brazed, non-welded connection or coupling of tubes. The non-brazed, non-welded tube bundle configurations using shape memory alloy (SMA) bands for connecting the tubes and the spacer element may address issues associated with stress concentration of brazed or welded joints. Shape memory alloy (SMA) bands extended around tubes joining at the spacer element offer smooth stress distribution without any sudden transition of stiffness from spacer element to the tubes. The tube spacing and fastening systems of the present disclosure may provide adaptive spacing and fastening and dismantling by employing thermally elastic compressive shape memory alloy (SMA) bands that continue to keep tube bundles in continued contact with spacer element even in case of contact wear as is customary for non-brazed and non-welded tube bundle configurations. The tube spacing and fastening systems of the present disclosure include shape memory alloy (SMA) bands as fastening elements that are provided with a memorized length, and are produced and installed generally around tubes so as to provide tube adaptive spacing. When the shape memory alloy (SMA) bands are at their operating temperature above the transition temperature of the shape memory alloy (SMA) bands, the shape memory alloy (SMA) bands transform to the memorized length, thereby providing reduced spacing and lateral loading to the tubes. The shape memory alloy (SMA) bands thus inherently provide adaptive spacing for the tubes in the tube bundles, in relation to each other and the spacer element. Exemplary shape memory alloys may include alloys of any of Ni—Ti, or Ni—Ti—Hf, or Ni—Ti—Pd or Ti—Au—Cu Any of the fastening elements of the present disclosure may be a shape memory alloy band. The shape memory alloy bands operate as fasteners to isolate a joint assembly of one or more tubular structures. In some examples, the shape memory alloy (SMA) properties improve the reliability and performance of tube assembly as compared to conventional metal fasteners. The shape memory alloy (SMA) bands enable a high performing and reliable isolation joint assembly through stress induced martensite transformation in shape memory alloy (SMA) band fasteners. For example, shape memory alloy (SMA) bands have superelasticity, variable stiffness, and high energy dissipation. These features may provide the following benefits: Superelasticity: NiTi based shape memory alloy (SMA) bands demonstrate superelastic behavior up to eight percent to ten percent of recoverable strain. This is compared to 0.2 percent of recoverable strain in typical metal (e.g., steel). The superelastic behavior allows the shape memory alloy (SMA) fasteners to undergo large deformation under high engine imbalance condition without failure and allows for the shape memory alloy (SMA) band to recover back to the shape memory alloy (SMA) band's initial shape when the load (e.g., engine condition) is released. Variable stiffness: NiTi based shape memory alloy (SMA) bands demonstrate unique variable stiffness that, combined with superelastic behavior, may be tuned to control the system response under different loading or engine operating condition. That is, tuned to allow control of the degree of fastening of the tubular structures. High energy dissipation: shape memory alloy (SMA) exhibit high damping properties during martensitic phase transformation through hysteretic damping that may assist control of a vibratory response. NiTi shape memory alloy (SMA) bands may demonstrate high hysteretic material damping up to six percent, which is higher than conventional metal (e.g., steel) bands. Furthermore, the shape memory alloy (SMA) bands design can be used as an effective isolation system to control tube response under engine vibration and/or imbalance condition as follows: Normal engine vibration: At lower strains (less than one percent), the elastic modulus of the austenite phase of the shape memory alloy (SMA) band comes into action to withstand normal engine operating condition. High engine vibration and imbalance loads: Under this engine condition, the shape memory alloy (SMA) band can be designed to deform to moderate to high strains levels (up to eight percent). At this strain level, the shape memory alloy (SMA) band behaves as a superelastic material with plateau stress. There may be little or no change in stress level, such that tube joint assembly can withstand large range deformation with almost no increase in stress levels. This low elastic modulus behaviour of the shape memory alloy (SMA) band acts as an effective isolation system for the tubular structures from high input vibration or engine imbalance loads. Extreme engine imbalance condition like blade out: The shape memory alloy (SMA) band can be designed for large strain (eight percent to ten percent) development under extreme engine imbalance condition. Increased elastic modulus and high strength martensitic phase of fastener can withstand extreme imbalance condition without failure and can recover back to the initial shape of the shape memory alloy (SMA) band when the load is released. The tube spacing and fastening systems of the present disclosure may include multiple configurations of spacer elements including recessed block, solid unrecessed block, thin-walled, cross formation, or star formation spacer elements that provide a wide flexibility in the number of tubes to be engaged and adaptability in the design of the fastening elements to effectively support and spatially separate individual tubes in an assembled bundle. In some examples, the spacer element may be a thick-walled, solid block. Such a block may include surface features on the contact surfaces to reduce stresses between the thin-walled tubes and the thick-walled spacer element. In some examples, the spacer element may be thin-walled. The tube spacing and fastening systems of the present disclosure may provide effective stress distribution at tube spacing and fastening system joints, low stress field through protrusions, and/or indentations (also known as ‘beads’/‘dimples’) contoured on recessed blocks, solid blocks, thin-walled, cross formation, or star formation spacer elements, filleted joints and, thereby, improve reliability of each configuration of the tube bundle assemblies. The tube spacing and fastening systems of the present disclosure may provide cost effective configurations that eliminate inspection and quality control issues related to permanently joined tube bundle assemblies such as brazed joints or welded joints. The tube spacing and fastening systems of the present disclosure improves ‘Time on Wing’ with by reducing typical field issues related to brazed or welded joints. The tube spacing and fastening systems of the present disclosure inherently provide adaptive spacing and compact tube bundle routing for optimal tube packaging that save significant amount of space, cost, and weight. In one instance, the fastening element may be replaced without disregarding the tubes. Further aspects of the present disclosure are provided by the subject matter of the following clauses. A system includes a spacer element configured to engage a plurality of tubular structures, to spatially separate the plurality of tubular structures from one another, and to distribute stress in the plurality of tubular structures. A fastening element is configured to extend around at least a portion of an outer surface of the plurality of tubular structures, and to fasten the plurality of tubular structures to the spacer element in an adaptively spaced configuration. The system according to any preceding clause, wherein the adaptively spaced configuration comprises a first length of the fastening element below a predetermined temperature range and a second length of the fastening element above the predetermined temperature range. The first length is different from the second length. The system according to any preceding clause, wherein the adaptively spaced configuration comprises a first configuration, wherein the plurality of tubular structures are movably spaced around the spacer element and a second configuration, wherein the plurality of tubular structures are immovably spaced around the spacer element. The system according to any preceding clause, wherein the spacer element includes a first thin-walled bracket to engage a first tubular structure of the plurality of tubular structures and a second thin-walled bracket to engage a second tubular structure of the plurality of tubular structures. The first thin-walled bracket and the second thin-walled bracket join at a top end of the spacer element and at a bottom end of the spacer element. The system according to any preceding clause, wherein the spacer element includes a first cradle bracket configured to engage a first tubular structure of the plurality of tubular structures, a second cradle bracket configured to engage a second tubular structure of the plurality of tubular structures, and a core part separating the first cradle bracket and the second cradle bracket. The first cradle bracket, the second cradle bracket, and the core part join at a top end of the spacer element and at a bottom end of the spacer element. The system according to any preceding clause, wherein a first joint between the first cradle bracket and the top end, or a second joint between the second cradle bracket and the top end, or a third joint between the first cradle bracket and the bottom end, or a fourth joint between the second cradle bracket and the bottom end, or any combination thereof, comprises a filleted joint. The system according to any preceding clause, further includes a first recess formed between the first cradle bracket and a first corresponding surface of the core part, and a second recess formed between the second cradle bracket and a second corresponding surface of the core part. The first recess is configured to accommodate a first part of the fastening element, and the second recess is configured to accommodate a second part of the fastening element. The system according to any preceding clause, wherein a first tubular structure of the plurality of tubular structures engages with the first cradle bracket at a first contact surface and a second tubular structure of the plurality of tubular structures engages with the second cradle bracket at a second contact surface. The first contact surface, or the second contact surface, or both of the first contact surface and the second contact surface includes a plurality of surface features configured to distribute the stress in the plurality of tubular structures. The system according to any preceding clause, wherein the plurality of surface features comprises a plurality of protrusions, or indentations, or any combination thereof. The system according to any preceding clause, wherein the spacer element includes a core part positioned at a center of the spacer element, and a plurality of radial arms arranged in a predetermined formation, each radial arm joining at a respective base with the core part. At least one pair of adjacent radial arms and the core part form a cradle bracket configured to engage a corresponding tubular structure in the cradle bracket. The system according to any preceding clause, wherein the predetermined formation comprises a cross formation, or a star formation, or any combination thereof. The system according to any preceding clause, wherein the fastening element comprises a shape memory alloy (SMA) band. The system according to any preceding clause, wherein the shape memory alloy (SMA) band comprises nickel-titanium shape-memory alloy. A method includes providing a spacer element, engaging a plurality of tubular structures to the spacer element, spatially separating the plurality of tubular structures from one another, and distributing stress in the plurality of tubular structures, extending a fastening element around at least a portion of an outer surface of the plurality of tubular structures, and fastening the plurality of tubular structures to the spacer element in an adaptively spaced configuration. The method according to any preceding clause, wherein the fastening of the plurality of tubular structures to the spacer element in the adaptively spaced configuration comprises fastening the plurality of tubular structures to the spacer element by a first length of the fastening element below a predetermined temperature range, and fastening the plurality of tubular structures to the spacer element by a second length of the fastening element above the predetermined temperature range. The first length is different from the second length. The method according to any preceding clause, wherein the fastening of the plurality of tubular structures to the spacer element in the adaptively spaced configuration comprises fastening the plurality of tubular structures to the spacer element in a first configuration, wherein the plurality of tubular structures are movably spaced around the spacer element, and a second configuration, wherein the plurality of tubular structures are immovably spaced around the spacer element. The method according to any preceding clause, wherein the engaging of the plurality of tubular structures to the spacer element comprises engaging a first tubular structure of the plurality of tubular structures to a first thin-walled bracket of the spacer element, engaging a second tubular structure of the plurality of tubular structures to a second thin-walled bracket of the spacer element, and joining the first thin-walled bracket, the second thin-walled bracket at a top end of the spacer element and at a bottom end of the spacer element. The spatially separating the plurality of tubular structures from one another comprises spatially separating the first thin-walled bracket and the second thin-walled bracket by a hollow space in between the first thin-walled bracket and the second thin-walled bracket. The method according to any preceding clause, wherein the engaging of the plurality of tubular structures to the spacer element comprises engaging a first tubular structure of the plurality of tubular structures to a first cradle bracket of the spacer element, engaging a second tubular structure of the plurality of tubular structures to a second cradle bracket of the spacer element, and joining the first cradle bracket, the second cradle bracket, and a core part of the spacer element at a top end of the spacer element and at a bottom end of the spacer element. The spatially separating the plurality of tubular structures from one another comprises spatially separating the first cradle bracket and the second cradle bracket by the core part positioned in between the first cradle bracket and the second cradle bracket. The method according to any preceding clause, wherein the extending of the fastening element comprises filleting a first joint between the first cradle bracket and the top end, or a second joint between the second cradle bracket and the top end, or a third joint between the first cradle bracket and the bottom end, or a fourth joint between the second cradle bracket and the bottom end, or any combination thereof. The method according to any preceding clause, wherein the extending of the fastening element comprises accommodating a first part of the fastening element in a first recess between the first cradle bracket and a first corresponding surface of the core part, and accommodating a second part of the fastening element in a second recess between the second cradle bracket and a second corresponding surface of the core part. The method according to any preceding clause, wherein the engaging of each of the plurality of tubular structures to the spacer element comprises joining a first tubular structure of the plurality of tubular structures and the first cradle bracket at a first contact surface, joining a second tubular structure of the plurality of tubular structures and the second cradle bracket at a second contact surface. The distributing of stress in the plurality of tubular structures comprises providing a plurality of surface features on the first contact surface, or the second contact surface, or both of the first contact surface and the second contact surface. The method according to any preceding clause, wherein the providing of the plurality of surface features comprises providing a plurality of protrusions, or indentations, or any combination thereof. The method according to any preceding clause, wherein the providing of the spacer element comprises arranging a plurality of radial arms in a predetermined formation, joining each radial arm at a respective base with a core part of the spacer element, forming a cradle bracket with at least one pair of adjacent radial arms and the core part, and engaging a corresponding one of the plurality of tubular structures in the cradle bracket. The method according to any preceding clause, wherein the arranging of the plurality of radial arms in the predetermined formation comprises arranging the plurality of radial arms in a cross formation, or arranging the plurality of radial arms in a star formation, or arranging the plurality of radial arms in any combination thereof. The method according to any preceding clause, wherein the extending the fastening element comprises extending a shape memory alloy (SMA) band. The method according to any preceding clause, wherein the shape memory alloy (SMA) band comprises nickel-titanium shape-memory alloy. Although the foregoing description is directed to the preferred embodiments, it is noted that other variations and modifications will be apparent to those skilled in the art, and may be made without departing from the spirit or scope of the disclosure. Moreover, features described in connection with one embodiment may be used in conjunction with other embodiments, even if not explicitly stated above. | 59,054 |
11859744 | DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, exemplary embodiments of the present disclosure will be described in detail with reference to the accompanying drawings to enable those of ordinary skill in the art to easily understand and practice the present disclosure. In describing the present disclosure, when detailed description of a known related function or configuration is determined as having the possibility of unnecessarily obscuring the gist of the embodiments of the present disclosure, the detailed description thereof will be omitted. The terms used herein are terms defined in consideration of functions in embodiments of the present disclosure and may vary according to an intention or practice of a user or an operator. Therefore, the terms should be defined on the basis of the content throughout the specification. Also, the above-described aspects of the disclosure and additional aspects thereof will become apparent through embodiments described below. Even when illustrated as a single integrated configuration in the drawings, configurations of aspects or embodiments selectively described herein should be understood as being able to be freely combined with each other unless otherwise stated and unless technical contradiction is clear to those of ordinary skill in the art. Therefore, embodiments described herein and configurations illustrated in the drawings are merely the most preferred embodiments of the present disclosure and do not represent the entire technical idea of the present disclosure, and thus, it should be understood that various equivalents and modifications, which can replace the most preferred embodiments, may be present at the time of filing this application. FIG.1is a view for describing a side of an automatic chemical supply apparatus according to an embodiment. As illustrated, an automatic chemical supply apparatus1000(which is an automatic clean quick coupler unit (ACQC unit)) may include a male connector mounting portion100, a housing main body200, a transfer housing300, a transfer unit400, and a female connector500. In the automatic chemical supply apparatus, in order to connect a chemical tank and a chemical storage tank and supply chemicals from one side to the other side, a male connector20may be transferred in a forward-backward direction by the transfer unit400to fasten the male connector20to the female connector500. One side end portion of the transfer unit400may be inserted into an opening601formed in a wall body600. The wall body600refers to a wall constituting a building, and the opening601is formed to allow communication between the outside and inside of the building. When a worker mounts the male connector20on the male connector mounting portion100, which is connected to a chemical hose700, and fixes the male connector20, by operation of the transfer unit400, the male connector mounting portion100is moved forward, and the male connector20is inserted into (fastened to) the female connector500. The transfer unit400may consist of one or more stages and drivers and thus may slide the male connector mounting portion100back and forth on the stages. Along with the chemical hose700, a nitrogen hose800may also be connected to the automatic chemical supply apparatus1000and may supply nitrogen (N2) to a tank lorry to accelerate and facilitate supplying of chemicals by pressing. The housing main body200may accommodate the female connector500, and the transfer housing300may accommodate the transfer unit400. FIG.2is a view for describing an exterior of the automatic chemical supply apparatus according to an embodiment. The automatic chemical supply apparatus, in which a male connector is transferred in the forward-backward direction by a transfer unit to fasten the male connector to a female connector in order to connect a chemical tank and a chemical storage tank and supply chemicals from one side to the other side, may include a blocking door which consists of an opening/closing door902and a blocking unit903that are installed at a frame901and which is configured to block an interior of the automatic chemical supply apparatus from the outside in a state in which a hose is seated on a mounting portion, a hose opening which is disposed at the blocking door and through which the hose passes in a state in which the opening/closing door is closed, and an opening shutter unit930which is configured to open and close the hose opening. The opening shutter unit may include an opening cover unit and an opening/closing manipulation unit configured to manipulate opening and closing of the opening cover unit. According to an embodiment, the hose may include the chemical hose and the nitrogen hose800, and the hose opening may include a chemical hose opening910and a nitrogen hose opening920. The automatic chemical supply apparatus1000(which is an ACQC unit), in which a male connector is transferred in the forward-backward direction by a transfer unit to fasten the male connector to a female connector in order to connect a chemical tank and a chemical storage tank and supply chemicals from one side to the other side, may include a blocking door900, the chemical hose opening910, the nitrogen hose opening920, and the opening shutter unit930. The housing main body200may accommodate the female connector, and the transfer housing300may accommodate the transfer unit. The automatic chemical supply apparatus may include the chemical hose opening910but not include the nitrogen hose opening920. The blocking door900may consist of the opening/closing door902and the blocking unit903that are installed on the frame901and may serve to block an interior of the automatic chemical supply apparatus from the outside in a state in which the chemical hose and the nitrogen hose are seated on mounting portions thereof. The opening/closing door902may be disposed at an upper portion of the blocking door900, and the blocking unit903may be disposed at a lower portion of the blocking door900. The opening/closing door902may rotate or move with respect to the frame901to open or close one side portion of the frame. The rotation may be achieved by either a hinge structure or a sliding structure. A see-through window902-1is formed on the opening/closing door902, and thus a worker may check an internal state of the automatic chemical supply apparatus in a state in which the opening/closing door is closed. The blocking unit903may be openable and closable or may not be openable and closable. The blocking door900serves to prevent external leakage of chemicals inside the automatic chemical supply apparatus and block introduction of external foreign matter. Each of the chemical hose opening910and the nitrogen hose opening920may be disposed at the blocking door, and the chemical hose and the nitrogen hose may pass through the chemical hose opening910and the nitrogen hose opening920in a state in which the opening/closing door is closed. The chemical hose opening910and the nitrogen hose opening920may be disposed to be adjacent to each other, and an area of the chemical hose opening910may be larger than an area of the nitrogen hose opening920. The opening shutter unit930may be disposed on the blocking door900and may simultaneously open and close the chemical hose opening and the nitrogen hose opening. FIG.3is a view for describing a portion of a cross-section of the automatic chemical supply apparatus according to an embodiment,FIG.4is a view for describing an opening cover unit, andFIG.5is a view for describing an opening shutter unit. InFIG.5, A, B, and C are enlarged views of each corresponding portion. The opening shutter unit930may be disposed on the blocking door900. The opening shutter unit930may include an opening cover unit931and an opening/closing manipulation unit932configured to manipulate opening and closing of the opening cover unit931. Rotary rollers911may be disposed around the chemical hose opening910and the nitrogen hose opening920to allow the hoses to smoothly move back and forth. The opening cover unit931may include a chemical opening cover931-1configured to move upward or downward along a first cover rail to open or close the chemical hose opening and a nitrogen opening cover931-2configured to move upward or downward along a second cover rail to open or close the nitrogen hose opening. The opening cover unit931may further include a cover connecting portion931-3in addition to including the chemical opening cover931-1and the nitrogen opening cover931-2. The chemical opening cover931-1, the nitrogen opening cover931-2, and the cover connecting portion931-3may be integrally formed in the shape of a single plate or may not be integrally formed, but the chemical opening cover931-1, the nitrogen opening cover931-2, and the cover connecting portion931-3being integrally formed in the shape of a single plate as illustrated inFIG.4is preferable. The chemical opening cover931-1may slide upward or downward along a first cover rail R1to open or close the chemical hose opening. The nitrogen opening cover931-2may slide upward or downward along a second cover rail R2to open or close the nitrogen hose opening.FIG.5illustrates a state in which the chemical opening cover931-1and the nitrogen opening cover931-2are closed. The cover connecting portion931-3may be disposed between the chemical opening cover931-1and the nitrogen opening cover931-2to fix and connect the chemical opening cover and the nitrogen opening cover. The cover connecting portion931-3may protrude downward as illustrated inFIG.4in order to secure a space for providing (installing) the opening/closing manipulation unit932. The opening/closing manipulation unit932may be disposed at the cover connecting portion931-3. As illustrated inFIGS.3and5, the opening/closing manipulation unit932may include a manipulation plate932-1, a handle932-2, a handle connecting portion932-3, and a handle holder932-4. The manipulation plate932-1may be disposed at the blocking unit and have a pair of guide rails r1and r2formed thereon. The handle932-2may be disposed on the manipulation plate932-1, and a worker may slide the handle932-2upward or downward along the guide rails. The handle connecting portion932-3may be disposed in each of the guide rails r1and r2to fix and connect the handle932-2and the cover connecting portion931-3. The handle932-2and the handle connecting portion932-3may be hinge-connected so that the handle is rotatable. Therefore, the handle932-2may be horizontally pressed against the manipulation plate932-1and rotate to vertically protrude from the manipulation plate932-1. The opening/closing manipulation unit932may further include the handle holder932-4. The handle holder932-4may be disposed at an upper portion of the manipulation plate932-1and may have the handle932-2seated thereon to support the handle932-2. Therefore, when a worker lifts the handle932-2and places the handle932-2on the handle holder932-4, downward movement of the handle932-2may be prevented, and thus, a state in which the opening cover unit931closes the chemical opening cover931-1and the nitrogen opening cover931-2may be continuously maintained. Also, when the worker separates the handle932-2from the handle holder932-4, due to the gravity, the handle932-2and the opening cover unit931may move downward, and thus, a state in which the opening cover unit931opens the chemical opening cover931-1and the nitrogen opening cover931-2may be continuously maintained. According to an embodiment, the blocking unit903may include an inner blocking unit903-1and an outer blocking unit903-2as illustrated inFIG.3, and the cover connecting portion931-3may be disposed between the inner blocking unit903-1and an outer blocking unit903-2. Thus, it is advantageous for supporting and guiding the cover connecting portion931-3, and external exposure of the cover connecting portion may be avoided. A space in which the opening cover unit931may be accommodated may be provided in the inner blocking unit903-1. According to an embodiment, as illustrated inFIG.5, guide rollers933may be further provided on side surfaces of the chemical opening cover931-1and the nitrogen opening cover931-2that come into contact with the first cover rail R1and the second cover rail R2, respectively. Thus, the chemical opening cover931-1and the nitrogen opening cover931-2may smoothly slide along the cover rails R1and R2. The cover rails R1and R2may be disposed at the inner blocking unit903-1. According to an embodiment, in the inner blocking unit903-1, a buffering member934may be further provided below the chemical opening cover931-1and the nitrogen opening cover931-2. A spring, a cylinder, or a shock absorber may be configured as the buffering member934. Thus, an impact due to rapid downward movement of the chemical opening cover931-1and the nitrogen opening cover931-2may be reduced, and damage thereto may be prevented. According to an embodiment, a plurality of permanent magnets may be further provided on the guide rails r1and r2, and permanent magnets of different polarities (S-pole, N-pole) may be disposed to face each other to form a constant attractive force (B ofFIG.5). Thus, due to an increase in friction between the handle connecting portion932-3and the guide rails r1and r2and the permanent magnets performing a buffering function, rapid downward movement of the chemical opening cover931-1and the nitrogen opening cover931-2may be prevented. Also, at places where the handle connecting portion has passed, the permanent magnets may stick to each other and seal a gap. According to an embodiment, the automatic chemical supply apparatus may also automatically open or close the chemical hose opening910and the nitrogen hose opening920by sliding the opening cover unit931upward or downward using a driver such as a cylinder or a motor without using the handle, the handle connecting portion, or the handle holder. FIG.6is a view for describing the automatic chemical supply apparatus in which an elastic member is disposed on a guide rail. According to an embodiment, a plurality of elastic members935may be further provided on the guide rails r1and r2, and the elastic members may be disposed to face each other. Thus, due to an increase in friction between the handle connecting portion932-3and the guide rails r1and r2and the elastic members performing a buffering function, rapid downward movement of the chemical opening cover931-1and the nitrogen opening cover931-2may be prevented. Also, at places where the handle connecting portion has passed, the elastic members may stick to each other and seal a gap. Various other methods may be used to achieve the same effect. FIG.7is a view for describing a process in which a chemical hose opening and a nitrogen hose opening are opened and closed by manipulation of an opening/closing manipulation unit. As illustrated inFIG.7(a), the handle932-2is lifted by the worker, and the handle is rotated in the direction indicated by the arrow and is seated on the handle holder932-4so that the opening cover unit931closes the chemical hose opening and the nitrogen hose opening, and the state in which the chemical hose opening and the nitrogen hose opening are closed is continuously maintained. Thus, external foreign matter is prevented from entering the automatic chemical supply apparatus through the chemical hose opening or the nitrogen hose opening. For use of the automatic chemical supply apparatus, the handle932-2is further lifted by the worker in the direction indicated by the arrows as illustrated inFIG.7(b). Then, as illustrated inFIG.7(c), the handle932-2is rotated in the direction indicated by the arrow and is pressed downward so that the opening cover unit931opens the chemical hose opening and the nitrogen hose opening, and the state in which the chemical hose opening and the nitrogen hose opening are opened is continuously maintained. Thus, in a state in which the chemical hose and the nitrogen hose pass through the chemical hose opening and the nitrogen hose opening, respectively, and the opening/closing door902is closed, the chemical hose and the nitrogen hose may be moved in the forward-backward direction, and the male connector may be fastened to or separated from the female connector. According to the present disclosure, when an automatic chemical supply apparatus is not in use, by blocking a hose opening, it is possible to block introduction of foreign matter from the outside to the inside of the automatic chemical supply apparatus or external leakage of chemicals or fumes. In this way, malfunctioning can be prevented, and safety of workers can be promoted. Also, since a worker is able to easily open or close a chemical hose opening and a nitrogen hose opening by one operation, work efficiency and productivity of supplying chemicals can be improved. | 16,902 |
11859745 | DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS FIGS.1and2show a clamp2according to an embodiment of the disclosure. The clamp2comprises a first, lower arcuate portion4aand a second, upper arcuate portion4b. The first and second arcuate portions4a,4bare hingedly connected to one another. Specifically, the first arcuate portion4acomprises a pair of hinge arms6a,6bwhich are spaced laterally from one another. The hinge arms6a,6bare arcuate and have extent which is slightly greater than 180°. The hinge arms6a,6bthus define a recess. The second arcuate portion4bis provided with a hinge lobe8. A cylindrical stub shaft10a,10bprojects from each lateral side of the hinge lobe8. The stub shafts10a,10bare sized to be received within the recess defined by the hinge arms6a,6bto form a snap-fit connection. The first and second arcuate portions4a,4bare thus able to rotate between a closed position, as shown inFIG.1, and an open position, as shown inFIG.2. As shown particularly inFIGS.3and4, a radial, end surface of the hinge lobe8is provided with a pair of detent protrusions12a,12bwhich are angularly spaced from one another about the hinge lobe8. The detent protrusions12a,12binterface with an edge14of the first arcuate portion4a. Specifically, when opening the clamp2, the detent protrusion12amust be forced over the edge14, such that the detent protrusions12a,12bstraddle the edge14, as is best shown inFIG.3. In this position, the detent protrusion12aprevents the clamp2from closing and the detent protrusion12bprevents the clamp2from opening further. Thus, the detent protrusions12a,12bretain the clamp in the open position to improve ease of use. The clamp2may, however, be opened further in order to release the stub shafts10a,10bfrom the hinge arms6a,6bin order to detach the second arcuate portion4bfrom the first arcuate portion4aby applying sufficient force to force the detent protrusion12bover the edge14. Similarly, the clamp can be closed by applying sufficient force to force the detent protrusion12aover the edge14. The detent protrusions12a,12bmay be allowed to pass over the edge14through deformation of the clamp2. For example, deformation may occur in one or more of: the detent protrusions12a,12b, edge14, the stub shafts10a,10band the hinge arms6a,6b. The detent protrusions12a,12bmay be movable and biased outwardly by a biasing mechanism, such as a spring or the like, such that deformation of the detent protrusions12a,12bis permitted by deformation of the biasing mechanism. As described previously, the first and second arcuate portions4a,4bare hingedly connected to one another by a snap-fit connection. The snap-fit connection is formed with the first and second arcuate portions4a,4bopened at an angle which exceeds that shown inFIG.2such that both of the detent protrusions12a,12bare received on an interior side of the edge14. In this position, the opening of the recess formed by the hinge arms6a,6bmay sufficiently large to receive the stub shafts10a,10bwith relatively little or no resistance. In this position, there is therefore significant laxity or slack in the hinged joint. However, when the clamp2is moved to the normally open position, with the detent protrusions12a,12bstraddling the edge14, the stub shafts10a,10bare held securely by the hinge arms6a,6band this level of interference is maintained between the open and closed positions. Therefore, over the functional range of movement of the clamp2, the hinged connection exhibits a very low amount of play. The transition of the hinged connection from a loose connection which enables easy assembly to a tight connection which improves user experience (exuding quality) may be achieved by providing a cam profile on one or more of the interface surfaces between the first and second arcuate portions4a,4b, such as one or more of the hinge surfaces formed by the hinge arms6a,6band the stub shafts10a,10band/or the end surface of the hinge lobe8and an opposing surface of the first arcuate portion4a. The loose connection during assembly may reduce the likelihood of spallation/particulate being removed during assembly, which is particularly important in a clean-room environment. Having a wide opening which easily receives the stub shafts10a,10bis also particularly useful where the clamp2is constructed from a stiff material, such as a reinforced polymeric material like glass-reinforced nylon. The first and second arcuate portions4a,4beach comprise a semi-circular groove16a,16b. Side walls of the grooves16a,16bare angled with respect to one another such that the width of the groove tapers in a radial direction (i.e. the groove is narrower at a larger radius than at a smaller radius). In the closed position shown inFIG.2, the semi-circular grooves16a,16bof the first and second arcuate portions4a,4bmeet to form a substantially continuous circular channel. The distal, free ends of the first and second arcuate portions4a,4bare provided with a ratchet mechanism for locking the clamp2in the closed position. Specifically, the second arcuate portion4bis provided with a tongue18(rack) which projects from the second arcuate portion4bin a substantially circumferential direction. The tongue18comprises opposing lateral surfaces20a,20bwhich are each provided with one or more teeth. The first arcuate portion4ais provided with a receiving portion22. The receiving portion22defines a cavity24(seeFIG.3, particularly) which receives the tongue18. The receiving portion22defines a slot26(seeFIG.4, particularly) which opens outwardly and receives a separate pawl element28. The pawl element28is detachably connected to the receiving portion22via a snap-fit connection. In particular, as shown inFIG.3, the receiving portion22comprises an upper ridge30aand a lower ridge30bwhich project into the slot26. The pawl element28comprises complementary upper and lower grooves (not specifically labelled) formed in a body portion32of the pawl element28which receive the upper and lower ridges30a,30bto retain the pawl element28within the slot26. The snap-fit connection between the pawl element28and the receiving portion22is not required to withstand in-use loads which are substantially perpendicular to the orientation of the snap-fit connection. The pawl element28comprises a pair of actuation buttons34a,34bwhich are disposed at opposing lateral sides of the clamp2. As best shown inFIG.5, each of the actuation buttons34a,34bis provided with a finger36a,36btoward its lower end. The fingers36a,36bof the actuation buttons34a,34bare configured to engage with the teeth of the opposing lateral surfaces20a,20bof the tongue18respectively. Each of the actuation buttons34a,34bis connected to the body portion32of the pawl element28by a torsion bar. The torsion bars bias the actuation buttons34a,34bso that the fingers36a,36bare biased towards one another and into engagement with the teeth of the opposing lateral surfaces20a,20bof the tongue18. The fingers36a,36bmay be drawn away from the tongue18by squeezing the upper ends of the actuation buttons34a,34btoward one another such that the actuation buttons34a,34brotate about the torsion bars. This action generates a torque in the torsion bar which forces the fingers36a,36bback towards one another once the actuation buttons34a,34bare released. As shown inFIG.4, the receiving portion22is provided with a pair of angled recesses38a,38bwhich allow the actuation buttons34a,34bto be rotated as they are depressed. The tongue18is curved along its length so that the teeth are kept parallel to the pawl element28during rotation of the second arcuate portion4babout the hinge. As shown particularly inFIG.7, the clamp2may be employed to connect a pair of hose tail fittings40a,40bused to join two sections of hose (not shown) together. The tail fittings40a,40bcomprise a barb42a,42bwhich is inserted into the hose and a flange44a,44b. In use, with the clamp2in the open position shown inFIG.2, the flanges44a,44bare received in the semi-circular groove16aof the first arcuate portion4awith a gasket seal46disposed therebetween. As shown, the opposing surfaces of the flanges44a,44bmay be provided with circular grooves for receiving the gasket seal46. The clamp2is then closed such that the second arcuate portion4bis received over the flanges44a,44b. In this closed position, the tongue18is received in the receiving portion22and the teeth of the tongue18engage with the fingers36a,36bof the pawl element28. The teeth of the tongue18are asymmetrical such that the fingers36a,36bride over the teeth as the tongue18is inserted into the receiving portion22, but engage with the teeth if the tongue18is retracted from the receiving portion22. The first and second arcuate portions4a,4bcan therefore be squeezed together such that the teeth progressively pass the fingers36a,36b. Owing to the tapered geometry of the grooves16a,16b, this action causes the flanges44a,44bto be forced toward one another, compressing the gasket seal46disposed therebetween. The clamp2is therefore able to provide a fluid-tight seal between the tail fittings40a,40band the ratchet mechanism ensures that the first and second arcuate members4a,4bare retained in the closed position at the desired level of compression. In order to release the tail fittings40a,40bfrom the clamp2, the actuation buttons34a,34bare depressed, as described previously, so that the fingers36a,36bno longer engage with the teeth thereby allowing the tongue18to be freely removed from the pawl element28and the receiving portion22. As described previously, the tongue is provided with teeth of both of the opposing lateral surfaces20a,20b. This provides a number of benefits and options for the clamp2. In particular, the teeth may differ from one side to the other in their number, position, spacing (i.e. frequency/pitch), dimensions (e.g. height), etc. For example, as shown inFIG.5, the lateral surface20amay comprise a plurality of teeth having a fine pitch (akin to that of a cable-tie) and the opposing lateral surface20bmay comprise only a single tooth which is larger in height than the teeth of the lateral surface20a. The single, larger tooth of the surface20bmay be positioned partway along the tongue18at a position which corresponds to an optimum clamping force. Therefore, in operation, this would give the user an initial experience similar to tightening a cable-tie followed by a loud, positive snap when the clamp is in the intended position. The fingers36a,36bof the pawl element28may also differ from one another in their geometry and/or biasing to enable and/or accentuate this functionality. The tongue18may also contain a plurality of separate paths on one or both of the surfaces20a,20bwhich are offset from one another across the width of the surface20a,20b. For example, the surface20bmay contain a plurality of paths each comprising a single tooth for signifying that the clamp2has been adequately tightened, but located at different positions to correspond to the proper position for different uses. For example, the different paths may correspond to the requirements for different industries or may correspond to different tail fittings and/or gasket seals. The clamp2may be configured to use the required tooth path by selecting from a plurality of interchangeable pawl elements28which have fingers provided in the correct location to track along the required path. Alternatively, a single pawl element28may be used which can be modified to move the finger(s) into the correct position for the required path. A single, common design of the main clamp parts (i.e. the first and second arcuate portions4a,4b) can therefore cater for the many permutations of functionality offered by the configuration of the pawl element28(engineered to suit specific customer requirements). In other embodiments, the teeth on the opposing lateral surfaces20a,20bmay, however, be identical. Such an arrangement is beneficial in that the both of the actuation buttons34a,34bmust be depressed in order to open the clamp2. This redundancy avoids the clamp2being inadvertently released during service (including transportation and sterilisation of complete fluid-path assemblies in bags). The teeth on each of the opposing lateral surfaces20a,20bmay also differ along the length of the surface20a,20b. Such an arrangement may be used to provide the tactile, audible feedback described previously at certain positions. The opposing lateral surfaces20a,20bmay also use identical tooth profiles, but which are offset from one another. This effectively allows the combined pitch/resolution of the surfaces20a,20bto be doubled, as the fingers36a,36balternately engage with the teeth. Consequently, a larger, more robust tooth profile can be used and still achieve the same pitch/resolution as a single-sided rack. Alternatively, the fingers36a,36bmay be offset from one another to achieve the same effect. This could also be achieved using a single actuation button carrying a pair of offset fingers which engage a single toothed rack. This may be particularly beneficial when using certain materials, such as glass-reinforced nylon. In particularly, such materials may limit the effective engagement area of the teeth and therefore ultimately impose a minimum pitch of the teeth since the tooth profile should avoid sharp edges and therefore incorporate a slightly rounded edge. Moreover, a larger, more robust tooth profile is less likely to abrade and generate particulate contamination during normal operation. Retaining the ability to fine-tune the gasket sealing pressure allows a user to change (particularly, tighten) the pressure slightly after sterilisation (especially following autoclaving). The ratchet mechanism is both Gamma stable and autoclave stable such that its performance is not compromised by any material degradation due to repeated cycles of cleaning and subsequent sterilisation by autoclaving or gamma irradiation. The tongue18is resistant to creep/relaxation in use (especially during autoclaving in the assembled position) by virtue of the glass fibre reinforcement in the material. The use of interchangeable pawl elements28which are detachably connected to the clamp allows the clamp to be tailored to specific applications and users. For example, in certain applications, the actuation buttons34a,34bmay be removed or concealed such that the clamp can only be released by cutting, breaking or otherwise opening part of the pawl element. The clamp may require a specific tool for this purpose to prevent unauthorised release of the clamp. The pawl elements28may also be different colours to reflect a customer colour scheme or to allow differentiation between clamps performing different functions. The pawl elements28can also be branded for specific customers and can include technical information, such as the date of manufacture. Although not shown, the clamp may also provide visual as well as audible/tactile feedback regarding the position of the ratchet mechanism. For example, a simple scale of numbers may be used that are revealed to correspond with the position of the clamp. The linear rack has been described as having teeth located on a lateral surface of the clamp. However, it will be appreciated that the teeth could be perpendicular to this and located on radial surfaces of the clamp. The teeth may also be provided only on one surface, rather than opposing surfaces. With this arrangement, a single set of teeth may be engaged by two fingers carried by a single actuation button to improve resolution or two separate actuation buttons (with the fingers offset laterally or along the length of the rack) to provide redundancy, as described previously. The rack may also comprise a plurality of toothed paths which are offset from one another (along the same surface, rather than on opposing surfaces, as described previously) and engaged by separate fingers carried by a single actuation button or multiple actuation buttons in order to provide the tactile feedback mechanism described above. The adjacent toothed paths may be formed by a single set of teeth and only notionally divided into separate paths based on the passage of the fingers along the rack. The tactile/audible feedback may be generated by using enlarged teeth, as described, or may alternatively be generated by controlling the biasing force of the fingers. The or each actuation button may carry a plurality of fingers which simultaneously engage with the teeth to provide improved engagement. Although the pawl element28been described as using a torsion bar design, it will be appreciated that other arrangements may be used, such as a cantilever design. In certain applications, the pawl element28may also be integrally formed with the first arcuate member4a. FIGS.8to10show a clamp102according to another embodiment of the disclosure. The clamp102is similar to the clamp2described previously in many respects, but differs primarily in that it does not include a separate pawl element which is detachably connected to the clamp. The clamp102again comprises a first, lower arcuate portion104aand a second, upper arcuate portion104bwhich are hingedly connected to one another in a similar manner to that described for the clamp2. As described for the clamp2, the clamp102comprises a ratchet mechanism for locking the clamp102in the closed position. Specifically, the second arcuate portion104bis provided with a tongue118(rack) which comprises opposing lateral surfaces120a,120bwhich are each provided with one or more teeth. The first arcuate portion104ais provided with a receiving portion122. The receiving portion122defines a cavity124(seeFIG.10) which receives the tongue118. Each lateral side of the receiving portion122comprises a pawl portion134a,134b. The pawl portions134a,134bare connected to the receiving portion122only at their lower ends. The pawl portions134a,134bare therefore cantilevered and are allowed to pivot about their lower ends via a thinned section148a,148bwhich forms a hinge (seeFIG.10). A release tab150a,150bprotrudes perpendicularly from each pawl portion134a,134b. The release tabs150a,150bare positioned towards the free end of the pawl portions134a,134band thus are spaced from the hinged ends. As shown inFIG.10, each of the pawl portions134a,134bis provided with a pair of fingers136a,136b(only one finger may be used in other embodiments) which are spaced from the hinged ends of the pawl portion134a,134b. The fingers136a,136bare configured to engage with the teeth of the opposing lateral surfaces120a,120bof the tongue118respectively. The free ends of the pawl portions134a,134bare biased towards one another so that the fingers136a,136bengage with the teeth of the opposing lateral surfaces120a,120bof the tongue118. The fingers136a,136bmay be drawn away from the tongue18by pivoting the pawl portions134a,134babout the hinged ends. The clamp102may be held such that the operators thumb is positioned under the lower arcuate portion104a, and the index and middle finger are on top of the release tabs150a,150b. The release tabs150a,150bmay be pulled down so that they pivot about the hinged ends, thereby drawing the fingers136a,136baway from one another and out of engagement with the teeth of the tongue118so that the clamp102can be opened. The pawl portions134a,134bare resilient such that the fingers136a,136bare forced back towards one another once the release tabs150a,150bare released. As shown inFIG.8, the receiving portion122may be provided with an aperture152formed in its radial, end surface which allows the radial, end surface of the tongue118to be viewed when it is received within the receiving portion122. The radial, end surface of the tongue118may comprise a graduated scale along its length which is visible through the aperture152and thus provides an indication of the position of the tongue118within the receiving portion122and thus the relative positions of the arcuate portions104a,104b. The scale can therefore be used to ensure that the clamp102has been closed sufficiently. FIGS.11to13show a clamp202according to another embodiment of the disclosure. The clamp202is similar to the clamp102described previously in many respects, but the structure of the receiving portion222differs from that described previously. The clamp202again comprises a first, lower arcuate portion204aand a second, upper arcuate portion204bwhich are hingedly connected to one another in a similar manner to that described for the previous clamps2,102. The first and second arcuate portions204a,204bdiffer slightly from those described previously in that the first, lower arcuate portion204aextends around more than 180 degrees of the hose tail fittings. In other words, the first and second arcuate portions204a,204bare not equal halves, with the first arcuate portion204aextending over 192 degrees. This helps retain the components prior to clamping. As described for the clamps2,102, the clamp202comprises a ratchet mechanism for locking the clamp202in the closed position. Specifically, the second arcuate portion204bis provided with a tongue218(rack) which comprises opposing lateral surfaces220a,220bwhich are each provided with one or more teeth. The first arcuate portion204ais provided with a receiving portion222. The receiving portion222is defined by pawl portions234a,234bat either lateral side of the clamp202. The pawl portions234a,234bare connected only at their lower ends. The pawl portions234a,234bare therefore cantilevered and are allowed to pivot about their lower ends. A release tab250a,250bprotrudes perpendicularly from each pawl portion234a,234b. Each of the pawl portions234a,234bis provided with a pair of fingers236a,236b(only the pair of fingers236bis visible inFIG.11; only one finger may be used in other embodiments) which are spaced from the hinged ends of the pawl portion234a,234b. The fingers236a,236bare configured to engage with the teeth of the opposing lateral surfaces220a,220bof the tongue218respectively. Each pair of fingers236a,236bforms a primary, upper finger and a secondary, lower finger. The primary finger may be larger than the secondary finger. The primary finger may be used predominantly when the clamp is closed. The secondary finger engages with the tongue218and is used to increase the contact area when the clamp is under pressure. This effectively spreads the load between the two fingers, and acts as a backup in the unlikely event that the primary finger slips. A rib may be provided between the fingers at the innermost edge so as to join the fingers together. This rib reinforces both fingers and prevents deformation during pressurisation following an autoclaving procedure. A corresponding slot may be provided in the tongue218to receive the rib between the fingers236a,236b. The pawl portions234a,234bare cranked so that when vertical force is applied to the release tabs250a,250b, the pawl portions234a,234bmove away from the tongue218. This reduces the forces required to open the clamp. A pair of tab stops254a,254bare provided to limit movement of the pawl portions234a,234b. The tab stops254a,254bare disposed beneath the release tabs250a,250brespectively and contact the release tabs250a,250bwhen they are pulled down to open the clamp202. The tab stops254a,254btherefore prevent the pawl portions234a,234bfrom being opened excessively which could otherwise cause them to be permanently deformed. The tab stops254a,254balso serve a secondary purpose in that they prevent the user from placing their fingers under the release tabs250a,250band thus convey to the user the correct way of opening the clamp. As shown inFIG.13, the radial, end surface of the tongue218may comprise a graduated scale or other indicia along its length which is visible between the pawl portions234a,234band thus provides an indication of the position of the tongue218within the receiving portion222and thus the relative positions of the arcuate portions204a,204b. The scale can therefore be used to ensure that the clamp202has been closed sufficiently. The pawl portions234a,234bmay be provided with reference indicia such as arrows which are used to define the relative position of the scale on the tongue218. FIGS.14to17show a tamper-evident cover256which is snap-fitted onto the clamp and is used to conceal the pawl portions234a,234bto prevent them from being actuated and the clamp202opened. The cover256is a plastic injection moulded product made from polypropylene. The cover256forms a cavity which has a cross-section that approximately conforms to the outer profile of the receiving portion222(i.e. the pawl portions234a,234band the tab stops254a,254b). The cover256can therefore be introduced over the receiving portion222by sliding it in a radially inward direction over the pawl portions234a,234band the tab stops254a,254b. The cover256is provided with internal ribs257which locate in the space provided between the tab stops254a,254band the release tabs250a,250b. This ensures that the cover256does not rotate or twist during fitment. As shown inFIG.17, the cover256comprises a pair of barbs258a,258bwhich project within the cavity formed by the cover256. As shown, the barbs258a,258bare configured to deflect inwards and pass between the tab stops254a,254band the pawl portions234a,234band for a head of each barb258a,258bto hook onto the backside of the tab stop254a,254bonce it clears the tab stop254a,254b. The barbs258a,258bthus retain the cover256to prevent it being withdrawn from the receiving portion222. Further, the barbs258,258bare concealed within the cover256such that they cannot be accessed once the cover256has been fitted. The cover256forms a slot for receiving the tongue218such that it can pass between and engage with the pawl portions234a,234b. The cross-section of the cover256may be such that some movement of the release tabs250a,250bis permitted so that the tongue218can be inserted between the pawl portions234a,234bwith the cover in-situ. However, once the clamp202has been closed with the tongue218inserted into the receiving portion222, then it cannot be opened since the cover256prevents access to the release tabs250a,250b. Further, the cover256is made of sufficiently strong material that it cannot be deformed to allow the release tabs250a,250bto be actuated externally. The clamp202can only be opened by removing the cover256. The removal of the cover256is immediately evident and so the cover256prevents someone from tampering with the clamp202. The cover256is formed by a first, insert portion260and a second, peripheral portion262which are connected to one another by a pull-tab264. The insert portion260carries the barbs258a,258b, whereas the peripheral portion262defines the outer periphery (i.e. the cross section) of the cover256. An opening is formed between the pull-tab264and the insert portion260through which the indicia provided on the radial, end surface of the tongue218can be seen. The pull-tab264comprises a tab portion and a pair of tail portions extending from the tab portion. The tab portion is connected to the peripheral portion262by a frangible pip. The tail portions of the pull-tab264are each connected to the insert portion260and the peripheral portion262via thinned webs or membranes which form tear lines and allow the tail portions and thus the pull-tab264to be easily pulled away from the insert portion260and the peripheral portion262via the tab portion by tearing through the webs. The removal of the pull-tab264thus separates the insert portion260from the peripheral portion262. Consequently, the peripheral portion262is no longer constrained by the barbs258a,258band so can be removed from the clamp202. This allows the release tabs250a,250bto be accessed and actuated so that the clamp202can be opened. The insert portion260can also be removed from the clamp202by forcing the barbs258a,258bover the tab stops254a,254b. This process is shown inFIG.18. It will be appreciated that the structure of the tamper-evident cover could be adapted to also engage with the clamps2,102in a similar manner. Although the tamper-evident cover has been described with reference to a clamp, it will be appreciated that it may be used with other components. In particular, the tamper-evident cover may be used to conceal an actuator mechanism of a component in order to prevent it from being accessed and unwantedly activated. For example, the tamper-evident cover may be used with a flow control and/or shut off valve (such as the BioPure BioValve™) in order to prevent access to a handle or other actuator which may be used to open or close the valve. To avoid unnecessary duplication of effort and repetition of text in the specification, certain features are described in relation to only one or several aspects or embodiments of the disclosure. However, it is to be understood that, where it is technically possible, features described in relation to any aspect or embodiment of the disclosure may also be used with any other aspect or embodiment of the disclosure. It will be appreciated that the first and second arcuate portions need not be semi-circular and that additional (arcuate or non-arcuate) portions may be disposed between the first and second arcuate portions. The second arcuate portion may therefore be hingedly connected to the first arcuate portion via one or more additional portions. The disclosure is not limited to the embodiments described herein, and may be modified or adapted without departing from the scope of the present disclosure. | 29,601 |
11859746 | DETAILED DESCRIPTION FIG.1shows a three-dimensional view of an embodiment of a device2according to the disclosure for connecting two tubular objects. The device2has a connection piece housing4with a sleeve portion3and a sleeve-like element6which is inserted into an insertion opening8of the connection piece housing4. A connecting end10of the connection piece housing4may be coupled to one of the objects (not shown) to be connected. The connection piece housing4has on an outer periphery, i.e. on an outer envelope surface12, outer ramp surfaces14widening radially outwardly in the peripheral direction u. The outer ramp surfaces14have a substantially rectangular bottom surface. The sleeve-like element6has tabs16which extend in the axial direction a of the sleeve-like element6. The tabs16are arranged such that, when the sleeve-like element6is twisted, the tabs slide from a radial cut-out18onto the outer ramp surfaces14. Due to a spring-elastic design the tabs16are radially widened and are jammed at the same time onto the outer ramp surfaces14. For the preassembly, the tabs16may be configured with a certain degree of pretensioning so that they exert a slight clamping force onto the cut-outs18and as a result are secured thereto. The radial cut-outs18could also have a defining edge (not shown) which is oriented toward the insertion opening8and prevents the tabs16from slipping out. An open position of the device2according to an embodiment of the disclosure is shown here. The sleeve-like element also has a handling profile20which has a plurality of straight edges22adjoining one another. These edges are at a predetermined angle to one another and permit the engagement of a tool (not shown) so that it is also possible to introduce a greater torque onto the sleeve-like element6. The sleeve-like element6is shown inFIG.2in a plan view of a side facing toward the insertion opening8in the assembled state. The positions of the tabs16at the radially external positions may be identified here. Additionally, tab-shaped display elements24are shown at two installed positions which oppose one another, the mode of operation thereof being explained with reference to the following figures. By way of example, a connecting axis between the display elements24is perpendicular to a connecting axis between the tabs16. These components serve for indicating a successful locking between the sleeve-like element6and the connection piece housing4. As a result, a display element24is arranged offset by 90° to a tab16and vice versa. FIG.3shows a slightly different perspective of the device2in which a display element24is visible. This display element is located in a continuous radial cut-out26of the connection piece housing4in which a projection28extending in the peripheral direction u is located. The projection28encloses with an edge30remote from the insertion opening8a slot32into which the display element24may be pushed when the sleeve-like element6is rotated. The display element24and the projection28are designed such that when the display element24is displaced into the slot32as far as a specific position, the display element24is moved radially inwardly and is no longer visible to the user. This is shown in further detail inFIGS.5,6and7. A first engagement element34is produced on the sleeve portion3of the connection piece housing4by an edge of the radial cut-out18facing the insertion opening8. The sleeve-like element6has a corresponding second engagement element36which is produced in the form of a resilient latching element which is brought into engagement with the edge. FIG.4shows a detail of the sleeve-like element6with a tab-shaped display element24which extends radially outwardly from a foot38. The foot38may be designed to be resilient so that by a radially inwardly oriented force an elastic deformation of the foot38can be achieved, the display element24also being moved radially inwardly thereby. The second latching element36has by way of example a wedge shape by which the second latching element36, when the sleeve-like element6is inserted into the insertion opening8, may be deflected radially inwardly in order to be subsequently latched to the first engagement element34. FIGS.5,6and7show a ramp surface40in the radial cut-out26which in some regions extends radially outwardly along the projection28in the peripheral direction u. The ramp surface40is arranged on a side of the projection28remote from the slot32. When the sleeve-like element6is inserted into the connection piece housing4, the second engagement element36is located with a radially internal surface42on the ramp surface40. By rotating the sleeve-like element6in the peripheral direction u the display element24runs along the slot32on the projection28and onto the ramp surface40. When the radially internal surface42of the second engagement element36reaches the ramp surface40, it is urged radially outwardly. The foot38of the display element24, however, is in a surface contact with a radially internal surface of the projection28and as a result may not be moved radially outwardly. When the radially internal surface42is deflected and when the movement of the foot38is limited at the same time, the foot is bent such that the display element24connected thereto is pulled radially inwardly. The ramp surface40may be implemented on a ramp body44which on a side opposing the ramp surface40has an internal ramp body surface46which has a uniform radius and as a result has no radial extent. The ramp body44may be an integral component of the connection piece housing4. Alternatively, the ramp body44may also be bonded or welded to the projection28. FIG.8also shows a plan view of an insertion opening of the connection piece housing4. In this case, two recesses48and50opposing one another in the peripheral direction are shown, said recesses being shaped and arranged so as to correspond to the display elements24shown inFIG.2. The two display elements24have different widths which correspond to the widths of the recesses48and50. As a result, the sleeve-like element6may be inserted only in a single predetermined position into the connection piece housing6when the display elements24and the recesses48and50correspond with one another. A cut-out52which is arranged between the recesses48and50and which is arranged on an internal face of the connection piece housing4is also shown. An element which functions as an anti-twist device may be received herein. The invention is not limited to one of the above-described embodiments but is able to be modified in many different ways. All of the features and advantages disclosed in the claims, the description and the drawings, including structural details, spatial arrangements and method steps may be essential to the invention both per se and in the various combinations. All the features and advantages, including structural details, spatial arrangements and method steps, which follow from the claims, the description and the drawing can be fundamental to the invention both on their own and in different combinations. It is to be understood that the foregoing is a description of one or more preferred exemplary embodiments of the invention. The invention is not limited to the particular embodiment(s) disclosed herein, but rather is defined solely by the claims below. Furthermore, the statements contained in the foregoing description relate to particular embodiments and are not to be construed as limitations on the scope of the invention or on the definition of terms used in the claims, except where a term or phrase is expressly defined above. Various other embodiments and various changes and modifications to the disclosed embodiment(s) will become apparent to those skilled in the art. All such other embodiments, changes, and modifications are intended to come within the scope of the appended claims. As used in this specification and claims, the terms “for example,” “for instance,” “such as,” and “like,” and the verbs “comprising,” “having,” “including,” and their other verb forms, when used in conjunction with a listing of one or more components or other items, are each to be construed as open-ended, meaning that the listing is not to be considered as excluding other, additional components or items. Other terms are to be construed using their broadest reasonable meaning unless they are used in a context that requires a different interpretation. LIST OF REFERENCE DESIGNATIONS 2Device for connecting two tubular objects3Sleeve portion4Connection piece housing6Sleeve-like element8Insertion opening10Connecting end12Outer envelope surface of connection piece housing14Outer ramp surface16Tab18Radial cut-out20Handling profile22Edge24Display element26Radially continuous cut-out28Projection30Edge32Slot34First engagement element36Second engagement element38Foot40Ramp surface42Radially internal surface44Ramp body46Internal ramp body surface48Recess50Recess52Cut-outa Axial directionu Peripheral direction | 8,997 |
11859747 | DETAILED DESCRIPTION Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In order to facilitate understanding of the embodiments of the present invention, first, an outline of the prior art described in the patent document will be explained with reference toFIGS.1and2.FIG.1shows the safety joint100in the prior art, which is composed of a joint10on the side of a hydrogen gas filling device and a joint20(FIG.2) on the side of a filling hose. In the attached drawings, illustration of the hydrogen gas filling device and the filling hose is omitted.FIG.1shows a state in which the joint10is separated from the joint20. Although the joint10and the joint20have similar structural members (plug bodies1,11, valve bodies2,12, elastic members3,13, etc.), the similar structural members of the joints10,20are indicated by different reference numerals. The valve bodies2and12and the plug bodies1and11are made of metal. The joint20is constructed similarly to the joint10. InFIG.1, the plug body1is formed with a flow passage1A (1A-1to1A-3) and a valve accommodating portion1C for accommodating a valve body2therein. The flow passage1A includes a small-diameter region1A-1communicating with the filling device (existing the top inFIG.1), a large-diameter region1A-2relating to the valve accommodating portion1C, and a small diameter region1A-3communicating with a filling hose (existing the bottom inFIG.1). The valve accommodating portion1C constitutes a part of the flow passage1A. InFIG.1, in the valve accommodating portion1C of the plug body1is accommodated the valve body2so as to be movable in the flow direction of the flow passage1A (vertical direction inFIG.1). A spring3is arranged on the filling device side of the valve body2(above the valve body2inFIG.1). The spring3urges the valve body2toward the filling hose (downward inFIG.1), so that the valve body2is always pressed toward a tapered valve seat1B formed at the lower end of the valve accommodating portion1C. InFIG.1, the valve body2arranged in the valve body accommodating portion1C is composed of a large diameter portion2A, a tapered portion2B, and a small diameter portion2C. The tapered portion2B is formed at one end (lower end inFIG.1) of the large diameter portion2A, and is formed so as to be able to abut against the tapered valve seat1B formed in the plug body1. A groove2G is formed in the small diameter portion2C of the valve body2, and an O-ring4as a sealing member is accommodated in the groove2G. The small diameter portion2C of the valve body2can be inserted into the region1A-3on the filling hose side (lower side inFIG.1) of the flow passage1A, and when the joint10on the filling device side and the joint20on the filling hose side are separated (the case shown inFIG.1), the small diameter portion2C is inserted into the region1A-3. On the other hand, when the joint10and the joint20are connected (in the case ofFIG.2), the small diameter portion2C is located on the filling device side (above inFIG.1) from the region1A-3, and is not inserted in the region1A-3. InFIG.1, the tapered valve seat1B formed in the valve accommodating portion1C and the tapered portion2B formed at one end of the large diameter portion2A of the valve body2constitute a first sealing means2S1. When the tapered portion2B of the valve body2is seated on the valve seat1B of the plug body1, the valve (first sealing means2S1) is closed, and the state shown inFIG.1is obtained. On the other hand, when the tapered portion2B of the valve body2separates from the valve seat1B of the plug body1, the first sealing means2S1is opened and enters the state shown inFIG.2. Since both the valve body2and the plug body1are made of metal, when the valve body2is seated on the valve seat1B, a metal seal is formed to ensure airtightness. In particular, when the fluid fuel is at high pressure, the first sealing means2S1exhibits excellent sealing performance as well as pressure resistance. InFIG.1, the O-ring4accommodated in the groove2G of the small diameter portion2C of the valve body2contacts the inner wall surface of the region1A-3on the hose side of the flow passage1A when the joint10and the joint20are separated, and the O-ring4and the inner wall surface of the region1A-3constitute a second sealing means2S2. The contact of the O-ring4with the region1A-3allows the second sealing means2S2to exhibit sealing performance. On the other hand, when the small diameter portion2C moves toward the valve accommodating portion1C of the plug body1and the O-ring4does not come into contact with the filling hose side region1A-3(state shown inFIG.2), the second sealing means2S2cannot exhibit sealability. The contact (or contact in a sliding state) of the inner wall surface of the filling hose-side region1A-3and the O-ring4of the second sealing means2S2improve the sealing performance at low pressure. When the safety joint100shown inFIG.2is assembled, that is, when the joint10on the filling device side and the joint20on the filling hose side are connected, there is a rod8between the joint10and the joint20. The end portion of the rod8on the side of the filling device (upper inFIG.2) presses the valve body2on the side of the filling device, pushing the valve body2against the elastic force of the spring to separate the valve body2from the valve seat1B. On the other hand, the end of the rod8on the filling hose side (lower inFIG.2) presses the valve body12on the filling hose side to separate the valve body12from a valve seat11B. As a result, the first sealing means2S1and12S1(a valve constituted by the tapered portion2B of the valve body2and the valve seat1B and a valve constituted by the tapered portion12B of the valve body12and the valve seat11B) are opened. At the same time, in the second sealing means2S2and12S2, since the small diameter portion2C is not inserted in the region1A-3, and the small diameter portion12C is not inserted in the region11A-3, the O-ring4and the O-ring14are not in contact with the inner wall surfaces of the regions1A-3,11A-3, resulting in no sealing functions. The hydrogen gas consequently can flow from the filling device side to the filling hose side (fuel tank side of the vehicle) through the safety joint100(flow passages1A and11A of the joints10and20) without being sealed. When a hydrogen gas filling hose (not shown) is subjected to a tensile force greater than expected during hydrogen gas filling, the joint10on the filling device side and the joint20on the filling hose side are separated by a known mechanism (not shown). When the joint10and the joint20are separated, the rod8is disengaged from the joints10and20, so that the valve bodies2and12are pressed by the springs3and13, respectively to move toward the valve seats1B and11B of the plug bodies1and11, the tapered portions2B and12B of the valve bodies2and12are seated on the valve seats1B and11B, and the first sealing means2S1and12S1are closed. When the joint10and the joint20are separated, the small diameter portions2C and12C of the valve bodies2and12are inserted into the regions1A-3and11A-3, so that the second sealing means2S2constituted by the O-ring4and the filling hose side region1A-3and the second sealing means12S2constituted by the O-ring14and the filling hose side region11A-3exhibit sealing functions. As a result, when the joint10and the joint20are separated, the hydrogen gas (fluid fuel) on the filling device side is prevented from flowing out through the joint10, and the hydrogen gas on the filling hose side is prevented from flowing out through the joint20. Next, the first embodiment of the present invention will be described with reference toFIGS.3to7. As described above, during filling, since an ultra-high pressure hydrogen gas flows at high speed through the flow passages1A-2and11A-2in the safety joint, there is a risk that the O-rings4and14constituting the second sealing means may fall off. Moreover, if a foreign matter is mixed in the hydrogen gas to be filled, the foreign matter may come into contact with the O-rings4and14and damage them. In the present invention, a member is provided to cover the O-rings4and14when the valve is opened, thereby preventing the O-rings4and14from coming off or being damaged due to inflow of hydrogen gas. When the outline of the prior art was explained with reference toFIGS.1and2, the joint10on the filling device side was illustrated and explained, but in the explanation of the first embodiment shown inFIGS.3to7, the joint20will be illustrated and explained. As mentioned above, the joint10and the joint20have similar components. The joint10or20according to the first embodiment includes a cover15(a structure not provided in the prior art ofFIGS.1and2) as a member that covers the O-rings4and14when the valve is opened. Since the cover15is provided and functions, the shape of the valve body12(2), etc. in the first embodiment shown inFIGS.3to7are different from those of the prior art show inFIGS.1and2. However, the same reference numerals as inFIGS.1and2are used for the reference numerals of the members corresponding to the prior art shown inFIGS.3to7.FIGS.3to7show the members on the side of the joint20, and do not show the members on the side of the joint10. FIG.3shows a state in which the joint10on the side of the filling device (not shown) and the joint20on the side of the filling hose are separated. InFIG.3, the plug body11of the joint20is formed with a flow passage11A (11A-1to11A-3) and a valve body accommodating portion11C, and a valve body12is accommodated in the valve body accommodating portion11C. The flow passage11A includes a small-diameter region11A-3communicating with the filling device side (upper side inFIG.3), a large-diameter region11A-2forming the valve accommodating portion11C, and a small-diameter region11A-1communicating with the filling hose side (lower side inFIG.3). The valve accommodating portion11C is in communication with a filling device (not shown) through a region11A-3, and is in communication with a filling hose (not shown) through a region11A-1. The direction of hydrogen gas flow is indicated by the arrow Y inFIGS.3and7. InFIG.3in which the joint10on the filling device side (not shown) is separated, no hydrogen gas flows, and the arrow Y indicates an imaginary direction of hydrogen gas flow when the hydrogen gas flows. A hydrogen gas flows from the joint10(plug body1, seeFIG.1) on the filling device side to the joint20on the filling hose side (plug body11) (in the direction of the arrow Y1), and flows from the filling hose side coupling20(plug body11) to the filling hose (not shown) (arrow Y2). In the joint10(seeFIG.1), the direction of hydrogen gas flow is opposite to the directions Y1and Y2shown inFIG.3. InFIG.3, the valve body12is accommodated in the valve body accommodating portion11C of the plug body11so as to be movable in the direction of the flow passage11A (longitudinal direction of the flow passage11A: vertical direction inFIG.3). A spring13is arranged on the filling hose side (lower inFIG.3) of the valve body12. The spring13urges the valve body12toward the filling device (upward inFIG.3), so that the valve body12is always pressed toward the tapered valve seat11B formed at the upper end of the valve body accommodating portion11C. The valve body12and the plug body11are made of metal. A groove12G is formed in the small diameter portion12C of the valve body12, and an O-ring14as a sealing member is fitted (accommodated) in the groove12G. The small-diameter portion12C of the valve body12can be inserted into a region11A-3on the filling device side (upper side inFIG.3) of the flow passage11A, and when the joint10and the joint20separate from each other as shown inFIG.3, the small diameter portion12C is inserted into the region11A-3, and the valve body12is seated on the tapered valve seat11B formed at the upper end of the valve body receiving portion11C. On the other hand, in the case shown inFIG.7, that is, when the joint10on the filling device side and the joint20on the filling hose side are coupled, the small diameter portion12C is not inserted into the region11A-3, and is located on the filling hose side (lower inFIG.3) of the region11A-3. As described above, the valve body12is positioned in the valve body accommodating portion11C (region11A-2) inFIG.3. The details of the valve body12are shown inFIG.4. The valve body12will be described below with reference toFIGS.3and4. The valve body12includes a large diameter portion12A, a tapered portion12B formed at one end of the large diameter portion12A and abutting against the valve seat11B, and a small diameter portion12C extending upward inFIG.4from the tapered portion12B. Further, the valve body12has a tip rod-shaped region12D near the end (front end side) on the side (lower side inFIG.4) separated from the small diameter portion12C. The large-diameter portion12A is continuous with the tip rod-shaped region12D via a stepped portion, and has a disc shape. The outer diameter of the large diameter portion12A is larger than the inner diameter of the region11A-3. The small diameter portion12C is continuous with the large diameter portion12A via the tapered portion12B, and has a smaller outer diameter than the large diameter portion12A. The outer diameter of the small diameter portion12C is smaller than the inner diameter of the region11A-3, so that it can enter the region11A-3. A tapered portion12DT is formed on the tip side (filling hose side, lower side inFIGS.3and4) of the tip rod-shaped region12D in order to reduce the resistance to the hydrogen gas flow. Although not shown, the small diameter portion12C of the valve body12can be tapered at the filling device side end (upper side inFIG.3) to reduce resistance to reverse hydrogen gas flow. InFIGS.3and4, the tapered portion12B formed at one end of the large diameter portion12A of the valve body12and the valve seat11B formed in the plug body11constitute a first sealing means12S1. When the tapered portion12B of the valve body12is seated on the valve seat11B of the plug body11, the first sealing means12S1is closed (the state shown inFIG.3). On the other hand, when the tapered portion12B of the valve body12is separated from the valve seat11B of the plug body11, the first sealing means12S1is opened (the state shown inFIG.7). The first sealing means12S1, which is composed of the valve body12and the plug body11both made of metal, forms a metal seal when the tapered portion12B of the valve body12is seated on the valve seat11B. In particular, when the fluid fuel is at high pressure, it exhibits excellent pressure resistance as well as excellent sealing performance. InFIGS.3and4, the O-ring14accommodated in the groove12G formed in the small-diameter portion12C of the valve body12will be in contact with the inner wall surface of the region11A-3of the flow passage11A on the filling device side when the joint10(FIG.1) on the filling device side and the joint20on the filling hose side are separated (the state shown inFIG.3). The O-ring14and the inner wall surface of the region11A-3constitute the second sealing means12S2. When the O-ring14contacts with the inner wall surface of the region11A-3, the sealing performance is exhibited, and the second sealing means12S2is closed.FIG.4shows the state in which the O-ring14is incorporated into the valve body12. On the other hand, when the small diameter portion12C moves toward the valve accommodating portion11C of the plug body11and the O-ring14does not contact with the filling device side region11A-3(the state shown inFIG.7), the second sealing means12S2is also in an open state and does not exhibit sealing performance. In the second sealing means12S2, the contact (or sliding contact) between the inner wall surface of the region11A-3on the filling device side and the O-ring14improves the sealing performance at low pressure. InFIG.3, the valve body12located in the valve body accommodating portion11C (the region11A-2) is surrounded by a hollow cover15. Details of the cover15are shown inFIGS.5and6. The configuration and function of the cover15will be described with reference toFIGS.3to6. As shown inFIG.6, the cover15has hollow portions15C (15C-1,15C-2). The hollow portions15C-1and15C-2may be collectively referred to as the hollow portion15C. As clearly shown inFIG.6, the hollow portion15C of the cover15has a region15C-1with a large inner diameter and a region15C-2with a small inner diameter. The region15C-1with a large inner diameter is formed on the side of the region11A-3with a small inner diameter of the passage in the assembled states shown inFIGS.3and7. The disc-shaped large-diameter portion12A of the valve body12can enter the region15C-1having a large inner diameter. In the assembled states ofFIGS.3and7, the region15C-2with a smaller inner diameter is formed on the side of the region11A-2with a larger inner diameter of the passage. The large-diameter portion12A of the valve body12cannot enter the region15C-2with a small inner diameter. However, the tip rod-shaped region12D of the valve body12can enter the region15C-2with a small inner diameter. At least a portion of the valve body12is accommodated in the hollow portion15C of the cover15. That is, when the tapered portion12B of the valve body12is separated from the valve seat11B and is not seated on the valve seat11B, that is, when the valve (first sealing member12S1) is opened (in the case ofFIG.7), the region15C-1having a large inner diameter surrounds at least a portion of the region on the side of the large diameter portion12A of the valve body12from the second sealing means12S2(O-ring14). On the other hand, when the tapered portion12B of the valve body12is seated on the valve seat11B, that is, when the valve is closed (in the case ofFIG.3), the region15C-1having a large inner diameter in the hollow portion15C surrounds at least a portion of the large diameter portion12A and the small diameter portion12C of the valve body12. As shown inFIG.5, a plurality of projections15A (guides or fins) is formed on the outer peripheral portion15B of the cover15, each of the projections15A extending substantially over the entire length of the cover15in the direction of the flow passage. A hydrogen gas passage is formed by the projections15A, the outer peripheral portion15B of the cover15, and the inner peripheral surface of the region11A-2having the larger inner diameter of the passage. A hydrogen gas flows through the hydrogen gas passage when the joint10on the filling device side and the joint20on the filling hose side are coupled as shown inFIG.7. In the case shown inFIG.3, that is, when the joint10and the joint20are separated, no hydrogen gas flows in the hydrogen gas flow passage formed by the protrusions15A, the outer peripheral portion15B of the cover15, and the inner peripheral surface of the region11A-2. Although not shown inFIGS.5and6, guide grooves for guiding the projections15A of the cover15when the cover15moves in the flow passage direction may be formed on the inner peripheral surface of the region11A-2where the inner diameter of the flow passage11A is large. Such guide grooves may be omitted. In other words, the cover15may be rotatable inside the region11A-2of the flow passage11A of the plug body11having a large inner diameter. Also, only a portion of the protrusion15A needs to fit into the guide groove, and not all the protrusions15A need to fit into the guide grooves. In the illustrated first embodiment, when the valve is closed as shown inFIG.3, the stopper15D (FIG.6) formed at the end portion of the cover15on the filling device side is engaged with the ceiling of the region11A-2having the large inner diameter on the side of the filling device to form a space K (FIG.3). The space K may be omitted, and the end of the cover15on the side of the filling device may contact the ceiling of the region11A-2. In other words, unless the cover15interferes with the ceiling portion of the region11A-2with a large inner diameter on the side of the filling device and does not cover the O-ring14, the presence or absence of the space K shown inFIG.3doesn't matter. As shown inFIGS.5and6, the cover15has a tapered portion15E for reducing resistance at the end on the filling hose side (diagonally lower right inFIG.5: lower inFIG.6) as assembled. Although not shown, the end of the cover15on the filling device side (diagonally upper left inFIG.5: upper inFIG.6) as assembled can also be formed with a taper for reducing resistance. The tapered portion15E described above is effective because it faces the flow of hydrogen gas when applied to the cover of the joint10on the filling device side. On the other hand, the taper not shown is effective in facing the hydrogen gas flow when applied to the cover15of the joint20on the filling hose side. FIG.7shows the joint20on the filling hose side when the joint10on the filling device side and the joint20on the filling hose side are connected. The directions in which hydrogen gas flows inFIG.7are indicated by arrows Y (Y1, Y2). InFIG.7, the rod8is interposed between the joint10and the joint20, the end of the rod8on the filling hose side (lower inFIG.7) pressing the valve body12on the filling hose side against the elastic force of the spring13to separate the tapered portion12B of the valve body12from the valve seat11B. Although not shown, the end of the rod8on the side of the filling device (upper inFIG.7) presses the valve body2(not shown inFIG.7) of the joint10on the side of the filling device, in the joint10also the rod8separates the tapered portion2B of the valve body2from the valve seat1B (FIGS.1and2). As a result, the first sealing means12S1(a valve constituted by the tapered portion12B of the valve body12and the valve seat11B) of the joint20on the filling hose side is opened, and the first sealing means2S1of the joint10(not shown) on the filling device side is opened. InFIG.7, when the first sealing means12S1is opened, the small diameter portion12C of the second sealing means12S2of the joint20on the filling hose side is not inserted into the region11A-3and the O-ring14is not in contact with the inner wall surface of the region11A-3, so that the O-ring14does not perform its sealing function. Similarly, the O-ring4of the second sealing means2S2of the joint10(FIGS.1and2) on the filling device side (not shown) does not contact with the inner wall surface of the region1A-3, so that it does not exhibit its sealing function. Since the first sealing means12S1and2S1are in open states and the second sealing means12S2and2S2do not exhibit sealing functions, a high-pressure hydrogen gas flows from the hydrogen gas filling device side through the safety joint100(flow passages1A and11A of the joints10,20) to the filling hose side (fuel tank side of a vehicle). In the state shown inFIG.7, the region15C-1having a large inner diameter in the hollow portion15C of the cover15surrounds at least a portion of an area on the side of the large diameter portion12A of the valve body12from second sealing means12S2(O-ring14). The second sealing means12S2(O-ring14) can be protected accordingly against a high-pressure hydrogen gas flow passing through the flow passage formed in the outer peripheral portion15B of the cover15. The function of protecting the second sealing means12S2(O-ring14) by the cover15will be described later. As shown inFIG.2, there is a possibility that the O-ring14may fall off or be damaged when the valve is opened and high pressure hydrogen gas flows into the flow passage11A. However, according to the first embodiment shown inFIGS.3to7, the O-ring14accommodated in the recess12G of the valve plug12is surrounded and protected by the cover15, which prevents the O-ring14from falling off out of the groove12G. In addition, as will be described later, hydrogen gas does not flow in the internal space15C of the cover15, even if a foreign matter enters, the foreign matter will not contact the O-ring14, and the O-ring14will not be damaged. The flow of hydrogen gas in the cover15will be described. InFIG.7in which the valve is open, the valve body12and the cover15are in contact with each other as indicated by the symbol F. Specifically, the end surface of the large-diameter portion12A of the valve body12on the side of the tip rod-shaped region12D and the stepped portion of the hollow portion15C of the cover15come into contact with each other at the location indicated by the symbol F. When the end surface of the large diameter portion12A of the valve body12and the stepped portion of the cover15contact with each other, a part of the valve body12is accommodated inside the cover15(hollow portion15C). With this, an annular space is formed between the outer surface of the valve body12and the inner surface of the hollow portion15C of the cover15, the radial distance in the annular space is small and the resistance to fluid is large, which makes it difficult for hydrogen gas to flow. On the other hand, the resistance to fluid of the hydrogen gas flow passages radially outward of the cover15(the flow passages configured by the projections15A, the outer peripheral portion15B and the inner peripheral surface of the region11A-2having a large inner diameter) is much smaller in comparison to the resistance to fluid in the hollow portion15C of the cover15. Therefore, the hydrogen gas hardly flows downstream side (filling hose side) of the portion indicated by the symbol F, and flows through the passage configured by the adjacent projections15A of the cover15, the outer peripheral portion15B and the inner peripheral surface of the region11A-2having a large inner diameter of the flow passage. A hydrogen gas hardly flows into the hollow portion15C inside the cover15, which has high resistance to fluid. However, the flow rate of hydrogen gas flowing through the hollow portion15C of the cover15does not necessarily have to be zero (0). The resistance to fluid of the hollow portion15C is more significant than that of the flow passage outside the cover15(the hydrogen gas flow passage composed of the adjacent projections15A, the outer peripheral portion15B, and the inner peripheral surface of the region11A-2having a large inner diameter of the flow passage) should be as large as possible. In addition, a sealing material may be arranged at a contact point indicated by symbol F (the point at which the end surface of the large-diameter portion12A of the valve body12and the stepped portion of the hollow portion15C of the cover15contact) so that the flow rate of hydrogen gas through the hollow portion15C of the cover15can be zero. The flow rate of the hydrogen gas flowing through the hollow portion15C of the cover15is small (or does not flow), and the hydrogen gas flows through the flow passage with low resistance on the outer peripheral side of the cover15. As a result, the flow velocity of the hydrogen gas flow in the hollow portion15C of the cover15becomes very low or zero, and the O-ring14of the valve body12accommodated in the hollow portion15C of the cover15will not fall off due to the hydrogen gas flow flowing through the hollow portion15C. In the hollow portion15C, since the flow velocity of the hydrogen gas flow becomes slow (or becomes zero), even if the hydrogen gas mixed with a foreign matter collides with the O-ring14, the O-ring14will not be damaged. A second embodiment of the present invention will now be described with reference toFIG.8. In the safety joint100-1of the second embodiment shown inFIG.8, grooves (concave portions) are formed on the hydrogen gas flow passages1A and11A in the plug bodies1and11of the filling device side joint10and the filling hose side joint20, respectively are formed, and the O-rings4and14are fitted in the grooves (recesses). In that respect, it differs from the first embodiment shown inFIGS.3to7. In the second embodiment shown inFIG.8, redundant description of the same configuration as that of the first embodiment shown inFIGS.3to7will be avoided. Similar to the first embodiment ofFIGS.3-7, the second embodiment ofFIG.8will be described with respect to the joint20on the filling hose side. The joint10on the filling device side is not shown. InFIG.8, a concave portion11D (groove) is formed in the inner wall of the region11A-3of the filling hose side plug body11where the inner diameter of the passage is small. An O-ring14constituting a second sealing means is fitted (or housed) in the recess11D. When the joint20on the filling hose side and the joint10on the filling device side are separated and the valve is closed (the state shown inFIG.3of the first embodiment), although the O-ring14and the outer circumference of the valve body12(small diameter portion12C) constitutes the second sealing means12S2-1, the second sealing means12S2-1is not formed inFIG.8showing the valve open state. The region11A-3having a small inner diameter of the flow passage11A is provided with a shutter16that slides on the inner wall surface of the region11A-3to open or close the recess11D. The shutter16is interlocked with the axial movement of the valve body12, and when the valve is opened (the state ofFIG.7of the first embodiment: the state where the joint20on the filling hose side and the joint10on the filling device side are connected), the shutter16closes (blocks) the recess11D, when the valve is closed (the state shown inFIG.3of the first embodiment), the shutter16opens the recess11D. InFIG.8, the reference numeral16(A) indicates the shutter16positioned to close the recess11D when the valve is opened. The reference numeral16(B) denotes the shutter16positioned to open the recess11D when the valve is closed. As a mechanism for moving the shutter16(for example, in conjunction with movement of the valve body12), a conventionally known mechanism can be adopted. InFIG.8, when the joints10and20on the filling device side and the filling hose side are connected (when the valve is open: the state ofFIG.7of the first embodiment), since the joint recess11D, for the O-ring14, in the region11A-3of the flow passage11A is closed by the shutter16at position16(A), the O-ring is fitted in the recess11D is protected. As a result, the O-ring14is prevented from falling off by the high-pressure, high-speed hydrogen gas flowing through the flow passage11A, and even if a foreign matter is mixed in the hydrogen gas, the O-ring14will not come into contact with the foreign matter and will not be damaged. On the other hand, when the joints10and20are separated (when the valve is closed: the state shown inFIG.3of the first embodiment), in conjunction with the valve body12moving to close the valve, the shutter16is moved to the position shown by16(B) to open the recessed part11D, and to expose the O-ring14. The exposed O-ring14cooperates with the outer peripheral surface of the small-diameter portion12C of the valve body12to serve as the second sealing means12S2-1and exhibit sealing performance at low pressure. Other configurations and effects of the second embodiment shown inFIG.8are the same as those of the first embodiment shown inFIGS.3to7. It should be noted that the illustrated embodiments are merely examples and are not intended to limit the technical scope of the present invention. DESCRIPTION OF THE REFERENCE NUMERALS 1,11plug bodies1A,11A flow passages1A-2,11A-2regions with large inner diameter1A-3,11A-3regions with small inner diameter1B,11B valve seats1C,11C valve accommodating portions1D,11D concave portions2,12valve bodies2A,12A large diameter portions of valve bodies2B,12B tapered portions of valve bodies2C,12C small diameter portions of valve bodies2D,12D tip rod-shaped regions2S1,12S1first sealing means2S2,12S2,2S2-1,12S2-1second sealing means3,13elastic members4,14O-rings15cover15A projection (guides or fins)15B outer peripheral portion of covers15C hollow portions of cover15C-1hollow portion with large inner diameter of cover15C-2hollow portion with small inner diameter of cover16shutter100,100-1safety joints | 32,074 |
11859748 | DESCRIPTION OF EMBODIMENTS Embodiments of the present invention are described hereunder. Note that, although embodiments of the present invention are described by way of examples in the following description, the present invention is not limited to the examples described hereunder. As the result of conducting intensive studies with a view to solving the problem described above, the present inventors focused their attention on utilizing a production facility for a long pipe capable of conducting an X-ray inspection of a girth weld zone of a long pipe as described in Patent Literature 2. Specifically, a welding apparatus included in the production facility for a long pipe is an apparatus whose original purpose is to be used for performing girth welding of end portions of a plurality of pipes to weld the end portions together to form a long pipe. The present inventors had the idea of diverting the welding apparatus for use also in the case of girth welding a joint to an end portion of a long pipe. Further, an X-ray inspection apparatus included in the production facility for a long pipe is an apparatus whose original purpose is to be used for inspecting a girth weld zone of a long pipe. The present inventors had the idea of diverting the X-ray inspection apparatus for use also in a case of inspecting a girth weld zone of a joint. By diverting the aforementioned apparatuses for use as described above, a joint can be girth welded to an end portion of a long pipe by the welding apparatus. In addition, prior to the entire length of the long pipe being wound around a reel of a winding apparatus, a girth weld zone of the joint formed by the girth welding can be inspected by the X-ray inspection apparatus. Thus, the present inventors conceived of enabling appropriate connection of a joint to an end portion of a long pipe by diverting the aforementioned apparatuses for use as described above, and thereby completed the present invention. A joint connection method for a long pipe according to one embodiment of the present invention is a method for connecting a first joint and a second joint to a front end portion and a rear end portion of a long pipe, respectively, by using a production facility that includes a conveyance system, a welding apparatus, a winding apparatus and an X-ray inspection apparatus. The conveyance system conveys a pipe in a longitudinal direction. The welding apparatus is disposed along the conveyance system. The welding apparatus performs girth welding to weld together end portions of a plurality of pipes conveyed by the conveyance system to thereby form a long pipe. The winding apparatus is disposed along the conveyance system. The winding apparatus winds the long pipe that is conveyed by the conveyance system around a reel. The X-ray inspection apparatus is disposed between the welding apparatus and the winding apparatus along the conveyance system. The X-ray inspection apparatus inspects a girth weld zone of the long pipe. The joint connection method includes a first joint girth welding step, a first girth weld zone inspection step, a second joint girth welding step and a second girth weld zone inspection step. In the first joint girth welding step, a first joint is girth welded to a front end portion of a long pipe by the welding apparatus. In the first girth weld zone inspection step, a girth weld zone of the first joint is inspected by the X-ray inspection apparatus. In the second joint girth welding step, a second joint is girth welded to a rear end portion of the long pipe by the welding apparatus. In the second girth weld zone inspection step, a girth weld zone of the second joint is inspected by the X-ray inspection apparatus. According to the joint connection method of the present embodiment, in the first joint girth welding step and the second joint girth welding step, the welding apparatus which the production facility for a long pipe includes is used to girth weld a first joint to a front end portion of a long pipe and to girth weld a second joint to a rear end portion of the long pipe. Therefore, before the entire length of the long pipe is wound around a reel of the winding apparatus, it is possible to form a girth weld zone of the first joint and a girth weld zone of the second joint under the same welding conditions as in the case of forming a girth weld zone of the long pipe. Further, in the first girth weld zone inspection step and the second girth weld zone inspection step, the X-ray inspection apparatus which the production facility for a long pipe includes is used to inspect a girth weld zone of the first joint and to inspect a girth weld zone of the second joint. Therefore, before the entire length of the long pipe is wound around the reel of the winding apparatus, the girth weld zone of the first joint and the girth weld zone of the second joint are inspected by the X-ray inspection apparatus, and it can be adequately confirmed whether or not appropriate girth weld zones are formed so that a water leakage does not occur. Thus, reliability is obtained with regard to the connections of the first joint and the second joint. As described above, according to the joint connection method of the present embodiment, a first joint and a second joint can be appropriately connected to a front end portion and a rear end portion of a long pipe, respectively. Note that, in the present description, the meaning of the following terms is as follows. The term “long pipe” means a jointed pipe in which end portions of two or more pipes are girth welded to each other. The term “girth weld zone of a long pipe” means a girth weld zone formed between end portions of a plurality of pipes for forming a long pipe. The term “girth weld zone of a first joint” means a girth weld zone formed between a front end portion of a long pipe and a first joint. The term “girth weld zone of a second joint” means a girth weld zone formed between a rear end portion of a long pipe and a second joint. The term “front end portion” means the end portion on the downstream side in the conveyance direction of a long pipe. The term “rear end portion” means the end portion on the upstream side in the conveyance direction of a long pipe. In the joint connection method of the present embodiment, it is preferable to include the following components. The conveyance system includes pinch rollers that pinch and guide a long pipe, at a position that is furthest on the downstream side in the conveyance direction of the long pipe. The joint connection method further includes an attachment attaching step, an attachment girth welding step, a cutting step and an attachment detaching step. In the attachment attaching step, an attachment is attached to a rear end portion of the second joint. In the attachment girth welding step, a front end portion of a different pipe is girth welded to a rear end portion of the attachment by the welding apparatus. In the cutting step, in a state in which the second joint is located in the vicinity of the winding apparatus, the rear end portion of the long pipe to which the second joint is girth welded is fixed to the winding apparatus, thereafter, a region of the aforementioned different pipe located between the winding apparatus and the pinch rollers is cut. In the attachment detaching step, the attachment is detached from the second joint. In this case, in the cutting step, the long pipe, the second joint, the attachment and the different pipe are interjacent between the winding apparatus and the pinch rollers. Further, the rear end portion of the long pipe in this state is fixed to the winding apparatus. In other words, the rear end portion of the long pipe is fixed to the winding apparatus in a state in which a tensile force is applied to the long pipe wound by the winding apparatus. Therefore, in the cutting step, even when the different pipe is cut, the tensile force of the long pipe wound by the winding apparatus is maintained and the long pipe does not slacken. Next, in the attachment detaching step, by detaching the attachment from the second joint, a region of the different pipe girth welded to the attachment is simultaneously detached from the second joint, and a state is entered in which only the second joint is connected to the rear end portion of the long pipe. It is therefore possible to easily carry out a hydraulic pressure test or the like. Note that, a pipe (dummy pipe) that will not be a product can be used as the aforementioned “different pipe”. However, another long pipe that follows the long pipe which is wound by the winding apparatus may also be used as the “different pipe”. In the joint connection method of the present embodiment, preferably the attachment is a universal joint. In this case, because the attachment is a universal joint, even if a position at which the long pipe is wound by the winding apparatus and a position at which the long pipe is pinched by the pinch rollers differ from each other in the vertical direction, it is difficult for excessive bending stress to arise at the second joint or the attachment. It is therefore possible to prevent damage to the second joint and the attachment. A production method according to one embodiment of the present invention is a method for producing coiled tubing with joints, the coiled tubing being composed of a long pipe which is wound around a reel, the joints being connected to both end portions of the pipe, respectively, by using a production facility. The aforementioned production facility includes a conveyance system, a welding apparatus, a winding apparatus and an X-ray inspection apparatus. The conveyance system conveys a pipe in a longitudinal direction. The welding apparatus is disposed along the conveyance system. The welding apparatus performs girth welding to weld together end portions of a plurality of pipes conveyed by the conveyance system to thereby form a long pipe. The winding apparatus is disposed along the conveyance system. The winding apparatus winds the long pipe that is conveyed by the conveyance system around a reel. The X-ray inspection apparatus is disposed between the welding apparatus and the winding apparatus along the conveyance system. The X-ray inspection apparatus inspects a girth weld zone of the long pipe. In addition, the conveyance system includes pinch rollers that pinch and guide the long pipe, at a position that is furthermost on the downstream side in the conveyance direction of the long pipe. The production method includes a first joint girth welding step, a first girth weld zone inspection step, a long pipe formation step, a second joint girth welding step, a second girth weld zone inspection step, an attachment attaching step, an attachment girth welding step, a cutting step and an attachment detaching step. In the first joint girth welding step, a first joint is girth welded by the welding apparatus to the front end portion of a pipe that is initially conveyed. In the first girth weld zone inspection step, a girth weld zone of the first joint is inspected by the X-ray inspection apparatus. In the long pipe formation step, a long pipe is formed by repeating steps of performing girth welding to weld together end portions of pipes that follow the pipe to which the first joint is girth welded by means of the welding apparatus, and inspecting girth weld zones of the end portions by means of the X-ray inspection apparatus. In the second joint girth welding step, a second joint is girth welded to a rear end portion of the long pipe by the welding apparatus. In the second girth weld zone inspection step, a girth weld zone of the second joint is inspected by the X-ray inspection apparatus. In the attachment attaching step, an attachment is attached to a rear end portion of the second joint. In the attachment girth welding step, a front end portion of a different pipe is girth welded to a rear end portion of the attachment by the welding apparatus. In the cutting step, in a state in which the second joint is located in the vicinity of a winding apparatus, the rear end portion of the long pipe to which the second joint is girth welded is fixed to the winding apparatus, thereafter, a region of the different pipe located between the winding apparatus and the pinch rollers is cut. In the attachment detaching step, the attachment is detached from the second joint. According to the production method of the present embodiment, coiled tubing with joints can be produced composed of a long pipe which is wound around a reel and to both end portions (a front end portion and a rear end portion) of which joints (a first joint and a second joint) are connected, respectively. Hereunder, a joint connection method for a long pipe (hereinafter, as appropriate, may also be referred to as simply “joint connection method”) according to one embodiment of the present invention is described with reference being made as appropriate to the attached drawings. First, a production facility for a long pipe that is used in the joint connection method according to the present embodiment is described. <Production Facility for Long Pipe> FIG.1is a plan view that schematically illustrates an outline configuration of a production facility for a long pipe that is used in the joint connection method according to the present embodiment. As illustrated inFIG.1, a production facility100in the present embodiment includes a conveyance system1, a welding apparatus2, a winding apparatus3and an X-ray inspection apparatus4. The production facility100according to the present embodiment also includes a control unit10that controls operations of the conveyance system1, the welding apparatus2, the winding apparatus3and the X-ray inspection apparatus4. In addition, the production facility100according to the present embodiment includes a carry-in stand20on which a plurality of pipes P are placed. In the production facility100in the present embodiment, the welding apparatus2and the X-ray inspection apparatus4are configured to be movable independently from each other along the conveyance system1. In other words, the welding apparatus2and the X-ray inspection apparatus4are configured to be movable independently from each other along the conveyance direction of the pipe P (longitudinal direction of the pipe P). Specifically, for example, driving devices (not illustrated) such as pneumatic cylinders are attached to the welding apparatus2and the X-ray inspection apparatus4, respectively. Wheels (not illustrated) are attached to a lower part of the welding apparatus2and the X-ray inspection apparatus4, respectively. Further, on the floor surface of the production facility100, a rail (not illustrated) is provided along the conveyance direction of the pipe P. The welding apparatus2and the X-ray inspection apparatus4are configured so that, by the respective driving devices been driven by the control unit10, the respective wheels of the welding apparatus2and the X-ray inspection apparatus4roll on the rail and thus the welding apparatus2and the X-ray inspection apparatus4can move independently from each other along the conveyance system1. Therefore, as described later, in a case where it is determined by the X-ray inspection apparatus4that a girth weld zone of a long pipe is defective, rewelding and reinspection can be performed without driving the conveyance system1and the winding apparatus3in the reverse direction (conveying the pipe P in the reverse direction). Further, for example, by adjusting the separation distance between the welding apparatus2and the X-ray inspection apparatus4in accordance with the length of the pipe P to be subjected to girth welding so as to set the separation distance to a distance that is approximately equal to the length of the pipe P, it is also possible to concurrently perform girth welding by the welding apparatus2and inspection of a girth weld zone by the X-ray inspection apparatus4. The pipe P in the present embodiment is, for example, a stainless pipe. In a case where a long pipe P1formed by performing girth welding of the pipe P by means of the welding apparatus2is to be used as an umbilical tube, the pipe P is preferably a duplex (two-phase) stainless steel tube. The pipe P may also be an electric-resistance welded pipe or may be a seamless tube. The conveyance system1is a system that is driven by the control unit10and conveys the pipe P along a straight line in the longitudinal direction thereof (X-direction illustrated inFIG.1). Specifically, in the present embodiment, a plurality of pipes P that are placed on the carry-in stand20are carried in sequentially in a direction orthogonal to the longitudinal direction of the pipe P toward the conveyance system1(Y-direction illustrated inFIG.1). The plurality of carried-in pipes P are conveyed in the longitudinal direction of the pipe P by the conveyance system1. Note that, the carry-in stand20is equipped with a predetermined carry-in mechanism (not illustrated), and a plurality of pipes P are carried in sequentially when the carry-in mechanism is driven by the control unit10. The conveyance system1in the present embodiment is equipped with side clamping rollers11and V-rollers12. The side clamping rollers11are disposed so as to pinch the pipe P in the horizontal direction, on the upstream side in the conveyance direction (X direction) of the pipe P relative to the welding apparatus2. By rotating a motor or the like as a driving source, the side clamping rollers11impart a driving force in the longitudinal direction of the pipe P. The V-rollers12are disposed below the pipe P (including the long pipe P1) in a region from a position at which the pipe P is carried in from the carry-in stand20to the position of the winding apparatus3. The V-rollers12support the pipe P from below, and rotate accompanying conveyance of the pipe P in the longitudinal direction. By means of the above configuration, a driving force in the longitudinal direction is imparted by the side clamping rollers11to the pipe P before the pipe P is subjected to girth welding by the welding apparatus2, and to the long pipe P1before the long pipe P1is wound around a reel31by the winding apparatus3. A driving force in the longitudinal direction is imparted by the winding apparatus3to the long pipe P1after the long pipe P is wound around the reel31by the winding apparatus3. By this means, the pipe P and the long pipe P1are each conveyed in the longitudinal direction thereof. The conveyance system1in the present embodiment is also equipped with pinch rollers13that pinch and guide the long pipe P1, at a position that is furthest on the downstream side in the conveyance direction of the long pipe P1. The pinch rollers13in the present embodiment are formed from an elastic body such as rubber, and are disposed so as to pinch the long pipe P in the vertical direction. Note that, although in the present embodiment a configuration that includes the side clamping rollers11that impart a driving force and the V-rollers12and the pinch rollers13that are only driven without imparting a driving force thereto is described as an example of the conveyance system1, the present embodiment is not limited to this configuration. For example, a configuration may be adopted in which a driving source such as a motor is connected to the pinch rollers13, so that, by causing the pinch rollers13to rotate, a driving force in the longitudinal direction can be imparted to the long pipe P after being pinched by the pinch rollers13. In this case, it is not necessary for the winding apparatus3to impart a driving force in the longitudinal direction to the long pipe P1, and it suffices to cause the winding apparatus3to rotate so as to maintain a tensile force between the pinch rollers13and the winding apparatus3. Further, it is possible to adopt various configurations as the conveyance system in the present embodiment as long as the configuration can convey the pipe P in the longitudinal direction, such as, for example, a configuration in which a pusher that pushes the pipe P from the upstream side toward the downstream side in the conveyance direction is adopted instead of the side clamping rollers11. The welding apparatus2is disposed along the conveyance system1. The welding apparatus2is an apparatus that is driven by the control unit10and performs girth welding to weld together end portions of a plurality of the pipes P that are conveyed by the conveyance system1to thereby form the long pipe P1. The welding apparatus2in the present embodiment includes a girth welding machine (circumferential welding machine)21, and a pair of gripping apparatuses22aand22bwhich are disposed along the conveyance direction of the pipe P (longitudinal direction of pipe P) in a manner that sandwiches the girth welding machine21. The welding apparatus2in the present embodiment also includes a cooling apparatus (not illustrated). For example, forced-air cooling can be mentioned as an example of the cooling method of the cooling apparatus. At a timing at which an end portion of each of the pipes P has reached the position at which the girth welding machine21is disposed, the control unit10stops operation of the conveyance system1and the winding apparatus3and drives the respective gripping apparatuses22aand22b. By this means, the respective gripping apparatuses22aand22bgrip an end portion of each pipe P. In other words, a front end portion Pf of the pipe P which is positioned on the upstream side in the conveyance direction is gripped by the gripping apparatus22awhich is disposed on the upstream side in the conveyance direction of the pipe P. A rear end portion P1rof the pipe P (the long pipe P1) which is positioned on the downstream side in the conveyance direction is gripped by the gripping apparatus22bwhich is disposed on the downstream side in the conveyance direction. Further, the respective gripping apparatuses22aand22badjust the positions of the respective pipes P so that the axial centerlines of the respective pipes P coincide with each other. Next, the control unit10drives the girth welding machine21, and the girth welding machine21performs girth welding to weld together end portions of the respective pipes P whose positions had been adjusted. Finally, the control unit10drives the cooling apparatus, and the cooling apparatus cools a girth weld zone PW thus formed. After cooling of the girth weld zone PW ends, the control unit10releases the grip of the respective gripping apparatuses22aand22b, and drives the conveyance system1and the winding apparatus3to convey the long pipe P1. The winding apparatus3is disposed along the conveyance system1, on the downstream side in the conveyance direction of the pipe P (the long pipe P1) relative to the welding apparatus2. The winding apparatus3is an apparatus that is driven by the control unit10to wind the long pipe P1which is conveyed by the conveyance system1around the reel31. Specifically, the winding apparatus3in the present embodiment includes a rotation mechanism (not illustrated) that causes the reel31to rotate around its own central axis, and a movement mechanism (not illustrated) that causes the reel31to move back and forth in the central axis direction (Y-direction). The winding apparatus3causes the reel31to rotate by means of the rotation mechanism and also causes the reel31to move by means of the movement mechanism, to thereby wind the long pipe P1on the outer surface of the reel31. The X-ray inspection apparatus4is disposed along the conveyance system1, between the welding apparatus2and the winding apparatus3. The X-ray inspection apparatus4is an apparatus that is driven by the control unit10, and inspects the girth weld zone PW of the long pipe P1. At a timing at which the girth weld zone PW of the long pipe P1formed by the welding apparatus2has reached the position at which X-ray inspection apparatus4is disposed (specifically, a position at which X-rays are emitted by an X-ray source that the X-ray inspection apparatus4includes), the control unit10stops operation of the conveyance system1and the winding apparatus3. By this means, the control unit10stops the long pipe P1. The control unit10then drives the X-ray inspection apparatus4. The X-ray inspection apparatus4includes an X-ray inspection apparatus main body41, and X-ray leakage suppressing mechanisms42that are mounted in the vicinity of opening portions on an entrance side and an exit side of the X-ray inspection apparatus main body41. The X-ray inspection apparatus main body41inspects the girth weld zone PW of the long pipe P1in a state in which the long pipe P1protrudes to the outside from the opening portions on the entrance side (upstream side in the conveyance direction of the long pipe P1) and exit side (downstream side in the conveyance direction of the long pipe P1) of the X-ray inspection apparatus main body41. The X-ray leakage suppressing mechanisms42suppress the leakage of X-rays to outside from the opening portions on the entrance side and exit side of the X-ray inspection apparatus main body41while the girth weld zone PW of the long pipe P1is being inspected by the X-ray inspection apparatus main body41. The X-ray inspection apparatus main body41includes a housing41a, a pair of sleeves41bwhich is provided on the entrance side and exit side of the housing41a, respectively, and communicate with the housing41a, and an X-ray inspection machine41cwhich is disposed inside the housing41a. The X-ray inspection apparatus main body41inspects the girth weld zone PW of the long pipe P1by means of the X-ray inspection machine41c, in a state in which the long pipe P1is inserted through the inside of the X-ray inspection machine41cdisposed inside the housing41a, and the respective sleeves41b. The X-ray inspection machine41cincludes a rotation mechanism portion (not illustrated), an X-ray source (not illustrated), an X-ray image detector (not illustrated) and an image processing apparatus (not illustrated). The X-ray source is attached to the rotation mechanism portion, and when the rotation mechanism portion rotates, the X-ray source rotates in the circumferential direction of the long pipe P1(that is, about the central axis of the long pipe P1). The X-ray image detector is disposed at a position that faces the X-ray source with the long pipe P1interposed therebetween, and is an apparatus which detects X-rays emitted from the X-ray source and transmitted through the long pipe P1, and forms an image based on the detected X-rays. The X-ray image detector is also attached to the rotation mechanism portion, and when the rotation mechanism portion rotates, the X-ray image detector rotates in the circumferential direction of the long pipe P1integrally with the X-ray source. During rotation of the rotation mechanism portion, the X-ray source and the X-ray image detector maintain a state in which the X-ray source and the X-ray image detector face each other with the long pipe P1interposed therebetween. The image processing apparatus is an apparatus that performs image processing on an X-ray image picked up by the X-ray image detector, and inspects a girth weld zone PW of the long pipe P1. By performing image processing on an X-ray image, the image processing apparatus, for example, extracts a picture element region in which the picture element density is large (bright) as a defect region. The image processing apparatus then evaluates the magnitude of the area of the extracted defect region, and determines whether the quality of the girth weld zone PW is good or poor. As mentioned above, the X-ray leakage suppressing mechanisms42are mounted in the vicinity of opening portions on the entrance side and exit side of the X-ray inspection apparatus main body41. Specifically, the X-ray leakage suppressing mechanisms42are mounted in the vicinity of approximately circular opening portions of the pair of sleeves41bwhich the X-ray inspection apparatus main body41includes. More specifically, among the pair of sleeves41b, with respect to the sleeve41bprovided on the upstream side in the conveyance direction of the long pipe P, one X-ray leakage suppressing mechanism42is mounted in the vicinity of the opening portion on the upstream side thereof, and with respect to the sleeve41bprovided on the downstream side in the conveyance direction of the long pipe P1, the other X-ray leakage suppressing mechanism42is mounted in the vicinity of the opening portion on the downstream side thereof. The respective X-ray leakage suppressing mechanisms42that are mounted on the entrance side and exit side of the X-ray inspection apparatus main body41have the same configuration. Each of the X-ray leakage suppressing mechanisms42includes a blocking member constituted by a plurality of members which are capable of opening and closing in the radial direction (radial direction of the long pipe P1). When the plurality of members included in the blocking member are at a closed position in the radial direction, an approximately circular opening portion which the long pipe P1is inserted through is formed on the inner side thereof. When a girth weld zone PW of the long pipe P1is to be inspected by the X-ray inspection apparatus main body41(that is, when X-rays are to be emitted from the X-ray source), the control unit10drives the X-ray leakage suppressing mechanisms42so that the plurality of members constituting the respective blocking members move to the closed position in the radial direction. Therefore, after the plurality of members arrive at the closed position in the radial direction, if a girth weld zone PW of the long pipe P1is inspected by the X-ray inspection apparatus main body41, it is possible to suppress the leakage of X-rays to the outside from the opening portions of the X-ray inspection apparatus main body41(opening portions of the sleeves41b). On the other hand, when inspection of the girth weld zone PW of the long pipe P1by the X-ray inspection apparatus main body41ends (that is, irradiation of X-rays from the X-ray source stops) and the long pipe P1is to be conveyed by the conveyance system1, the control unit10drives the X-ray leakage suppressing mechanisms42. By this means, the plurality of members constituting the blocking members move to an open position in the radial direction. When the plurality of members are at the open position in the radial direction, the respective blocking members are at a position at which the blocking members do not interfere with the girth weld zone PW of the long pipe P1. Therefore, after the X-ray inspection by the X-ray inspection apparatus main body41ends, even if the long pipe P1is conveyed, there is no risk of the girth weld zone PW of the long pipe P1being interfered with by the blocking members, and conveyance of the long pipe P1is not hindered. Note that, in the present embodiment, in order to suppress the leakage of X-rays even more, as illustrated inFIG.1, a pair of X-ray leakage suppressing mechanisms42A having the same configuration as the X-ray leakage suppressing mechanisms42are mounted inside the housing41a. In a case where a girth weld zone PW of the long pipe P is inspected by the X-ray inspection apparatus4described above and it is determined that the girth weld zone PW is normal, the control unit10drives the conveyance system1and the winding apparatus3. By this means, the long pipe P1is conveyed and is wound around the reel31. On the other hand, in a case where it is determined by the X-ray inspection apparatus4that the girth weld zone PW of the long pipe P is defective, the procedures shown in the following (a) to (c) are executed. At such time, as described above, because the welding apparatus2and the X-ray inspection apparatus4are capable of moving independently from each other along the conveyance system1, the control unit10causes the welding apparatus2and the X-ray inspection apparatus4to appropriately move in the conveyance direction of the long pipe P. By this means, it is possible to execute the procedures shown in the following (a) to (c) without conveying the long pipe P1in the reverse direction. However, where appropriate, it is also possible to execute them after conveying the long pipe P1in the reverse direction.(a) Cut off and remove the girth weld zone determined as being defective.(b) Perform girth welding at the cutting location again.(c) Inspect the girth weld zone at which the long pipe is re-formed. Note that, with regard to a more specific configuration of the X-ray inspection apparatus4which the production facility100in the present embodiment includes, it is possible to adopt the same contents as in the production facility disclosed in Patent Literature 2. In addition, with regard to movement procedures and the like with respect to the welding apparatus2and the X-ray inspection apparatus4when it is determined by the X-ray inspection apparatus4that the girth weld zone PW of the long pipe P1is defective also, it is possible to adopt the same contents as in the production facility disclosed in Patent Literature 2. Therefore, a more specific description of the configuration and such procedures and the like is omitted here. However, a production facility for a long pipe that can apply the joint connection method according to the present embodiment described hereunder is not limited to the production facility described in Patent Literature 2, and it suffices that the conveyance system1, the welding apparatus2, the X-ray inspection apparatus4and the winding apparatus3are disposed in that order toward the downstream side in the conveyance direction of the long pipe P1. The production facility may also be a system in which the welding apparatus2and the X-ray inspection apparatus4are not configured to be movable independently from each other along the conveyance system1. <Joint Connection Method> Hereunder, the joint connection method according to the present embodiment that uses the aforementioned production facility100is described. FIG.2is a flowchart illustrating an outline of procedures of the joint connection method according to the present embodiment. The joint connection method according to the present embodiment is a method that connects a first joint and a second joint for subjecting the long pipe P1to a hydraulic pressure test or the like to the front end portion and the rear end portion of the long pipe P, respectively, using the production facility100. As illustrated inFIG.2, the joint connection method according to the present embodiment includes a joint girth welding step S1, a girth weld zone inspection step S2, an attachment attaching step S3, an attachment girth welding step S4, a cutting step S5and an attachment detaching step S6. The joint girth welding step S1includes a first joint girth welding step S1of girth welding a first joint to the front end portion of the long pipe P1, and a second joint girth welding step S12of girth welding a second joint to the rear end portion of the long pipe P1. The girth weld zone inspection step S2includes a first joint girth weld zone inspection step S21of inspecting a girth weld zone of the first joint, and a second joint girth weld zone inspection step S22of inspecting a girth weld zone of the second joint. Hereunder, each of these steps will be described in turn. [First Joint Girth Welding Step S11(Joint Girth Welding Step S1)] FIG.3AtoFIG.3Care views that schematically illustrate the first joint girth welding step S11and the first joint girth weld zone inspection step S21.FIG.3Ais a plan view illustrating a state in the first joint girth welding step S11.FIG.3Bis a plan view illustrating a state in the first joint girth weld zone inspection step S21.FIG.3Cis a view illustrating a state when a first joint5girth welded to a front end portion P1fof the long pipe P1is fixed to the reel31. InFIG.3C, aside view as seen from a horizontal direction orthogonal to the conveyance direction (X direction) of the long pipe P1is shown. Note that, inFIG.3AtoFIG.3C, constituent elements that are the same as constituent elements of the production facility100illustrated inFIG.1are denoted by the same reference characters as inFIG.1. This similarly applies with respect toFIG.4AtoFIG.4DandFIG.5AtoFIG.5Cto be described later. In the first joint girth welding step S11, as illustrated inFIG.3A, the first joint5is girth welded to the front end portion P1fof the long pipe P1by the welding apparatus2. Specifically, the control unit10(seeFIG.1) stops operation of the conveyance system1(seeFIG.1) at a timing at which the front end portion P1fof the long pipe P1(or the pipe P prior to being girth welded as illustrated inFIG.1) reaches the position at which the girth welding machine21included in the welding apparatus2is disposed. The long pipe P1in this case is, basically, the pipe P that is initially conveyed. The control unit10then drives the welding apparatus2according to the same procedures as in the case of performing girth welding (forming a girth weld zone PW (seeFIG.1)) to weld together end portions of the plurality of pipes P (seeFIG.1) described above. By this means, the front end portion P1fof the long pipe P1and a rear end portion5rof the first joint5are girth welded, and a girth weld zone W1is formed at the front end portion P1fof the long pipe P1(the rear end portion5rof the first joint5). More specifically, when performing girth welding of the first joint5to the long pipe P1, the gripping apparatus22adisposed on the upstream side in the conveyance direction grips the front end portion P1fof the long pipe P1. On the other hand, the first joint5is set in the gripping apparatus22bdisposed on the downstream side in the conveyance direction, and the gripping apparatus22bgrips the rear end portion5rof the first joint5. The respective gripping apparatuses22aand22badjust the position of the front end portion P1fof the long pipe P and the position of the rear end portion5rof the first joint5to cause the axial centerlines thereof to coincide with each other. The front end portion P1fof the long pipe P1and the rear end portion5rof the first joint5are then girth welded to each by the girth welding machine21. Note that, the rear end portion5r(end portion on the right side inFIG.3A) of the first joint5is preferably formed of a material of the same type and which has the same diameter as the long pipe P1. By this means, it is possible to easily form the girth weld zone W1under the same welding conditions as the case of forming the girth weld zone PW of the long pipe P1. The front end portion (end portion on the left side inFIG.3A) of the first joint5has, for example, a known structure that, when performing a hydraulic pressure test on the long pipe P1, can be connected (screwed) to a pipe (not illustrated) that supplies water for the hydraulic pressure test, and can maintain sealing performance even under high pressure. For example, the first joint5is a threaded connection connectable to a pipe for use in a hydraulic pressure test. [First Joint Girth Weld Zone Inspection Step S21(Girth Weld Zone Inspection Step S2)] In the first joint girth weld zone inspection step S21, as illustrated inFIG.3B, the girth weld zone W1of the first joint5is inspected by the X-ray inspection apparatus4. Specifically, the control unit10(seeFIG.1) stops operation of the conveyance system1(seeFIG.1) at a timing at which the girth weld zone W1of the first joint5has arrived at the position at which the X-ray inspection apparatus4is disposed (specifically, the position at which X-rays are emitted by the X-ray source of the X-ray inspection apparatus4). By this means, the long pipe P1is stopped. The control unit10then drives the X-ray inspection apparatus4according to the same procedures as in the case of inspecting the girth weld zone PW (seeFIG.1) described above. By this means, the girth weld zone W1of the first joint5is inspected. In a case where the girth weld zone W1is inspected and it is determined that the girth weld zone W1is normal, as illustrated inFIG.3C, the control unit10(seeFIG.1) drives the conveyance system1(seeFIG.1). By this means, the long pipe P1is conveyed, and is conveyed to the reel31. The first joint5is then fixed to a predetermined location of the winding apparatus3(for example, the outer surface of a frame of the reel31) using a predetermined fixing tool (not illustrated). Thereafter, the long pipe P1is wound around the reel31. On the other hand, in a case where it is determined that the girth weld zone W1is defective, similarly to the case of the aforementioned girth weld zone PW, the girth weld zone W1determined as being defective is cutoff and removed. In this case, it suffices to perform girth welding again at the cut-off location, and to inspect the girth weld zone W formed once more. In this case, as necessary, the control unit10may cause the welding apparatus2and the X-ray inspection apparatus4to move in the conveyance direction of the long pipe P1. After the first joint girth welding step S11and the first joint girth weld zone inspection step S21, girth welding is performed to weld end portions of the respective pipes P that follow the long pipe P1to which the first joint5is girth welded. The girth welding in this case is performed according to the same procedures as in the case of performing girth welding to weld together the end portions of the plurality of pipes P (seeFIG.1) described above. In addition, each time end portions are girth welded together, the girth weld zone at which the end portions are welded to each other is inspected. The inspection in this case is performed according to the same procedures as in the case of inspecting the girth weld zone PW (seeFIG.1) described above. The long pipe P1having a predetermined length is formed by repeating these steps of girth welding and inspection. [Second Joint Girth Welding Step S12(Joint Girth Welding Step S1)] FIG.4AtoFIG.4Dare views that schematically illustrate the second joint girth welding step S12, the second joint girth weld zone inspection step S22, the attachment attaching step S3and the attachment girth welding step S4.FIG.4Ais a view that illustrates a state in the second joint girth welding step S12.FIG.4Bis a view that illustrates a state in the second joint girth weld zone inspection step S22.FIG.4Cis a view that illustrates a state in the attachment attaching step S3.FIG.4Dis a view that illustrates a state in the attachment girth welding step S4. The views shown inFIG.4AtoFIG.4Dare each a plan view. In the second joint girth welding step S12, as illustrated inFIG.4A, a second joint6is girth welded to the rear end portion P1rof the long pipe P by the welding apparatus2. Specifically, the control unit10(seeFIG.1) stops operation of the conveyance system1(seeFIG.1) and the winding apparatus3at a timing at which the rear end portion P1rof the long pipe P1has arrived at the position at which the girth welding machine21included in the welding apparatus2is disposed. The control unit10then drives the welding apparatus2according to the same procedures as in the case of performing girth welding (forming the girth weld zone PW (seeFIG.1)) to weld together end portions of the plurality of pipes P (seeFIG.1) described above. By this means, the rear end portion P1rof the long pipe P1and a front end portion6fof the second joint6are girth welded to each other, and a girth weld zone W2is formed at the rear end portion P1rof the long pipe P1(the front end portion6fof the second joint6). More specifically, when performing girth welding of the second joint6to the long pipe P1, the gripping apparatus22bdisposed on the downstream side in the conveyance direction grips the rear end portion P1rof the long pipe P1. On the other hand, the second joint6is set in the gripping apparatus22adisposed on the upstream side in the conveyance direction, and the gripping apparatus22agrips the front end portion6fof the second joint6. The respective gripping apparatuses22aand22badjust the position of the rear end portion P1rof the long pipe P1and the position of the front end portion6fof the second joint6to cause the axial centerlines thereof to coincide with each other. The rear end portion P1rof the long pipe P and the front end portion6fof the second joint6are then girth welded together by the girth welding machine21. Note that, the front end portion6f(end portion on the left side inFIG.4A) of the second joint6is preferably formed of a material of the same type and which has the same diameter as the long pipe P1. By this means, it is possible to easily form the girth weld zone W2under the same welding conditions as in the case of forming the girth weld zone PW of the long pipe P1. The rear end portion (end portion on the right side inFIG.4A) of the second joint6has, for example, a known structure that, when performing a hydraulic pressure test on the long pipe P1, can be connected (screwed) to a pipe (not illustrated) that discharges water and air used for the hydraulic pressure test, and can maintain sealing performance even under high pressure. For example, the second joint6is a threaded connection connectable to a pipe for use in a hydraulic pressure test. [Second Joint Girth Weld Zone Inspection Step S22(Girth Weld Zone Inspection Step S2)] In the second joint girth weld zone inspection step S22, as illustrated inFIG.4B, the girth weld zone W2of the second joint6is inspected by the X-ray inspection apparatus4. Specifically, the control unit10(seeFIG.1) stops operation of the conveyance system1(seeFIG.1) and the winding apparatus3at a timing at which the girth weld zone W2of the second joint6has arrived at the position at which the X-ray inspection apparatus4is disposed (specifically, the position at which X-rays are emitted by the X-ray source of the X-ray inspection apparatus4). By this means, the long pipe P1is stopped. The control unit10then drives the X-ray inspection apparatus4according to the same procedures as in the case of inspecting the girth weld zone PW (seeFIG.1) described above. By this means, the girth weld zone W2of the second joint6is inspected. In a case where the girth weld zone W2is inspected and it is determined that the girth weld zone W2is normal, the attachment attaching step S3(seeFIG.2) is executed. On the other hand, in a case where it is determined that the girth weld zone W2is defective, similarly to the case of the aforementioned girth weld zone PW, the girth weld zone W2determined as being defective is cut off and removed. In this case, it suffices to perform girth welding again at the cut-off location, and to inspect the girth weld zone W2formed once more. In this case, as necessary, the control unit10may cause the welding apparatus2and the X-ray inspection apparatus4to move in the conveyance direction of the long pipe P1. [Attachment Attaching Step S3] In the attachment attaching step S3, as illustrated inFIG.4C, an attachment7is attached to a rear end portion6rof the second joint6. Attachment of the attachment7may be performed, for example, by causing the welding apparatus2and the X-ray inspection apparatus4to move to the upstream side in the conveyance direction of the long pipe P1by means of the control unit10, and thereafter performing manual attachment of the attachment7at the position which the X-ray inspection apparatus4is at prior to moving. Although a specific configuration example of the attachment7is described later, for example, an internal thread part is formed at a front end portion7f(end portion on the left side inFIG.4C) of the attachment7, and the attachment7is attached to the rear end portion6rof the second joint6by screwing together the internal thread part and an external thread part formed at the rear end portion6rof the second joint6. In other words, the attachment7is detachably attached by means of a threaded connection structure to the second joint6. [Attachment Girth Welding Step S4] In the attachment girth welding step S4, as illustrated inFIG.4D, a front end portion Pdf of a dummy pipe (a pipe that will not be a product) Pd is girth welded to a rear end portion7r(end portion on the right side inFIG.4D) of the attachment7by the welding apparatus2. Specifically, for example, the control unit10(seeFIG.1) causes the welding apparatus2to move until the rear end portion7rof the attachment7arrives at the position at which the girth welding machine21included in the welding apparatus2is disposed. Thereafter, the control unit10drives the welding apparatus2according to the same procedures as in the case of forming the girth weld zone PW (seeFIG.1) described above. By this means, the dummy pipe Pd is girth welded to the rear end portion7rof the attachment7, and a girth weld zone W3is formed at the rear end portion7rof the attachment7(the front end portion Pdf of the dummy pipe Pd). More specifically, when performing girth welding of the dummy pipe Pd to the attachment7, the gripping apparatus22bdisposed on the downstream side in the conveyance direction grips the rear end portion7rof the attachment7. On the other hand, the dummy pipe Pd is set in the gripping apparatus22adisposed on the upstream side in the conveyance direction, and the gripping apparatus22agrips the front end portion Pdf of the dummy pipe Pd. The respective gripping apparatuses22aand22badjust the position of the rear end portion7rof the attachment7and the position of the front end portion Pdf of the dummy pipe Pd to cause the axial centerlines thereof to coincide with each other. The rear end portion7rof the attachment7and the front end portion Pdf of the dummy pipe Pd are then girth welded to each other by the girth welding machine21. Note that, a pipe formed of a material of the same type and which has the same diameter as the long pipe P1is preferably used as the dummy pipe Pd. Further, the rear end portion7rof the attachment7is preferably formed of a material of the same type and which has the same diameter as the long pipe P1. By this means, it is possible to easily form the girth weld zone W3under the same welding conditions as in the case of forming the girth weld zone PW of the long pipe P1. Note that, in order to confirm that the soundness of the weld, it is desirable to conduct an inspection by means of the X-ray inspection apparatus4with respect to the girth weld zone W3also. However, because the attachment7is not used when conducting a hydraulic pressure test or the like on the long pipe P1, inspection by means of the X-ray inspection apparatus4need not be performed, and an inspection by visual observation or the like may be performed instead. [Cutting Step S5] FIG.5AtoFIG.5Care views that schematically illustrate the cutting step S5and the attachment detaching step S6.FIG.5Ais a view illustrating a state in an early stage of the cutting step S5.FIG.5Bis a view illustrating a state in the final stage of the cutting step S5.FIG.5Cis a view illustrating a state in the attachment detaching step S6. In each ofFIG.5AtoFIG.5C, a side view as seen from a horizontal direction orthogonal to the conveyance direction (X direction) of the long pipe P1is shown. In the cutting step S5, as illustrated inFIG.5A, a state is entered in which the second joint6is positioned in the vicinity of the winding apparatus3. Specifically, the control unit10(seeFIG.1) stops operation of the conveyance system1(seeFIG.1) and the winding apparatus3at a timing at which the second joint6(the rear end portion P1rof the long pipe P1) has reached a position in the vicinity of the reel31included in the winding apparatus3. Next, as illustrated inFIG.5B, the rear end portion P1rof the long pipe P1to which the second joint6is girth welded is fixed to the winding apparatus3(frame of the reel31) using a predetermined fixing tool8. Thereafter, a region of the dummy pipe Pd that is a region located between the winding apparatus3and the pinch rollers13is cut. For example, a tool having a configuration in which one end is attached (fastened by bolts) to the winding apparatus3, and the other end pinches the rear end portion P1rof the long pipe P1can be used as the fixing tool8. Cutting of the dummy pipe Pd can be performed, for example, manually by a worker using a portable cutting machine. Note that, as illustrated inFIG.5AandFIG.5B, the dummy pipe Pd has at least a length such that, when the second joint6reaches a position in the vicinity of the winding apparatus3(the reel31), the dummy pipe Pd can be pinched by the pinch rollers13in a state in which the dummy pipe Pd is girth welded to the rear end portion7rof the attachment7. [Attachment Detaching Step S6] In the attachment detaching step S6, as illustrated inFIG.5C, the attachment7is detached from the second joint6. It suffices to perform detachment of the attachment7by manually releasing the screwed connection between the internal thread part formed at the front end portion7fof the attachment7and the external thread part formed at the rear end portion6rof the second joint6. At such time, a part Pda of the dummy pipe Pd girth welded to the rear end portion7rof the attachment7will also be detached together with the attachment7. Note that, in the case of reusing the attachment7, although the attachment7may be used after removing the part Pda of the dummy pipe Pd girth welded thereto, it is also possible to use the attachment7in a condition in which the part Pda of the dummy pipe Pd is not removed and remains girth welded thereto. In other words, it is also possible to use the remaining part Pda of the dummy pipe Pd as the rear end portion7rof the attachment7. In this way coiled tubing with joints can be produced in which the coiled tubing is composed of the long pipe P1which is would around the reel31and to both end portions (the front end portion P1fand the rear end portion P1r) of which joints (the first joint5and the second joint6) are connected, respectively. FIG.6AandFIG.6Bare views that illustrate a specific configuration example of the attachment7in the present embodiment.FIG.6Ais a view that illustrates a state in which one member (a third member73) among the members constituting the attachment7has been detached.FIG.6Bis a view that illustrates a state in which the attachment7is attached to the rear end portion of the second joint6. As illustrated inFIG.6AandFIG.6B, the attachment7includes a first member71that is substantially circular in cross section, a second member72that is substantially circular in cross section, a third member73that is substantially circular in cross section, and a shaft member74constituted by a bolt or a nut. The respective cross-sectional shapes of the first member71and the second member72are not particularly limited, and may be substantially rectangular. The first member71and the second member72are connected in a manner in which the first member71and the second member72are capable of turning about a central axis C of the shaft member74. In other words, the attachment7is a universal joint (single-shaft universal joint) in which the first member71and the second member72are capable of freely turning about the central axis C. A rear end portion73r(end portion on the right side inFIG.6AandFIG.6B) of the third member73is preferably formed of a material of the same type and which has the same diameter as the dummy pipe Pd. An internal thread part721is formed at a rear end portion72r(end portion on the right side inFIG.6AandFIG.6B) of the second member72. An external thread part is formed at a front end portion73f(end portion on the left side inFIG.6AandFIG.6B) of the third member73. As illustrated inFIG.6B, the attachment7is assembled by manually screwing together the aforementioned external thread part and the internal thread part721. In other words, the third member73is detachably attached to the second member72by means of a threaded connection. Similarly, an internal thread part711is formed at a front end portion71f(end portion on the left side inFIG.6AandFIG.6B) of the first member71. An external thread part is formed at the rear end portion6rof the second joint6. As illustrated inFIG.6B, the attachment7is attached to the rear end portion6rof the second joint6by manually screwing together the aforementioned external thread part and the internal thread part711. In other words, the attachment7is detachably attached to the second joint6by means of a threaded connection. According to the joint connection method of the present embodiment described above, before the entire length of the long pipe P1is wound around the reel31of the winding apparatus3, it is possible to form the girth weld zone W1of the first joint5and the girth weld zone W2of the second joint6by means of the welding apparatus2under the same welding conditions as in the case of forming the girth weld zone PW of the long pipe P1. Further, before the entire length of the long pipe P1is wound around the reel31of the winding apparatus3, the girth weld zone W1of the first joint5and the girth weld zone W2of the second joint6are inspected by the X-ray inspection apparatus4, and it can be adequately confirmed whether or not the girth weld zones W1and W2are formed in an appropriate manner so that a water leakage does not occur. Therefore, reliability is obtained with regard to the connections of the first joint5and the second joint6. Thus, according to the joint connection method of the present embodiment, the first joint5and the second joint6can be appropriately connected to the front end portion P1fand the rear end portion P1rof the long pipe P1, respectively. Further, according to the joint connection method of the present embodiment, in the cutting step S5, as illustrated inFIG.5B, the long pipe P1, the second joint6, the attachment7and the dummy pipe Pd are interjacent between the winding apparatus3and the pinch rollers13. In this state, the rear end portion P1rof the long pipe P1to which the second joint6has been girth welded is fixed to the winding apparatus3using the fixing tool8. In other words, in a state in which a tensile force is applied to the long pipe P1wound by the winding apparatus3, the rear end portion P1rof the long pipe P is fixed to the winding apparatus3. Therefore, in the cutting step S5, even when the dummy pipe Pd is cut, the tensile force of the long pipe P1wound by the winding apparatus3is maintained and the long pipe P1does not slacken. In other words, a state in which the long pipe P1is tightly wound can be maintained, and the winding state does not become undone. Subsequently, in the attachment detaching step S6, as illustrated inFIG.5C, by detaching the attachment7from the second joint6, a state is entered in which only the second joint6is connected to the rear end portion P1rof the long pipe P1. Therefore, it is possible to easily conduct a hydraulic pressure test or the like. In addition, according to the joint connection method of the present embodiment, the attachment7is a universal joint. Therefore, as illustrated inFIG.5B, even if the position at which the long pipe P is wound by the winding apparatus3and the position at which the dummy pipe Pd is pinched by the pinch rollers13differ from each other in the vertical direction, it is difficult for excessive bending stress to arise at the second joint6or the attachment7. It is therefore possible to prevent damage to the second joint6and the attachment7. Note that, in the present embodiment, although the second joint girth welding step S12, the second joint girth weld zone inspection step S22, the attachment attaching step S3and the attachment girth welding step S4are executed in this order, the present embodiment is not limited thereto. For example, it is possible to execute the attachment attaching step S3, and thereafter execute the second joint girth welding step S12. In this case, in the second joint girth welding step S12, by girth welding the second joint6to the rear end portion P1rof the long pipe P1by means of the welding apparatus2, the second joint6and the attachment7will be connected at the same time to the rear end portion P1rof the long pipe P1. Further, in this case, after the second joint girth welding step S12, either step among the second joint girth weld zone inspection step S22and the attachment girth welding step S4may be executed first. However, in a case where it is determined as a result of executing the second joint girth weld zone inspection step S22that the girth weld zone W2is defective, it is necessary to perform an operation such as cutting off the girth weld zone W2. Therefore, when taking into account the ease of performing operations, it is preferable to execute the second joint girth weld zone inspection step S22prior to execution of the attachment girth welding step S4. Note that, a pipe to be used as a pipe to be girth welded to the rear end portion P1rof the attachment7is not limited to the dummy pipe Pd, and it is also possible to use another long pipe (a long pipe that will be a product) P1which follows the long pipe P1which is wound by the winding apparatus3. In a case where another long pipe P1which follows the long pipe P which is wound by the winding apparatus3is used as the pipe to be girth welded to the rear end portion P1rof the attachment7, and not the dummy pipe Pd that is used in the present embodiment, the joint connection method according to the present embodiment is executed in order from the first joint girth welding step S11with respect to the aforementioned following other long pipe P1also. When the attachment detaching step S6is executed with respect to the long pipe P wound by the winding apparatus3, the following other long pipe P1is in a state in which it is pinched by the pinch rollers13. Therefore, when executing the first joint girth welding step S11with respect to the following other long pipe P1, it suffices to convey the following other long pipe P1in the reverse direction until the front end portion P1fof the following other long pipe P1reaches the position at which the girth welding machine21is disposed. Furthermore, according to the production method of the present embodiment, by utilizing the joint connection method of the present embodiment, coiled tubing with joints can be produced in which the coiled tubing is composed of the long pipe P1which is wound around the reel31and to both end portions (the front end portion P1fand the rear end portion P1r) of which joints (the first joint5and the second joint6) are connected, respectively. REFERENCE SIGNS LIST 1Conveyance System2Welding Apparatus3Winding Apparatus4X-ray Inspection Apparatus5First Joint6Second Joint7Attachment8Fixing Tool10Control Unit31Reel100Production facility for a Long PipeP PipeP1Long PipePd Different Pipe (Dummy Pipe)PW, W1, W2, W3Girth Weld Zone | 62,962 |
11859749 | DETAILED DESCRIPTION The use herein of the term “axial” and variations thereof refers to a direction that extends generally along an axis of symmetry, a central axis, or an elongate direction of a particular component or system. For example, an axially-extending structure of a component may extend generally along a direction that is parallel to an axis of symmetry or an elongate direction of that component. Similarly, the use herein of the term “radial” and variations thereof refers to directions that are generally perpendicular to a corresponding axial direction. For example, a radially extending structure of a component may generally extend at least partly along a direction that is perpendicular to a longitudinal or central axis of that component. The use herein of the term “circumferential” and variations thereof refers to a direction that extends generally around a circumference or periphery of an object, around an axis of symmetry, around a central axis, or around an elongate direction of a particular component or system. Conventional grommet systems typically connect to a routing element (e.g., a conduit, a boot, or any other component that may receive one or more components therein) and include a fastener that is designed such that the routing element is required to be stretched over the fastener prior to assembly to a structure (e.g., a panel, or another structure having an opening through which the grommet system may facilitate passage of the routing element and the components received within the routing element). The process of stretching the routing element over the fastener in conventional grommet systems is burdensome from a manufacturing perspective and requires increased time and cost for manufacturers. In general, conventional grommet systems may include a seal to facilitate forming a sealed passageway through a structure (e.g., an opening in a panel) for the routing element and the components received therein. With the routing element being stretched over the fastener, convention grommet systems require substantial compressive force during installation to compress the seal prior to engaging the fastener. In addition, conventional grommet systems fail to provide an indication that the seal has been completely compressed and that the fasteners is completely installed/locked. The present disclosure overcomes these deficiencies by providing a grommet assembly that is easily installed through a structure and forms a sealed passageway for a routing element via a simplified installation process that requires less force, when compared with conventional grommet systems. For example, a grommet system according to the present disclosure may include a primary seal and a secondary seal that combine to provide a sealed passageway through the structure and the routing element. In some embodiments, the grommet system may include a grommet and a lock ring that is configured to couple to the grommet. The lock ring may be coupled to the grommet, for example, via an input displacement (e.g., rotation) being applied to the lock ring, which, in turn, fastens the lock ring to the grommet and compresses the routing element between the grommet and the lock ring to form the secondary seal. In some embodiments, the grommet and/or the lock ring may include an indicator that is configured to provide a haptic, visual, and/or audible indication that the lock ring is completely fastened to the grommet, which also indicates that the secondary seal is formed. FIG.1illustrates a sealed pass-through grommet system10according to one aspect of the present disclosure. In the illustrated embodiment, the grommet system10includes a pair of grommet assemblies12arranged on opposing ends of a conduit14. Each of the grommet assemblies12provides a sealed passageway through a panel16and the conduit14, which enables, for example, wiring components to be routed through the panels16, the conduit14, and the grommet assemblies12. Each of the grommet assemblies12includes the same components, therefore, one of the grommet assemblies12will be described with reference to the following figures. The grommet assembly12includes a grommet18and a lock ring20configured to be selectively fastened to the grommet18. As illustrated inFIGS.2-6, the grommet18includes a platform22, a panel portion24extending from a first surface26of the platform22, and a ring portion28extending from a second surface30of the platform22. In the illustrated embodiment, the panel portion24and the ring portion28extend from the platform22in opposing directions (e.g., axially away from one another). The panel portion24extends axially away from the first surface26(seeFIG.6) and defines a generally oval shape. The panel portion24is generally hollow and includes a pair of panel retention features32arranged on laterally-opposing ends (e.g., a left end and a right end from the perspective ofFIG.3) of the panel portion24. In general, the panel retention features32are configured to selectively engage an opening34in the panel16(seeFIG.12) and retain the grommet18within the opening34. In the illustrated embodiment, the panel retention features32include a pair of retention arms36. The retention arms36are arranged within a cutout38that extends partially around a periphery of each of the retention arms36. For example, one edge of each of the retention arms36is formed integrally with, or attached to, the panel portion24and the remaining edges are free-floating (e.g., not in contact) with respect to the panel portion24due to the cutout38. In this way, for example, the retention arms36may flex laterally with respect to the panel portion24(e.g., toward and away from one another, or left to right from the perspective ofFIG.3). In the illustrated embodiment, each of the retention arms36includes a ramped surface40that, when the panel portion24is inserted into the opening34of the panel16, is configured to engage the edge of the opening34to retain the grommet18within the opening34and prevent the grommet18from displacing axially relative to the opening34. The ring portion28extends axially away from the second surface30(e.g., a top surface from the perspective ofFIG.2) and defines a generally annular shape. The ring portion28defines a passageway42that extends axially through the grommet18along a center axis44. The passageway42enables components (e.g., wires, wire bundles, cables, connectors, etc.) to be inserted through the grommet18. The ring portion28includes an outer surface46having a plurality of grommet clamping features48arranged around the outer surface46. For example, in the illustrated embodiment, the ring portion28includes four grommet clamping features48arranged circumferentially around the outer surface46in equally-spaced increments. In some embodiments, the ring portion28may include more or less than four grommet clamping features48spaced circumferentially around the outer surface46in any increment. In the illustrated embodiment, each of the grommet clamping features48defines a generally helical protrusion50that extends radially outwardly from the outer surface46and is angled helically relative to the center axis44. That is, each of the grommet clamping features48defines a helical path as it extends circumferentially along the outer surface46. The second surface30of the platform22includes one or more ring retention features52. In the illustrated embodiment, the second surface30of the platform22includes a pair of ring retention features52arranged on laterally-opposing sides of the second surface30. In the illustrated embodiment, the ring retention features52each define a ramped tab54that protrudes axially away from the first surface26. The ramped tabs54are rotationally offset from a centerline56that extends longitudinally through a center of the grommet18(seeFIG.5). For example, one of the ramped tabs54is arranged on one side of the centerline56and another of the ramped tabs54is arranged on an opposing side of the centerline56. In some embodiments, the grommet18may include more or less than two ramped tabs54that are arranged at any location along the second surface30. Turning toFIGS.6and7, the grommet18includes a primary seal58that defines a generally oval shape. AlthoughFIGS.2-5do not illustrates the primary seal58on the grommet18, the primary seal58may be overmolded onto the grommet18. Specifically, as illustrated inFIGS.6and7, once the primary seal58is overmolded to the grommet18, the primary seal58extends around a periphery of the first surface26. In some embodiments, the primary seal58may be an adhesive strip. In general, the lock ring20may be selectively fastened to the grommet18, for example, to form a secondary seal in addition to the primary seal58. In some embodiments, the secondary seal may be formed via compression of a portion of the conduit14that occurs when the lock ring20is fastened to the grommet18. With reference toFIGS.8-11, the lock ring20includes a central hub60and one or more locking flanges62. The central hub60defines a generally annular shape and includes a central aperture64formed in a top wall66and an inner surface68that extends axially from the outer periphery of the top wall66. When the lock ring20is fastened to the grommet18, the central aperture64may be arranged generally concentrically with the passageway42formed in the grommet18. In the illustrated embodiment, the inner surface68of the central hub60includes a plurality of ring clamping features70arranged around the inner surface68. In the illustrated embodiment, the central hub60includes four ring clamping features70arranged circumferentially around the inner surface68in equally-spaced increments. In some embodiments, the central hub60may include more or less than four ring clamping features70spaced circumferentially around the inner surface68in any increment. In the illustrated embodiment, each of the ring clamping features70defines a generally wedged protrusion72that extends radially inwardly from the inner surface68. Each of the wedged protrusions72includes a helical surface74that is angled helically (i.e., each of the helical surfaces74defines a helical path as it extends circumferentially along the inner surface68). For example, when the grommet assembly12is assembled, the helical surfaces74may be angled helically relative to the center axis44. In the illustrated embodiment, the lock ring20includes a pair of locking flanges62arranged on laterally-opposing sides of the central hub60. Each of the locking flanges62extends radially outwardly from an outer surface76of the central hub60and includes an axially-extending tightening surface78, a locking slot80, and a lead-in recess82. The tightening surfaces78may be gripped by a user or engaged by a tool to rotationally tighten the lock ring20. The locking slots80and the lead-in recesses82extend along a generally circumferential path (i.e., as the lock ring20is rotated the locking slot80and the lead-in recess82are arranged to sequentially engage the ramped tabs54). In the illustrated embodiment, the locking slots80extend axially through the locking flanges62and circumferentially along a portion of the locking flanges. Each of the locking slots80is configured to receive a corresponding one of the ramped tabs54therein. The lead-in recesses82may be arranged rotationally upstream of the locking slots80. That is, during rotation of the lock ring20relative to the grommet18, the ramped tabs54may first engage the lead-in recesses82and then snap into the locking slots80. In the illustrated embodiment, the lead-in recesses82define a recess that extends axially into the locking flanges62and circumferentially from a location that is generally aligned circumferentially with the tightening surfaces78to a location between the tightening surfaces78and the locking slots80. With specific reference toFIGS.10and11, in some embodiments, the lock ring20may be assembled to the conduit14prior to fastening to the grommet18. For example, in the illustrated embodiment, the conduit14includes a conduit flange84and a conduit bead85arranged at each end of the conduit14. To assemble the conduit14to the lock ring20, the conduit14may be passed through the central aperture64of the lock ring20and pulled through until the conduit flange84engages the top wall66of the central hub60. The engagement between the conduit flange84and the top wall66may act as a stop for the conduit14and prevent the conduit14from being pulled further through the central aperture64. While the engagement between the conduit flange84and the top wall66may prevent the conduit from being further pulled through the lock ring20, the lock ring20may be rotatable relative to the conduit flange84. With the lock ring20assembled to the conduit14, the one or more components being routed through the conduit14may be inserted through the lock ring20and the conduit14. For example, one or more wires, one or more connectors, a wiring harness, and/or any additional components needing to be routed through the conduit14may be inserted through the assembled lock ring20and the conduit14forming a conduit subassembly. Operation and assembly of the grommet assembly12will be described with reference toFIGS.1and12-18. Looking first toFIGS.12and13, the grommet18with the primary seal58overmolded thereto may be installed into the opening34formed in the panel16. Specifically, the panel portion24of the grommet18may be inserted axially through the opening34. As the panel portion24is inserted through the opening34, the edge of the opening34may engage retention arms36and force the retention arms36to flex laterally inward until the edge of the opening34engages the ramped surface40on the retention arms36. Once the edge of the opening34engages the ramped surface40, the retention arms36may flex laterally outward to snap the grommet18into the opening34. The engagement between the ramped surfaces40and the edge of the opening34prevents the grommet18from displacing axially relative to the opening34(i.e., prevents removal of the grommet18from the opening34). With the grommet18secured axially by the retention arms36, the axial insertion of the grommet18into the opening34brings the primary seal58into engagement with the panel16. In some embodiments, the panel16and the grommet18may be subjected to a heat cycle to activate the adhesive in the primary seal58. For example, in some non-limiting applications, the grommet assembly12may be installed on a panel in an automotive application. In this non-limiting application, a paint oven may provide heat to activate the adhesive in the primary seal58. In some embodiments, once the primary seal58is activated, the primary seal58may be permanently attached to the panel16and form a seal at the interface between the panel16and the periphery of the grommet18. In some embodiments, as will be described herein, the primary seal58may not require heat activation for form a seal between the panel16and the grommet18. With reference toFIGS.14and15, once the grommet18is installed into the opening34of the panel16and sealed to the panel16via the primary seal58, the subassembly including the conduit14and the lock rings20may be installed to the grommet18. Only one of the grommet/panel assemblies is illustrated in the figures but the following description would be applied to the other grommet/panel assembly to complete the assembly of the grommet system10(seeFIG.1). Initially, the ends of the components routed through the conduit14may be inserted through the passageway42formed axially through the grommet18. The lock ring20may then be axially inserted over the grommet18, so that the ring portion28is received within the central hub60of the lock ring20. The lock ring20may be completely inserted onto the grommet when the grommet clamping features48are circumferentially offset from the ring clamping features70. With the lock ring20axially inserted over the grommet18, the grommet clamping features48may be aligned to engage with the ring clamping features70, upon rotation of the lock ring20relative to the grommet18. The lock ring20may be rotated relative to the grommet18(e.g., clockwise in the illustrated non-limiting example ofFIGS.14and15). The rotation of the lock ring20relative to the grommet18brings the grommet clamping features48into engagement with the ring clamping features70. Specifically, the helical surfaces74on the wedged protrusions72of the lock ring20may engage and slide along the helical protrusions50of the grommet18. Due to the helical shape of the helical surfaces74and the helical protrusions50, the relative rotation between the lock ring20and the grommet18may result in the lock ring20displacing axially toward the grommet18. The lock ring20may be rotated relative to the grommet18, further drawing the lock ring20axially closer to the grommet18, until the ring retention features52snap into the locking slots80. For example, as the lock ring20is rotated relative to the grommet18, the lead-in recesses82the ramped tabs54to promote smoother rotation of the lock ring20relative to the grommet18. That is, the lead-in recesses82may reduce the torque necessary to overcome the initial engagement between the ramped tabs54and the locking flanges62, and the axial flexing of the locking flanges62relative to the platform22(e.g., in an upward direction from the perspective ofFIG.14), necessary to traverse over the ramped tabs52. Continued rotation of the lock ring20results in the ramped tabs54traversing along the locking flanges62until they are aligned with the locking slots80, at which point the ramped tabs54snap into the locking slots80and axially protrude therethrough, which allows the locking flanges62to axially flex relative to the platform22(e.g., downwardly from the perspective ofFIG.15). In this way, for example, the interaction between the ramped tabs54and the locking slots80may provide a visual, haptic, and/or audio indication that the lock ring20is completely fastened to the grommet18. For example, when the ramped tabs54snap into the locking slots80, a user may hear an audible click and/or feel the displacement of the locking flanges62that results from the ramped tabs54snapping into the locking slots80. Turning toFIGS.16-18, the axial displacement of the lock ring20toward the grommet18that occurs during rotation of the lock ring20compresses the conduit flange84between the grommet18and the lock ring20. As such, once the lock ring20is completely fastened to the grommet18, the conduit flange84is compressed between the ring portion28of the grommet18and the top wall66of the lock ring20. In addition, the conduit bead85may be compressed against the inner side of the ring portion28. The compression of the conduit flange84and the conduit bead85forms a secondary seal86along the passageway42. That is, with the lock ring20completely fastened to the grommet18, the passageway42extends through the grommet18, the lock ring20, and the conduit14and includes the primary seal58and the secondary seal86to prevent, for example, liquids (e.g., water) from entering the passageway42and reaching the components being routed through the grommet assembly12and the conduit14. In the illustrated embodiment, the secondary seal86is axially separated from a plane along which the primary seal58and is axially separated from a plane along which the opening34in the panel16is defined. In this way, for example, the secondary seal86raises the next possible location for leakage away from the panel16, thereby reducing the possibility of leakage due to liquid pooling on the panel16. In some non-limiting applications, the grommet system10may be used to route components in a tailgate on a vehicle. However, the design and properties of the grommet assembly12may be utilized for routing components at any location within a vehicle, for example, a floor, a door, a floor pan, a dash, or on a mild hybrid electric vehicle. In some non-limiting applications, the grommet assembly12may be used as an access point in a body of a vehicle where a seal is required when not in use. For example, the grommet assembly12may be used as an access point for a parking brake assembly, a fuel pump, and/or an electronic module. It should be appreciated that the design and properties of the grommet assembly12may be applied to other applications other than a conduit. For example, the design and properties of the grommet assembly12may be implemented to seal a wiring boot, a flanged pipe, a tube, or any other component that requires a sealed passageway through a panel, a wall, or another structure. For example,FIGS.19and20illustrate a grommet system100according to another aspect of the present disclosure. In the illustrated embodiment, the grommet system100includes a grommet assembly102coupled to a boot104(e.g., a cable boot or a wiring boot). The grommet assembly102provides a sealed passageway through a panel106and the boot104, which enables, for example, wiring components107(e.g., wires, wire bundles, cables, connectors, etc.) to be routed through the panel106, the boot104, and the grommet assembly102. The grommet assembly102includes a grommet108and a lock ring110configured to be selectively fastened to the grommet108. As illustrated inFIGS.21-25, the grommet108includes a platform112, a panel portion114extending from a first surface116of the platform112, and a ring portion118extending from a second surface120of the platform112. In the illustrated embodiment, the panel portion114and the ring portion118extend from the platform112in opposing directions (e.g., axially away from one another). The panel portion114extends axially away from the first surface116(e.g., a bottom surface from the perspective ofFIG.22) and defines a generally annular or ring shape with a bulb121that protrudes radially outward along a portion of the circumference of the panel portion114(seeFIG.25). The panel portion114is generally hollow and includes a plurality of panel retention features122arranged around the panel portion114. In general, the panel retention features122are configured to selectively engage an opening124in the panel106(seeFIG.20) and retain the grommet108within the opening124. In the illustrated embodiment, the panel retention features122generally include a plurality of retention arms126. The retention arms126are arranged within a cutout128that extends partially around a periphery of each of the retention arms126. For example, one edge of each of the retention arms126is formed integrally with, or attached to, the panel portion114and the remaining edges are free-floating (e.g., not in contact with) with respect to the panel portion114due to the cutout128. In this way, for example, the retention arms126may flex radially with respect to the panel portion114. In the illustrated embodiment, each of the retention arms126includes a ramped surface130that, when the panel portion114is inserted into the opening124of the panel106, is configured to engage an edge of the opening124to retain the grommet108within the opening124and prevent the grommet108from displacing axially relative to the opening124. The ring portion118extends axially away from the second surface120(e.g., a top surface from the perspective ofFIG.22) and defines a generally annular shape. The hollow shape defined by the panel portion114and the ring portion118defines a passageway132that extends axially through the grommet108along a center axis134. The passageway132enables components (e.g., wires, wire bundles, cables, connectors, etc.) to be inserted through the grommet108. The ring portion118includes a grommet sealing bead135arranged at an axial end thereof (e.g., a top edge from the perspective ofFIG.21) and an outer surface136having a plurality of grommet clamping features138arranged around the outer surface136. For example, in the illustrated embodiment, the ring portion118includes four grommet clamping features138arranged circumferentially around the outer surface136in equally-spaced increments. In some embodiments, the ring portion118may include more or less than four grommet clamping features138spaced circumferentially around the outer surface136in any increment. In the illustrated embodiment, each of the grommet clamping features138defines a generally radial protrusion that extends radially outwardly from the outer surface136and is angled helically relative to the center axis134. That is, each of the grommet clamping features138defines a helical surface140that extends along a helical path as it extends circumferentially along the outer surface136(seeFIGS.22and23). With specific reference toFIGS.21and24, the platform112defines a flanged portion141that extends radially outward and circumferentially along a portion of the platform112. The platform112includes a plurality of lock verification ribs142, an initial alignment notch144, a final alignment pin145, and a locking wedge146. Each of the lock verification ribs142protrudes axially from the second surface120of the platform112and extends radially along the second surface120of the platform112. Each of the lock verification ribs142is spaced circumferentially from an adjacent lock verification rib142. In this way, for example, the lock verification ribs142define a sequence of circumferentially-spaced ribbed protrusions that span circumferentially along a portion of the second surface120of the platform112. In the illustrated embodiment, the portion of the second surface120along which the lock verification ribs142span is arranged circumferentially opposite to the flanged portion141. The initial alignment notch144and the final alignment pin145are circumferentially separated and arranged on a periphery of the platform112. Specifically, the initial alignment notch144defines a radially recessed notch formed in the outer periphery of the flanged portion141, and the final alignment pin145protrudes radially outward from a periphery of the platform112at a location that is circumferentially spaced from the initial alignment notch144. The circumferential direction between the initial alignment notch144and the final alignment pin145may define a direction in which the lock ring110is required to be rotated to fasten to the grommet108(e.g., clockwise in the illustrated embodiment ofFIG.24). The circumferential distance between initial alignment notch144and the final alignment pin145may define a rotational distance that the lock ring110must be rotated in the required direction to fasten to the grommet108. In the illustrated embodiment, the locking wedge146extends radially outwardly onto the flanged portion141from the outer surface136of the ring portion118. The locking wedge146includes a planar surface147that extends radially and may define a stop to prevent unwanted unfastening between the grommet108and the lock ring110(e.g., rotation in a counterclockwise direction). In the illustrated embodiment, the grommet108includes visible indicators (e.g., words, shapes, cutouts, arrows, lines, etc.) that may aid a user in assembling the grommet assembly102. For example, the indicators may aid a user is aligning the lock ring110relative to the grommet108prior to fastening (e.g., rotating) the lock ring110to the grommet108, and/or aid a user in determining when the lock ring110is completely fastened to the grommet108. With reference toFIG.25, the grommet108includes a primary seal148that defines a generally annular or ring shape with a seal bulb149that protrudes radially outward along a portion of the circumference of the primary seal148. AlthoughFIGS.21-24illustrate the grommet108without the primary seal148, the primary seal148may be overmolded onto the grommet108. Once the primary seal148is overmolded to the grommet108, the primary seal148extends around a periphery of the first surface116. In some embodiments, the primary seal148may be an adhesive strip. In general, the lock ring110may be selectively fastened to the grommet108, for example, to form a secondary seal in addition to the primary seal148. In some embodiments, the secondary seal may be formed via compression of a portion of the boot104that occurs when the lock ring110is fastened to the grommet108. With reference toFIGS.26-29, the lock ring110includes a central hub150and a locking flange152that extends radially outwardly from the central hub150. The central hub150defines a generally annular shape and includes a central aperture154, a top wall156, an inner surface158that extends axially from an inner periphery of the top wall156, and an outer surface159that extends axially from an outer periphery of the top wall156. In the illustrated embodiment, the top wall156may include a ring sealing bead161that protrudes axially therefrom and extends circumferentially around an inner side (e.g., a side arranged internally to the central hub150) of the top wall156. When the lock ring110is fastened to the grommet108, the central aperture154may be arranged generally concentrically, or axially aligned, with the passageway132formed in the grommet108. That is, the center axis134may extend centrally through the grommet108and the lock ring110once assembled. In the illustrated embodiment, the outer surface159of the central hub150includes a plurality of ring clamping features160arranged circumferentially around the outer surface159. In the illustrated embodiment, the central hub150includes four ring clamping features160arranged circumferentially around the outer surface159in equally-spaced increments. In some embodiments, the central hub150may include more or less than four ring clamping features160spaced circumferentially around the inner surface158in any increment. In the illustrated embodiment, each of the ring clamping features160defines a protrusion that extends radially inwardly from the inner surface158and is angled helically relative to the center axis134. That is, each of the ring clamping features160defines a helical surface164that extends along a helical path as it extends circumferentially along the outer surface159. In the illustrated embodiment, the inner surface158includes a plurality of boot retention tabs162that extend radially outwardly from an axial end of the inner surface158. In the illustrated embodiment, the inner surface158includes four boot retention tabs162arranged circumferentially around the end of the inner surface158in equally-spaced increments. In other embodiments, the inner surface158may include more or less than four boot retention tabs162arranged in any increment. In the illustrated embodiment, the locking flange152includes a locking arm168, a ring alignment notch170, a boot alignment aperture171, and a verification or locking tab172. The locking arm168is attached to the locking flange152at one end thereof and a distal end of the locking arm168is free-floating. In this way, for example, the distal end of the locking arm168may be flexible in a general radial direction. The distal end of the locking arm168includes a radially-extending locking surface173that extends toward the central hub150(seeFIG.29). The ring alignment notch170extends radially into an outer periphery of the locking flange152. In other embodiments, the ring alignment notch170may be in the form of a pin, arrow, marking, or identifier (e.g., a dot, an engraved shape, or any other visible marking formed on locking flange152). The boot alignment aperture171defines a circumferentially-extending aperture that is formed adjacent to the locking arm168. In the illustrated embodiment, the verification tab172is arranged circumferentially opposite to the locking arm168. The verification tab172is attached to the locking flange152at one end thereof and a distal end of the verification tab172is free-floating. In this way, for example, the distal end of the verification tab172may be flexible in a general axial direction. The distal end of the verification tab172may include a ramped surface176that ramps at an angle axially away from (e.g., upward from the perspective ofFIG.27) a bottom surface178of the verification tab172. In the illustrated embodiment, the lock ring110includes visible indicators (e.g., words, shapes, arrows, lines, etc.) that may aid a user in assembling the grommet assembly102. For example, the indicators may indicate a direction in which to rotate the lock ring110relative to the grommet108. In addition, the indicators may aid a user is aligning the lock ring110relative to the grommet108prior to fastening (e.g., rotating) the lock ring110to the grommet108. Further, the indicators may aid a user in determining whether the verification tab172is providing an indication that the lock ring110is completely fastened to the grommet108. In the illustrated embodiment, the central hub150includes a plurality of radially-extending ribs180arranged circumferentially around an outer periphery of the central hub150. Each of the ribs180extends radially outwardly and may enable a tool to be coupled thereto, or provide structure for a user to grip onto, and assist in rotation of the lock ring110. In some embodiments, the lock ring110may be assembled to the boot104prior to fastening to the grommet108. Turning toFIGS.30-31, in the illustrated embodiment, the boot104includes a boot flange184, a boot retention ring185, and a boot alignment tab187. In the illustrated embodiment, the boot flange184extends radially outwardly from an axial end of the boot104. The boot retention ring185extends radially inwardly from an inner surface of the boot104. In the illustrated embodiment, the boot alignment tab187extends radially outwardly from a periphery of the boot flange184. The boot alignment tab187is dimensioned to be arranged within the boot alignment aperture171of the lock ring110(seeFIG.34). To assemble the boot104to the lock ring110, the boot104may be at least partially inserted into the central aperture154of the lock ring110, so that the boot flange184is received within a channel189formed in the central hub150(seeFIG.27) and the boot alignment tab187is circumferentially aligned with and at least partially received within the boot alignment aperture171of the lock ring110. The alignment and interaction between the boot alignment tab187and the boot alignment aperture171may ensure proper rotational orientation of the boot104within the lock ring110, and prevent relative rotation between the boot104and the lock ring110after the boot104is inserted into the lock ring110. The boot104may be inserted into the lock ring110until the boot retention ring185axially passes and engages the boot retention tabs162on the lock ring110(seeFIG.35). The engagement between the boot retention ring185and the boot retention tabs162on the lock ring110may act as a stop and axially retain the boot104within the lock ring110prior to fastening to the grommet108. With the lock ring110assembled to the boot104, the one or more components (e.g., the wiring components107) being routed through the boot104may be inserted through the lock ring110and the boot104. For example, one or more wires, one or more connectors, a wiring harness, a cable, a cable bundle, and/or any additional components needing to be routed through the boot104may be inserted through the assembled lock ring110and the boot104forming a boot subassembly. Further operation and assembly of the grommet assembly102will be described with reference toFIGS.19-35. Looking first toFIGS.19-25, the grommet108with the primary seal148overmolded thereto may be installed into the opening124formed in the panel106. Specifically, the panel portion114of the grommet108may be inserted axially through the opening124. As the panel portion114is inserted through the opening124, an edge of the opening124may engage the retention arms126and force the retention arms126to flex radially inward until the edge of the opening124engages the ramped surface130on the retention arms226. Once the edge of the opening124engages the ramped surface130, the retention arms126may flex radially outward to snap the grommet108into the opening124. The engagement between the ramped surfaces130and the edge of the opening124prevents the grommet108from displacing axially relative to the opening124(e.g., prevents unwanted removal of the grommet108from the opening124). In the illustrated embodiment, the opening124includes a bulb-shaped protrusion similar in shape to the bulb121of the panel portion114. During installation, the bulb121may be inserted into the bulb-shaped protrusions of the opening124. The interaction between the bulb121and the bulb-shaped protrusion formed in the opening124may prevent the grommet108from rotating within the opening124after installation. In other embodiments, the bulb121may define an alternative shape. For example, a protrusion or recess formed in the panel portion114and a corresponding shape formed in the opening124may be used to prevent rotation of the grommet108after installation into the panel106. With the grommet108secured axially by the retention arms126, the axial insertion of the grommet108into the opening124brings the primary seal148into engagement with the panel106. The panel106and the grommet108may be subjected to a heat cycle to activate the adhesive in the primary seal148. For example, in some non-limiting applications, the grommet assembly102may be installed on a panel in an automotive application. In this non-limiting application, a paint oven may provide heat to activate the adhesive in the primary seal148. In some embodiments, once the primary seal148is activated, the primary seal148may be permanently attached to the panel106and form a seal at the interface between the panel106and the periphery of the grommet108. In some embodiments, as will be described herein, the primary seal148may not require heat activation for form a seal between the panel106and the grommet108. With reference toFIGS.21-33, once the grommet108is installed into the opening124of the panel106and sealed to the panel106via the primary seal148, the subassembly including the boot104and the lock ring110may be installed to the grommet108. Initially, the ends of the components routed through the boot104may be inserted through the passageway132formed axially through the grommet108. The lock ring110may then be axially inserted over the grommet108, so that the ring portion118is received within the central hub150of the lock ring110. As the lock ring110is inserted axially onto the grommet108, the ring alignment notch170on the lock ring110may be circumferentially aligned with the initial alignment notch144on the grommet108(seeFIG.32). This circumferential arrangement provided by aligning the ring alignment notch170with the initial alignment notch144may ensure that the grommet clamping features138are circumferentially offset from the ring clamping features160, which allows the lock ring110to be completely inserted axially onto the grommet108. With the lock ring110axially inserted over the grommet108, the grommet clamping features138may be aligned to engage with the ring clamping features160, upon rotation of the lock ring110relative to the grommet108. As illustrated in the transition betweenFIG.32andFIG.33, the lock ring110may be rotated relative to the grommet108(e.g., clockwise in the illustrated embodiment). The rotation of the lock ring110relative to the grommet108brings the grommet clamping features138into engagement with the ring clamping features160. Specifically, the helical surfaces164on the ring clamping features160of the lock ring110may engage and slide along the helical surfaces140on the grommet clamping features138of the grommet108. Due to the helical interaction between the helical surfaces164and the helical surfaces140, the relative rotation between the lock ring110and the grommet108may result in the lock ring110displacing axially toward the grommet108. As the lock ring110is rotated relative to the grommet108, the verification tab172may provide a visual and/or audible indication that the lock ring110is rotating relative to the grommet108and, after sufficient relative rotation, completely fastened thereto. For example, as the lock ring110is rotated, the ramped surface176of the verification tab172may sequentially slide over the lock verification ribs142, which axially displaces and offsets the distal end of the verification tab172relative to the platform112and the locking flange152(e.g., upward from the perspective ofFIG.32). As the verification tab172sequentially slides over the lock verification ribs142, an audible (e.g., a click) may be heard by the user confirming that the lock ring110is being properly rotated relative to the grommet108. The lock ring110may continue to be rotated relative to the grommet108until the ring alignment notch170circumferentially aligns with the final alignment pin145on the grommet108(seeFIG.34). Once the ring alignment notch170circumferentially aligns with the final alignment pin145, the ramped surface176of the verification tab172may displace past the last of the lock verification ribs142and the verification tab172may be arranged axially flush with the locking flange152on the lock ring110(seeFIG.33). In this way, for example, the verification tab172, the ring alignment notch170, and the final alignment pin145may provide a visual indication for when the lock ring110is completely fastened to the grommet108. In general, the indication of completed fastening provided by the verification tab172, the ring alignment notch170, and the final alignment pin145represents one embodiment. In other embodiments, the lock ring110and/or the grommet108may include a flexible feature or structure, other than the verification tab172that may visually indicate complete assembly, for example, by changing positions once the lock ring110is completely fastened to the grommet108. In addition to the verification tab172, the locking arm168may aid in rotationally locking the lock ring110to the grommet108, once the lock ring110is completely fastened to the grommet108. For example, the distal end of the locking arm168may engage the locking wedge146during rotation of the lock ring110. Once the distal end of the locking arm168engages the locking wedge146, the distal end of the locking arm168may flex radially outward until the locking surface173of the locking arm168rotationally passes the planar surface147of the locking wedge146, which occurs once the lock ring110is completely fastened to the grommet108. The distal end of the locking arm168then snaps radially inward and brings the locking surface173into engagement with the planar surface147of the locking wedge146. In this way, for example, the locking arm168may prevent relative rotation between the lock ring110and the grommet108(e.g., in a counterclockwise direction in the illustrated embodiment) after the lock ring110is completely fastened to the grommet108. Turning toFIG.35, the axial displacement of the lock ring110toward the grommet108that occurs during rotation of the lock ring110compresses the boot flange184the between the grommet108and the lock ring110. Specifically, once the lock ring110is completely fastened to the grommet108, the boot flange184is compressed between the grommet sealing bead135of the ring portion118on the grommet108and the ring sealing bead161of the lock ring110. In the illustrated embodiment, the grommet sealing bead135of the ring portion118is radially aligned with the ring sealing bead161to aid in pinching the boot flange184therebetween. The compression of the boot flange184between the grommet108and the lock ring110forms a secondary seal186along the passageway132. That is, with the lock ring110completely fastened to the grommet108, the passageway132extends through the grommet108, the lock ring110, and the boot104and includes the primary seal148and the secondary seal186to prevent, for example, liquids (e.g., water) from entering the passageway132and reaching the components being routed through the grommet assembly102and the boot104. In the illustrated embodiment, the secondary seal186is axially separated from a plane along which the primary seal148and is axially separated from a plane along which the opening124in the panel106is defined. In this way, for example, the secondary seal186raises the next possible location for leakage away from the panel106, thereby reducing the possibility of leakage due to liquid pooling on the panel106. In some non-limiting applications, the grommet system100may be used to route components through a floor or another location on a vehicle. However, the design and properties of the grommet assembly102may be utilized for routing components at any location within a vehicle, for example, a tailgate, a door, a floor pan, a dash, or on a mild hybrid electric vehicle. In some non-limiting applications, the grommet assembly102may be used as an access point in a body of a vehicle where a seal is required when not in use. For example, the grommet assembly102may be used as an access point for a parking brake assembly, a fuel pump, and/or an electronic module. In some embodiments, the grommet108, the lock ring110, and/or the boot104may be modified to provide an alternative seal contact for the secondary seal186. For example, as illustrated inFIG.36, the lock ring110may include two ring sealing beads161that are radially spaced from one another. When the grommet assembly102is assembled, the secondary seal186may be formed by the compression of the boot flange184between the grommet sealing bead135and the two ring sealing beads161. The grommet sealing bead135may be arranged radially between the two ring sealing beads161to aid in bending of the boot flange184during compression between the lock ring110and the grommet108. With reference toFIG.37, in another embodiment, the ring sealing bead161of the lock ring110may be radially offset relative to the grommet sealing bead135to aid in bending of the boot flange184during compression between the lock ring110and the grommet108. In addition, the boot104may include a boot bead190that protrudes axially from the boot flange184(e.g., upward from the perspective ofFIG.37) and that is arranged radially outwardly relative to the grommet sealing bead135and the ring sealing bead161. In another embodiment, as illustrated inFIG.38, the boot104may not include the boot bead190. As described herein, the primary seal58,148may define alternative forms. For example, as illustrated inFIGS.39and40, the primary seal58,148may be in the form of a foam seal that extends circumferentially around a periphery of the panel portion114on the grommet108, and is in engagement with the first surface116of the platform112. Although the foam seal is illustrated as being installed on the grommet108, it may be applied similarly to the grommet18or any other grommet designed using the properties and techniques disclosed herein. In another embodiment, as illustrated inFIGS.41and42, the primary seal58,148may be in the form of a thermoplastic elastomer seal that is sealed around a periphery of the platform112and extends radially outwardly from the periphery of the platform112. Although the thermoplastic elastomer seal is illustrated as being installed on the grommet108, it may be applied similarly to the grommet18or any other grommet designed using the properties and techniques disclosed herein. In some embodiments, the anti-rotation geometry defined between the grommet and the panel may define alternative shapes and/or structures. For example, as illustrated inFIGS.43and44, a grommet according to the present disclosure may include a pin portion200that extends radially outwardly from an outer periphery of the grommet. The pin portion200includes a pin202that extends axially downwardly (e.g., from the perspective ofFIG.44) and is configured to be inserted into an aperture formed in the panel106. In this way, for example, the pin202may key the grommet to the panel and prevent relative rotation therebetween. In some embodiments, a grommet according to the present disclosure may define an alternative shape (e.g., compared to the oval shape of the grommet18and the bulb formed in the grommet108). For example, as illustrated inFIG.45, the grommet108may include a planar surface204that interrupts the generally round shape defined by the remainder of the grommet108. Alternatively, as illustrated inFIG.46, the grommet108may include a radially inwardly extending protrusion that extends circumferentially over a portion of the periphery of the grommet108. The shapes defined by the grommets illustrated inFIGS.45and46may prevent rotation of the grommet108after installation into the panel106. In some non-limiting applications, it may be desirable to allow a grommet assembly to rotate after installation. In these non-limiting examples, the grommet and the corresponding opening formed in the panel may define a circular or round shape that allows the grommet (and the lock ring and routing element coupled thereto) to rotate relative to the panel after assembly. As described herein, the verification and alignment during assembly that is provided by the grommet assemblies12and102may be defined by alternative structures or mechanisms. For example,FIGS.47-52illustrate an alternative configuration for a grommet assembly300that includes a boot301, a grommet302, and a lock ring304. The design and properties of the boot301, the grommet302, and the lock ring304may be similar to the boot104, the grommet108, and the lock ring110, respectively, with similar features identified using like reference numerals, except as described below or as illustrated by the figures. As illustrated inFIG.47, the grommet302may include a boot alignment feature306that is configured to align and engage with a corresponding feature on the boot301. In the illustrated embodiment, the boot alignment feature306is in the form of an alignment wedge308that protrudes radially inwardly from the inner surface of the ring portion118. In other words, the alignment wedge308protrudes radially into the passageway132formed through the grommet302. In addition, the platform112includes a lock-verification aperture310and a grommet alignment aperture312. The lock-verification aperture310and the grommet alignment aperture312are circumferentially separated and arranged adjacent to a periphery of the flanged portion141. The alignment wedge308may be rotationally aligned with the lock-verification aperture310to provide an indication to a user or an automated machine of where the alignment wedge308is located on the grommet302. With reference toFIG.48, the boot301may include an alignment feature314that is configured to engage the boot alignment feature306in a keyed relationship to prevent relative rotation between the boot301and the grommet302during assembly. In the illustrated embodiment, the alignment feature314defines a wedged recess formed in the outer periphery of the boot301. The shape and size of the wedged recess defined by the alignment feature314conforms to the size and shape of the alignment wedge308on the grommet302. In this way, for example, once the alignment wedge308is received within the alignment feature314, the boot301may be keyed to the grommet302and be prevented from rotating relative to the grommet302. In the embodiment ofFIG.48, the boot alignment tab187may extend axially away from the boot flange184(e.g., upward from the perspective ofFIG.48). In addition, the boot301may include one or more boot beads316extending circumferentially around an outer surface of the boot104. With reference toFIGS.49-52, the lock ring304may include an alignment aperture318extending axially at least partially through the locking flange152at a location adjacent to the outer periphery of the locking flange152. In addition, the lock ring304may include a verification tab320that is circumferentially separated from the alignment aperture318. One edge of the verification tab320is attached to the central hub150adjacent to the locking flange152and a pair of slots are arranged on opposing sides of the verification tab172. In this way, for example, a distal end of the verification tab320may be in a free-floating arrangement, which enables the distal end of the verification tab320to flex in an axial direction. The distal end of the verification tab320may include a pin322that protrudes axially away from (e.g., downward from the perspective ofFIG.49) a bottom surface of the verification tab320. An aperture324may be formed in the top wall156of the central hub150, which circumferentially aligns with the locking flange152. When the boot301is assembled to the lock ring304, the boot alignment tab187extends through the aperture324formed in the top wall256. With the boot301installed into the lock ring304, the boot alignment tab187may extend over a portion of the top wall156to act as a stop and prevent axial displacement of the boot104, for example, in a downward direction from the perspective ofFIGS.49and50. Once the boot301is assembled to the lock ring304, the lock ring304and the boot301may be inserted axially onto the grommet302, which may be inserted into a panel in accordance with the grommets described herein. Once the lock ring304is installed onto the grommet302, the lock ring304may be rotated relative to the grommet302to fasten the lock ring304to the grommet302, which may compress the boot301between the grommet302and the lock ring304. As the lock ring304is rotated, the pin322on the verification tab320may initially engage the flanged portion141of the grommet302, which axially displaces and offsets the distal end of the verification tab320relative to the platform112and the locking flange152(e.g., upward from the perspective ofFIG.49). The verification tab320may remain axially offset from the locking flange152until the lock ring304is rotated to a point where the pin322rotationally aligns with the lock-verification aperture310. Once the pin322aligns with the lock-verification aperture310, the distal end of the verification tab320displaces axially relative to the locking flange152and becomes axially flush or aligned with the locking flange152. In this way, for example, the verification tab320may provide a visual indication for when the lock ring304is completely fastened to the grommet302. In addition, the verification tab320may provide an audible indication that occurs when the pin322snaps into the lock-verification aperture310. Furthermore, the pin322extending axially into the lock-verification aperture310may aid in preventing the lock ring304from displacing rotationally relative to the grommet302. In addition to the verification tab320, the grommet alignment aperture312may provide an additional visual indication that the lock ring304is completely fastened to the grommet302. For example, as illustrated in the sequence ofFIG.51, once the lock ring304is completely fastened to the grommet302, the alignment aperture318rotationally aligns with the grommet alignment aperture312, thereby providing another visual indication that the lock ring304is completely fastened to the grommet302. With reference toFIG.52, the axial displacement of the lock ring304toward the grommet302that occurs during rotation of the lock ring304compresses the boot flange184and the boot beads316between the grommet302and the lock ring304. As such, once the lock ring304is completely fastened to the grommet302, the boot flange184is compressed between the ring portion118of the grommet302and the top wall156of the lock ring304. In addition, the boot beads316may be compressed between the central hub152and the inner side of the ring portion118. The compression of the boot flange184and the boot beads316forms the secondary seal186along the passageway132. That is, with the lock ring304completely fastened to the grommet302, the passageway232extends through the grommet302, the lock ring304, and the boot301and includes the primary seal148and the secondary seal186to prevent, for example, liquids (e.g., water) from entering the passageway132and reaching the components being routed through the boot301. It should be appreciated that alternative mechanisms may be leveraged for inserting and retaining a grommet within a panel than those disclosed herein. For example, the hole plug retention mechanism disclosed in U.S. Published Patent Application No. 2019/0360587 and U.S. Published Patent Application No. 2019/0211929, which are incorporated by reference in their entirety, may be integrated in addition to or alternatively to the grommet retention features described herein. The design and properties of the grommet assemblies12,102, and300provide several advantages over conventional grommet systems. For example, the formation of a primary seal and the fastening between a grommet and a lock ring are separated. That is, the primary seal is formed during a heat cycle and, therefore, is not dependent on the fastening between the grommet and the lock ring. In addition, the arrangement of the primary seal at an interface between a panel and the grommet arranges the primary seal at the most important location for leakage prevention. Further, arranging the primary seal around the periphery of the grommet reduces the footprint required by the grommet on the panel, which reduces the overall packaging size of the grommet assembly. In addition to the primary seal, a secondary seal is formed during the fastening of the lock ring to the grommet. The secondary seal is axially separated from the primary seal and is axially separated from a plane along which an opening in the panel is defined. In this way, for example, the secondary seal raises the next possible location for leakage away from the panel, thereby reducing the possibility of leakage due to liquid pooling on the panel. Further, the fastening between the lock ring and the grommet is significantly simplified (i.e., rotation of the lock ring) when compared to conventional grommet system that require a substantial amount of force for assembly. The grommet assemblies12,102, and300also provide an indication that the lock ring has been properly and completely assembled to the grommet ensuring that the secondary seal is formed. Within this specification embodiments have been described in a way which enables a clear and concise specification to be written, but it is intended and will be appreciated that embodiments may be variously combined or separated without parting from the invention. For example, it will be appreciated that all preferred features described herein are applicable to all aspects of the invention described herein. Thus, while the invention has been described in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the invention are set forth in the following claims. | 59,145 |
11859750 | DETAILED DESCRIPTION Embodiments of the present invention provide systems, methods and apparatus for implementing medical-gas (or, “med-gas”) panel connectors in reconfigurable wall systems. For example, in one embodiment, a med-gas panel connector system includes a frame assembly. The frame assembly includes a horizontal frame member, a vertical frame member connected to the horizontal frame member, and a ceiling integration assembly. The med-gas panel connector system also includes a medical-gas outlet removably secured to at least one of the horizontal frame member and the vertical frame member via a bracket. In addition, a manifold is removably secured to the ceiling integration assembly, the manifold being at least partially disposed inside the medical-gas panel connector system, and a flexible gas line connects the manifold to the medical-gas outlet. As understood more fully from the specification and claims, the modular walls having med-gas panels of the present disclosure provide a number of important advantages in the art. For example, the med-gas panel connectors and systems of the present disclosure include internal frame members that incorporate a plurality of outlets, gas lines, and manifolds that are compliant with National Fire Protection Association (NFPA) 99 standards and regulations and can be easily installed and integrated into a pre-existing central gas system of a hospital or other medical facility. The med-gas panel connectors can be incorporated into reconfigurable walls that are easy to replace and reconfigure depending on the specific needs of a patient room. The med-gas panel connectors of the present disclosure also simplify the plumbing required in typical med-gas headwall systems and use modular connections that do not require pre-testing or certification before use. Turning now to the figures,FIG.1Aillustrates a modular wall system10including a med-gas panel connector system100. In at least one embodiment, the modular wall system10comprises a number of individual panels15removably secured together to form one or more walls within a patient room of a hospital. Modular wall systems10such as that illustrated inFIG.1are reconfigurable so that various spaces created by the modular wall system10can be formed as needed. These spaces, such as a patient room, operating room, or other rooms within a hospital, may thus be rearranged, customized, and reconfigured to meet the changing needs of the hospital. For example, in at least one embodiment, the modular wall system10is configured to form a patient room. In such an embodiment, the modular wall system10extends from the floor20to the ceiling plenum25of the patient room to form a closed space in which one or more patients may reside. As noted above, in at least one embodiment, the modular wall system10includes a number of individual panels15removably secured together to form larger wall sections of the modular wall system10. The embodiment of the modular wall system10illustrated inFIG.1Aincludes two wall portions removably secured together at a ninety-degree angle. However, in one or more other embodiments, any number of wall portions may be secured together at various angles to form various customized spaces. Also, one or more other embodiments of the modular wall system10may include more or less than the number and size of individual panels15shown inFIG.1A. Of particular note, at least a portion of the modular wall system10includes a med-gas panel connector system100. At least one embodiment of a med-gas panel connector system100includes six med-gas outlets110. The number of med-gas outlets110within a med-gas panel connector system100may vary in one or more other embodiments. Hospital patient rooms often require access to certain medical gases, such as oxygen, used for patients or medical devices within the room. Each med-gas outlet110provides an outlet to which a doctor or other medical professional can attach a hose or tube and route certain medical gases to the patient or medical device from the med-gas outlets110. In the illustrated embodiment ofFIG.1A, the modular wall system10includes a single med-gas panel connector system100that extends only partially between the ceiling plenum25and the floor20. In at least one embodiment, the modular wall system10may comprise two or more med-gas panel connector systems100. Also, in at least one embodiment, the size of the med-gas panel connector system100may be larger or smaller than that illustrated inFIG.1A. For example, in at least one embodiment, the med-gas panel connector system100may form a panel of the modular wall system10that extends all the way from the ceiling plenum25to floor20of the patient room. Various embodiments of the modular wall system10may comprise various sizes and number of individual panels15and med-gas panel connector systems100as needed for any particular room configuration. In addition, the placement of the med-gas panel connector system100may vary in one or more other embodiments. For example, in at least one embodiment, the med-gas panel connector system100is disposed on a lower section of the modular wall system10. Hospitals typically include central gas supplies and central gas lines to carry gases from the central gas supply through the walls, ceiling plenums, and floors of the hospital. The med-gas outlets110illustrated inFIG.1Aare connected to the central gas lines of the hospital through the med-gas panel connector system100. Various components of the med-gas panel connector system100, including the med-gas outlets110and other internal components (not shown inFIG.1A) are modular and rearrangeable so that the modular wall system10can incorporate the med-gas panel connector system100at various positions within the modular wall system10and still connect to the central gas lines of the hospital with minimal effort and complication. Along these lines,FIG.1Billustrates the med-gas panel connector system100shown inFIG.1Awith the outer panel or cover removed. As such, the internal components of the med-gas panel connector system100that allow the aforementioned design flexibility within the modular wall system10are shown. In at least one embodiment, the med-gas panel connector system100includes one or more med-gas outlets110, one or more manifolds115, and one or more gas lines120connecting the one or more manifolds115to the one or more med-gas outlets110. In addition, the med-gas panel connector system100includes one or more horizontal frame members125and one or more vertical frame members130. In at least one embodiment, the horizontal frame members125and the vertical frame members130are elongate members. Additionally, or alternatively, at least one embodiment includes gas lines120having Diameter Index Safety System (DISS) adapters at the ends thereof for connecting to the manifold115. The gas lines120and/or manifolds115may also include non-interchangeable screw thread (NIST) connections at the med-gas outlet110to ensure proper installation with the correct gas lines120. The gas lines120may also include NIST connections at either end so as to ensure industry standards and to be compatible with the manifolds115and med-gas outlets110of the med-gas panel connector systems100described herein. In addition, the gas lines120may comprise flexible hosing that bends and/or flexes without cracking or breaking. In at least one embodiment, the med-gas panel connector system100includes one or more horizontal frame members125and one or more vertical frame members130. The horizontal125and vertical130frame members provide structure to the med-gas panel connector system100and attachment points for the med-gas outlets110, manifolds115, and gas lines120. In at least one embodiment, the horizontal frame members125and the vertical frame members130comprise elongate members having one or more holes disposed therethrough. At least one embodiment of the med-gas panel connector system100also includes a ceiling integration assembly135. An assembler and/or installer of the med-gas panel connector system100may route the one or more gas lines120through the holes in the horizontal frame members125and/or vertical frame members130between the manifolds115and med-gas outlets110. Additionally, or alternatively, the installer or assembler can route gas lines120around the frame members125,130. As seen inFIG.1B, in at least one embodiment, the gas lines120are longer than the distance between a given manifold115and corresponding med-gas outlet110. The flexibility of the gas lines120allows for the extra slack to be curled or bent within the med-gas panel connector system100. In addition, the flexibility and modularity of the system allows for gas lines120which do not need to be cut perfectly to length. Instead, one or more standard chosen lengths of gas lines120may be employed so that an installer and/or assembler of the med-gas panel connector system100can use the same length of gas lines120to connect any one manifold115to any med-gas outlet110, even if the distance between the manifold115and med-gas outlet110varies between systems. Again, the assembler and/or installer does not need to precisely measure and cut gas lines120to the exact length. This saves time and costs associated with installing embodiments of the med-gas panel connector systems100described herein. In addition, at least one embodiment of the med-gas panel connector system100includes one or more gas lines122routed from the illustrated med-gas panel connector system100to adjacent systems or through adjacent panels15of the modular wall system10illustrated inFIG.1A. Thus, one or more gas lines122may advantageously extend from the manifolds115of one med-gas panel connector system100to the med-gas outlet110of another panel or system. Thus, in at least one embodiment, one or more manifolds115secured within one med-gas panel connector system100may provide connections for med-gas outlets110of one or more other portions of the modular wall system10. As such, in one or more embodiments, the med-gas panel connector system100may include med-gas outlets110but no manifolds115. In such an embodiment, the med-gas outlets110are connected to the manifold(s)115of a separate med-gas panel connector system100via gas lines122routed through one or more holes in corresponding vertical frame members130and/or horizontal frame members125. Accordingly, in embodiments of modular wall systems10that include more than one med-gas panel connector system100, an installer and/or assembler may rearrange and reconfigure the placement of various med-gas outlets110as needed or desired. Furthermore, once an installer or assembler installs the med-gas connection system100and other reconfigurable wall panels15, the end user can easily replace, remove, relocate, or reconfigure the med-gas connection system100without necessarily replumbing or welding gas line120connections within the med-gas panel connector system100or reconfigurable wall system10. As noted above, each embodiment of med-gas panel connector systems100described herein are easily installed the reconfigurable with other reconfigurable wall panels15to form customizable spaces, such as hospital patient rooms, operating rooms, and the like. In at least one embodiment, the ceiling integration assembly135is integrated into the existing ceiling plenum25of a hospital or other healthcare facility, as seen inFIG.1A. Turning now toFIG.2, as noted above, at least one embodiment of the med-gas panel connector system100includes one or more manifolds115.FIG.2illustrates an embodiment of a manifold115according to the present disclosure. In at least one embodiment, the manifold115secures to the ceiling integration assembly135using bolts, screws, clips, or the like, or a combination thereof. In at least one embodiment, the manifold115is secured to the ceiling integration assembly135anywhere along the length of thereof. In this way, an installer or assembler can position the manifold115within the med-gas panel connector system100to correspond to the positions of the medical-gas outlets110or other frame members125,130. In at least one embodiment, for example, the manifold115is positioned centrally along the length of the ceiling integration assembly135. In at least one embodiment, the manifold115is positioned closer to the end of the ceiling integration assembly135. In yet another embodiment, numerous manifolds115may be positioned at different locations along the length of the ceiling integration assembly135. After installation, each manifold115secured to the ceiling integration assembly135may be rearranged or moved along the length of the ceiling integration assembly135. For example, after installing the manifold115shown inFIG.2, an end user or installer can loosen or remove the screws, bolts, or other securement means noted above, slide or otherwise move the manifold115to a different location along the length of the ceiling integration assembly135, and re-secure/re-tighten the securement means to secure the manifold115at a different location. In this way, in at least one embodiment, the manifold115is slidably or removably secured to the ceiling integration assembly135. In this way, the manifold115is easily reconfigurable and repositionable within the med-gas panel connector systems100described herein. Advantageously, as noted above, the gas lines120may include extra length, which allows the repositioning of the manifolds115and/or med-gas outlets110without removing the gas lines120from the manifolds115or the med-gas outlets110. Thus, the gas lines120may advantageously remain secured to the manifolds115and/or med-gas outlets110as the manifolds115and/or med-gas outlets110are rearranged or reconfigured within the med-gas panel connector systems100described herein. The manifold115includes a manifold inlet pipe205, which extends from the top of the manifold115into the ceiling plenum25of the hospital or other health-care facility. In at least one embodiment, the manifold inlet pipe205connects to a central gas line or supply of the hospital to carry medical gas from the central gas line to the manifold115. In at least one embodiment, the manifold115includes one or more outlets210to deliver gases from the manifold115to the gas lines120of the med-gas connector system100. In at least one embodiment, the outlets210are disposed at least partially within the medical-gas panel connector system100. Each gas line120may connect to an outlet210of the manifold115via threaded nuts or other threaded connection mechanisms215. As noted above, the outlets210of the manifold may include NIST connections to ensure that only compliant gas lines120, which are appropriate for medical gas systems, can be connected to the outlets210of the manifold115. As a further safety precaution, in at least one embodiment, the one or more outlets210of the manifold115include a demand valve that only opens when the correct gas line120is connected to the outlet210. In at least one embodiment, the gas line connection mechanism215includes the demand valve as well. In other embodiments, only the connection mechanism215includes a demand valve. In either case, one will appreciate that the demand valve ensures that the manifold115will not deliver medical gases to non-compliant and/or incorrectly placed gas lines120. If, on the other hand, a manufacturer or assembler connects the correct gas line120to the outlet210of the manifold115, the demand valve opens and allows medical gas to pass from the manifold inlet pipe205, through the manifold115, and into the gas line120. FIGS.3A and3Billustrate an embodiment of a manifold115similar to the manifold115illustrated inFIG.2. In particular,FIG.3Aillustrates a side view of an embodiment of the manifold115. In at least the illustrated embodiment, the manifold115includes two outlets210extending opposite the manifold inlet pipe205. In at least one embodiment, the outlets210each include a DISS adapter305and a threaded portion310. Also, in at least one embodiment, the threaded portion310is customized to be unique, thus preventing incorrect connections of the industry standard gas lines120to the manifold115, as noted above. Each DISS adapter305may be separately installed on the outlets210of the manifold115depending on the need of the client. The DISS adapters305provide a connection that complies with industry regulations and is compatible with industry standard gas lines120. Additionally, embodiments of manifolds115that include DISS adapters305do not need to be pre-tested or certified before use. FIG.3Billustrates a top view of the manifold115illustrated inFIG.3A.FIG.3Bshows the manifold inlet pipe205connected to the top of the manifold115and threaded mounting holes315. In at least one embodiment, the manifold115is secured to the ceiling integration assembly135of the modular wall system105via bolts extending through the threaded mounting holes315, as shown inFIG.2. As such, in at least one embodiment, the manifold115easily detaches and re-secures to various locations along the ceiling integration assembly135as needed. Also, in at least one embodiment, the gas lines120easily detach and re-attach to the various manifold outlets210as needed without brazing or welding. At least one embodiment of the manifold115, such as the manifold115ofFIGS.2-3B, include two outlets210. At least one other embodiment may include more or less than two outlets210. For example,FIGS.4A and4Billustrate a side view of an embodiment of a manifold115that includes four outlets210. Again, in at least one embodiment, each outlet210includes a unique threaded portion310and a DISS adapter305similar to the manifold outlets210shown inFIG.3A.FIG.4Billustrates a top view of the manifold115ofFIG.4A, including four threaded mounting holes315and the manifold inlet pipe205. Various embodiments of the manifold115include any number or configuration of outlets210. For example, at least one embodiment can include two or three outlets210of the same gas type. One or more other embodiments include four or more outlets210. For example, other embodiments are configured with six outlets210, seven outlets210, eight outlets210, nine outlets210, or ten or more outlets210. FIG.5illustrates an embodiment of a single port riser500that includes a manifold inlet pipe205and a single outlet210. The single port riser500includes an inlet pipe205to which the outlet210is directly connected via a riser505and a lock-nut510. The outlet210can also include a DISS adapter305similar to the outlets210of the other embodiments described herein. Turning now to the med-gas outlets110,FIG.6illustrates an embodiment of a med-gas outlet110that includes a panel605and a latch valve assembly610. The latch valve assembly610is available in various industry standard styles that are compatible with gas valves that are inserted to access and regulate the gasses or vacuum for hoses or medical devices. A gas line120may be connected to an inlet on the back side of the med-gas outlet110to carry gas from a manifold115to the med-gas outlet110. In at least one embodiment, the inlet to which the gas line120is connected on the back side of the med-gas outlet110includes a check valve and a DISS adapter and/or NIST threaded portion similar to those included with the manifold outlets210described herein. In at least one embodiment, the latch valve assembly610also includes a demand valve. As noted above, the med-gas panel connector systems100of the present disclosure include one or more vertical frame members130and one or more horizontal frame members125. In at least one embodiment, the med-gas outlet110is secured to the various frame members125,130of the modular wall system10using one or more brackets615. In at least one embodiment, the med-gas outlet110is secured to the bracket615and the bracket615is secured to one or more vertical frame members130. FIG.6illustrates an embodiment of a bracket615that secures the med-gas outlet110to two vertical frame members130. In at least one embodiment, the bracket615includes a number of through-holes. In such an embodiment, the bracket615is secured to the vertical frame members130via bolts passing through the through-holes of the bracket615and through-holes of the vertical frame member130. Additionally, or alternatively, in at least one embodiment, one or more outlets110may be secured to one or more horizontal frame members125. In the illustrated embodiment ofFIG.6, the position of the med-gas outlet110may be adjusted by securing the bracket615using any of the through-holes of the vertical frame member130. In the illustrated embodiment ofFIG.6, a single med-gas outlet110is secured to frame members125,130by a single bracket615. In at least one embodiment, the bracket615may secure multiple outlets110to the frame members125,130. In this way, multiple outlets110may be ganged together. For example, in at least one embodiment, two or more med-gas outlets110may be disposed on the bracket615side-by side in a horizontal configuration. In at least one embodiment, two or more med-gas outlets110may be disposed on the bracket615vertically above and below one another. In at least one embodiment, three or more med-gas outlets110can be ganged together in a combination of horizontal and vertical configurations as described above on a single bracket615. In any case, the bracket615secures the one or more med-gas outlets110to the frame members125,135within the med-gas panel connector systems100described herein. In addition, the vertical frame members130may be secured anywhere along the one or more horizontal frame members125of the med-gas panel connector system100. Additionally, or alternatively, the med-gas outlet110may be adjusted along frame members125,130that do not include through-holes. In such an embodiment, a clip, clamp, or other removable securement means may secure the med-gas outlet110to the frame members125,130such that the med-gas outlet110can be repositioned along the length of any of the frame members125,130. Thus, the brackets615and frame members125,130of the present disclosure provide design flexibility so that a manufacturer can position the med-gas outlets110at various locations within a med-gas panel connector system100by varying the positions of the vertical frame members130and horizontal frame members125. Additionally, or alternatively, the med-gas outlets110may be repositioned by moving the bracket615relative to the frame members125,130. For example, referring toFIG.1, an assembler or installer can add, remove, or rearrange any number of vertical and horizontal frame members130,125to achieve any number of desired manifold115and med-gas outlet110positions.FIGS.1and6show exemplary med-gas outlet110positions, but an installer and/or assembler can rearrange the frame members125,130, med-gas outlets110, gas lines120, and manifolds115to achieve any number of configurations. For example, an installer or assembler can form a system that includes only one or two med-gas outlets110arranged near the bottom of the med-gas panel connector system100. Alternatively, an installer can assemble a system that includes ten to twenty med-gas outlets110, or even more than twenty med-gas outlets110, which are arranged anywhere within the med-gas panel connector system100. Also, for example, an installer and/or assembler can include any number of vertical and/or horizontal frame members130,125in an upper portion of the med-gas panel connector system100so that numerous med-gas panels110may be secured to the upper portion of the med-gas panel connector system100. Additionally, or alternatively, in at least one embodiment, the manifolds115may be disposed at the bottom of the med-gas panel connector system100if needed to connect to central gas lines within the floor of a hospital or other healthcare facility. In such an embodiment, the inlet pipe205of the manifold115may extend out the bottom of the med-gas panel connector system100through one or more horizontal frame members125. Also, whileFIG.1illustrates a system that includes three manifolds115, an assembler or installer can assemble a system that includes more or less than three manifolds115, such as four, five, six, or seven manifolds115, whether required for configurability or local code. Again, all components and embodiments of the med-gas panel connector systems100described herein are compliant with NFPA 99 standards and regulations. The present invention can be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. | 24,941 |
11859751 | DETAILED DESCRIPTION OF EMBODIMENTS In this description, references to “one embodiment”, “an embodiment”, or “embodiments” mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate references to “one embodiment”, “an embodiment”, or “embodiments” in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, structure, act, etc. described in one embodiment may also be included in other embodiments but is not necessarily included. Thus, the present technology can include a variety of combinations and/or integrations of the embodiments described herein. Referring toFIGS.1to4, an embodiment of a clamp style closure device for a pressure vessel or pipeline is shown. In some embodiments, closure assembly10can comprise hub11, which can be adapted to be attached to pressure vessel opening (not shown) or end of pipe (not shown) by welding with use of an appropriately sized bevel13located on the posterior portion of hub11matching that of the pressure vessel opening or pipe end. On the anterior end of hub11, male flange14can be provided extending outwardly from the body and circumferentially around the hub edge. Hub11can comprise circular bore12, which can define the central axis of the closure assembly. In some embodiments, door21can be pivotally attached to hub11via hinge mechanism31for opening and closing closure assembly10. In some embodiments, door21can be circular in configuration with male flange22that is matched dimensionally with male flange14of hub11. Anterior end23and posterior end24of door21can be planar and parallel. Door21can comprise concentric o-ring seal groove127offset from posterior end24of door21in a face-type configuration that can accept elastomer seal25in the form of an o-ring or other configuration that can create a pressure tight seal between hub11and door21. In some embodiments, the plane of sealing surface28of hub11can be substantially perpendicular to the axis of hub bore12, and can be further inclined between zero degrees and fifteen degrees (relative to the normal of the axis of hub bore12) to better accept the seal contained within door21. FIGS.1to6illustrate two halves of split annular ring41and42, for use with closure assembly10, that can be split equally with a vertical plane passing through the axis of hub11. Pivot blocks43and44can be attached to the bottom portion of split annular ring41and42, which can contain through holes49and50, respectively. In some embodiments, hub pivot block46can be attached to the bottom of the outer surface of hub11with circular hole153parallel to the axis of hub11. In some embodiments, the alignment of holes49,50and153can be such that pivot pin150can pass axially through all holes and allow the two halves of split annular ring41and42to rotate about the axis of pivot pin150. Pivot pin150can comprise external threads for installation of nut48to secure the split annular ring assembly in place. In some embodiments, spacer bushing151can be installed between hub pivot block46and pivot pin150to maintain alignment of split annular ring41and42, mating hub flange14and door flange22. To maintain planar movement of split annular ring41and42about hub contact face28, guide bar240can attach to the outer periphery of hub11and can be captured within a slot of guide bar241. As split annular ring41and42advances to the open position, surfaces242and243, as shown inFIGS.11to14, can come into contact and limit the movement of split annular ring41and42about pivot pin150. In some embodiments, one set of guide bars240,241can be mirrored about hub11vertical plane for each split annular ring41and42. Referring toFIGS.4and21, in some embodiments, split annular ring41and42can act as a means for drawing hub male flange14and door male flange22together to facilitate contact between hub contact face28and door contact face29when rotated into the closed position about pivot pin150. Split annular ring41and42can comprise inner channel143concentric to hub bore12that is wide enough to accept both the axial width of hub male flange14and door male flange22. In some embodiments, the sides of inner channel143, and the corresponding contact sides of hub male flange14and door male flange22can be parallel. The included contact angle between opposing sides of inner channel143can vary from zero degrees to 10 degrees. In some embodiments, split annular ring41and42can comprise clearance arcs51and52, which can further comprise of circular sectors of a diameter exceeding the outer diameter of door male flange22as they are projected on split annular ring41and42in the open position. In some embodiments, arcs51and52can extend through the anterior outer surface of split annular ring41and42or through both the anterior and posterior outer surface of split annular ring41and42. Referring toFIGS.1to8, in some embodiments of closure assembly10, hinge assembly31can be provided as a means to support the weight of door21during opening and closing operations and, additionally, to allow door21to be pivoted about the vertical axis of hinge shaft134to facilitate access to hub bore12by employing use of door handle120. Hinge assembly31can comprise upper and lower mounting plates135and136, respectively, operatively coupled to hub11, wherein mounting plates135and136can be coupled to hub11with fasteners or can be integral to the structure of hub11. Mounting plates135and136can be affixed by cross member137to maintain parallelism between plates135and136and to maintain parallelism between cross member137and hub contact face28. Mounting plates135and136can comprise two opposing and axial mounting holes that can accept upper and lower bearing blocks33and34that can be aligned parallel with the vertical axis of hub11. In some embodiments, hinge assembly31can comprise upper and lower mounting plates35and36, respectively, operatively coupled to door21and can be either be coupled to door21with fasteners or be integral to the structure of door21. Mounting plates35and36can be affixed by cross member37to maintain parallelism between plates35and36and to maintain parallelism between cross member37and door contact face29. Mounting plates35and36can comprise two opposing and axial mounting holes that can accept hinge bearing housing147and can pivot about the axis of hinge shaft134. Hinge shaft134can be supported axially within the hinge bearing housing147by means of upper and lower shaft collars37and237(lower shaft collar137not shown) and radially by upper and lower bearings39and239(lower bearing239not shown). Upper and lower bearings39and239(lower bearing239not shown) can be sealed by means of upper and lower seal ring38and238(lower seal ring238not shown). Each end of hinge shaft134can be threaded and can have upper and lower nut135and235(lower nut235not shown) threaded thereupon. Adjustment of door21positioning within the vertical plane can be achieved by alternatively loosening upper and lower nuts135and235(lower nut235not shown) on both ends of hinge shaft134. With reference toFIGS.7,8and15, upper and lower bearing blocks33and34(lower bearing block34not shown) can be operatively coupled to upper and lower mounting plates135and136, as described above. Hinge shaft134can be disposed inside adjustment collar149. The outside of collar149can comprise of oppositely arranged planar edges137,138,139and140. In some embodiments, upper and lower bearing blocks33and34can comprise oppositely arranged screws141,142,143and144located with threaded holes arranged radially with hinge shaft134axis that can contact edges137,138,139and140. By loosening and alternately tightening opposing screws141,142,143and144, axis hinge shaft134and, by extension, door contact face29, can be tilted in minute increments to achieve parallelism between hub contact face28and door contact face29, and concentricity between the circular outer edges of hub male flange14and door male flange22. In some embodiments, circular dished cap145can be installed over upper and lower bearing blocks33and34and be retained by a plurality of screws. FIGS.9to14illustrate, in some embodiments for use with closure assembly10, an over-center toggle mechanism attached to the top of split annular ring41and42, which can function to move split annular ring41and42into its locked position, and to expand split annular ring41and42into the unlocked position through rotation about pivot pin150. Toggle block61can be mounted radially on one half of split annular ring41on the end opposite pivot block43, as shown inFIG.1. Likewise, toggle block62can be mounted radially on one half of the annular ring42on the end opposite pivot block44. In some embodiments, toggle block61can comprise two tines63that can accept the body of toggle block62during the locking operation, as shown inFIGS.4,11and15. Toggle blocks61,62can further comprise through-holes164and165, respectively, that can align axially when split annular ring41and42are in the closed and locked position, and parallel with the axis of hub11. In some embodiments, toggle handle66can comprise tines160that can straddle toggle block62. Toggle linkages64,65can be installed on either side of toggle blocks61,62. In some embodiments, toggle pin67can be inserted through holes provided by toggle linkage64,65and toggle block61. Toggle pin68can be inserted through holes provided by toggle linkage64,65and toggle handle66, as shown inFIGS.11and12. Toggle pin69can be inserted through holes provided by toggle block62and toggle handle66, as shown inFIG.10. During the action of pivoting toggle handle66about the axis of toggle pin69, toggle linkages64,65can, subsequently, pivot about toggle pins67,68forcing the split annular ring41and42to pivot about pivot pin150. Toggle linkages64,65can comprise through-hole160and161, respectively, that can align axially with holes164and165on toggle blocks61and62, respectively, when split annular ring41and42are in the closed and locked position and is parallel with the axis of hub11. Referring toFIG.17, in some embodiments, closure assembly10can comprise pressure alert stem70, further comprising of tee-shaped head71configured to turned by hand wherein pressure alert stem70can be tightened hand-tight and not over-torqued with a wrench. Pressure alert stem70can further comprise cylindrical extension72and threaded body73on the end opposite tee-shaped head71. Cylindrical extension72can further comprise circumferential groove79disposed therearound. In some embodiments, threaded body73can comprise longitudinal groove74parallel with pressure alert stem70axis. Longitudinal groove74can extend from threaded body end75through entire longitudinal length of threaded body73at a depth equal to or greater than the root diameter of the thread. An appropriately sized o-ring76can be passed over threaded body73and installed into o-ring groove77adjacent end surface78. Referring toFIG.18, one embodiment of locking pin80is shown. In some embodiments, locking pin80can comprise of cylindrical pin180having pin end86disposed at one end therefor and end profile87disposed at an opposing end thereof. Locking pin80can further comprise locking pin handle88operatively coupled to cylindrical pin180via locking pin handle shaft85disposed therebetween, wherein locking pin handle shaft85can be substantially perpendicular to cylindrical pin180. In some embodiments, locking pin handle shaft85can comprise first and second ends wherein the first end can be operatively coupled to cylindrical pin180with fastener89, which can comprise a set screw, a dowel pin, a spring pin or any other fastening means well known to those skilled in the art, and wherein locking pin handle88can be operatively coupled to second end of locking pin handle shaft85. Referring toFIGS.15and16, in some embodiments, radial hole90can be provided in hub11having straight or taper thread91located towards outer surface92of hub11. Threaded bushing94, comprising an external straight or tapered thread matching straight or tapered thread91, and straight internal thread95matching the size of threaded body73of pressure alert stem70, can be installed into radial hole90. In some embodiments, stem housing96can be attached radially to outer surface92of hub11with radial hole97concentric to radial hole90. In some embodiments, stem housing96can comprise longitudinal hole98relative to radial hole97that can further comprise a profile identical to end profile87of lock pin80as shown inFIG.18, and wherein longitudinal hole98can be parallel to the axis of hub11. In some embodiments, slot99(as shown inFIGS.13and14) can be parallel to longitudinal hole98and perpendicular to radial hole97and can further extend into radial hole97and be sized to accept locking pin handle shaft85. Locking pin80can be installed in stem housing96by cylindrical pin being disposed in longitudinal hole98wherein locking pin handle shaft85can disposed through slot99of sidewall182of stem housing96and attached to cylindrical pin180with fastener89. Locking pin handle shaft85can then be installed onto locking pin handle shaft85on an exterior side of sidewall182. In some embodiments, the diameter of locking pin handle shaft85and the height of slot99can each be smaller than or equal to the diameter of cylindrical pin180. In some embodiments, the dimensions of locking pin handle88can be larger than the height of slot99. In so doing, cylindrical pin180can translate longitudinally within longitudinal hole98as locking pin handle shaft85likewise translates along slot99of stem housing96, such that movement of locking pin handle shaft85is constrained within slot99. In this manner, locking pin80can move laterally from a locked position, as shown inFIG.15, to an unlocked position, as shown inFIG.16, wherein end profile87of locking pin80does not extend out of longitudinal hole98of stem housing96. This overcomes the problem of requiring additional clearance to remove locking pin80from the assembly altogether, which was required in prior art solutions as described above, as well as keeping locking pin80constrained to stem assembly96thereby removing the risk of damaging or misplacing locking pin80altogether. Referring toFIGS.15and16, the safety features and characteristics of closure assembly10are shown. With toggle mechanism60, split annular ring41and42and door21in the closed position, toggle linkage holes160and161, toggle block holes164and165, and stem housing longitudinal hole98can align along a common axis and, thus, allow locking pin80to be installed until locking pin handle shaft85contacts the end of slot99(as shown inFIGS.13and14) of pressure alert stem housing96, thus inhibiting the movement and function of toggle mechanism60and split annular ring41and42. Pressure alert stem70can be inserted through radial hole97up to threaded bushing94. Pressure alert stem70can then be threaded into threaded bushing94until stem end surface78contacts threaded bushing94and pressure alert stem o-ring76is confined within threaded bushing94effecting a seal. Referring toFIG.19, pressure alert stem70is shown being inserted into radial hole97. Disposed in recess194pressure alert stem housing96can be lock mechanism191. As shown inFIG.19, when key192is turned to the “unlock” position as shown, locking pin193retracts into lock mechanism191, as shown. Referring toFIG.20, pressure alert stem70is shown fully inserted in radial hole97, wherein key192can be turned to the “lock” position (as shown) thereby causing locking pin193to extend from lock mechanism191into groove79of pressure alert stem70thereby preventing pressure alert stem70from being removed from radial hole97thus locking closure assembly10. In some embodiments, closure assembly10can comprise an alternate sealing configuration, as shown inFIGS.21,22,25and26. In some embodiments, hub11can comprise concentric recess129disposed therearound about hub bore12, wherein recess129can be configured to receive concentric protrusion128disposed adjacent groove127disposed on door21, similar to a tongue and groove configuration. In some embodiments, groove127can comprise a rectangular or right trapezoidal cross-section configuration. Protrusion128and recess129can comprise complimentary profiles wherein protrusion128is disposed in recess129when door21is closed and joined together with hub11by split annular rings41and42, and wherein protrusion edge170overlaps with ledge171of recess129. As gas or fluid pressures increase within hub bore12within closure assembly10, the pressure can urge door21away from hub11. As this occurs, protrusion128can partially retract from recess129but still maintain retention of o-ring seal25within groove127. Without this configuration of protrusion128and recess129, excessive pressure within closure assembly10could otherwise cause o-ring seal25to expand outward from groove127into the interstitial gap between door21and hub11, thus resulting in a breach in the seal therebetween. With the embodiments in the foregoing fully engaged, closure actuation is prevented until it can be verified no differential pressure exists within hub bore12. To accomplish this, pressure alert stem70can be rotated counter-clockwise until o-ring seal76backs out of threaded bushing94. If differential pressure exists within hub bore12, the media (liquid and/or gas) present within hub11would expel through longitudinal groove74, alerting the operator of a differential pressure condition within hub11. With o-ring seal76broken and media venting, threaded body73would still be sufficiently engaged to prevent pressure alert stem70from being expelled out of radial hole97, thus preventing harm to the operator. When alerted to a differential pressure situation within hub11, the operator can then rotate pressure alert stem70clockwise to re-seal o-ring76within threaded bushing94and follow procedures to reduce the differential pressure to zero. If, during the counter-clockwise rotation of pressure alert stem70and breaking of o-ring seal76, that no differential pressure is observed, pressure alert stem70may be fully extracted from threaded bushing94and finally out of stem housing96. Only then can locking pin80be disengaged by sliding the pin longitudinally through toggle linkage holes160and161, toggle block holes164and165, and stem housing longitudinal hole98until locking pin handle shaft85contacts the posterior end of slot99within stem housing96. Toggle mechanism60can then be actuated causing split annular ring41and42to rotate around pivot pin150and allow door21to rotate about hinge shaft134axis. In some embodiments, locking pin80can provide an additional advantage over the prior art in that it can incorporate an extra layer of redundancy to the holding characteristics of toggle mechanism60. If, in the event that a failure should occur in one or more features of toggle mechanism60, locking pin80would remain engaged within toggle blocks61and62, thereby reducing the possibility of split annular ring41and42movement and door21opening while hub11contains differential pressure. Referring toFIGS.21,22,25and26, in some embodiments, door21can comprise one or more pressure bypass grooves227, each comprising a circular indentation on the inside surface of seal groove127on door21, which can act as a means for pressure within hub bore12to enter the void space between groove127and o-ring25thereby pushing o-ring25against hub11. As gas or fluid pressures increase within hub bore12within closure assembly10, the pressure can urge door21away from hub11. Pressure entering pressure bypass groove227can allow the o-ring25to advance o-ring25to seal as the door21moves away from hub11. As pressure with closure assembly10is reduced and door21retracts, pressure within the groove127can pass through pressure bypass grooves227inwardly into hub bore12, thereby retracting o-ring25into groove127. In the prior art door seal arrangements as depicted inFIGS.23and24, an o-ring seal273ais disposed within a groove272in door270and retained by hub271. As pressure acts upon door270and hub271, door270advances away from hub271creating a separation allowing the o-ring seal273bto flow into the void region274bresulting in damage and ultimate failure of the o-ring seal. As pressure within void region275is reduced, the o-ring seal237bmay become entrapped between door270and hub271inhibiting the o-ring seal237bretraction into groove272. Referring toFIGS.22,25and26, in some embodiments, door21can comprise one or more pressure bypass grooves227, each comprising a circular indentation on the inside surface of seal groove127on door21, which can act as a means for pressure within hub bore12to enter void space174between groove127and o-ring seal25thereby pushing o-ring25against door surface170and hub surface176. As depicted inFIGS.21and25, in the absence of system pressure, o-ring seal25is deformed within groove127by hub11as a result of the clamping action of clamp rings41and42, resulting in seal contact on groove surfaces170,173and175and hub surface176. In some embodiments, groove127can comprise a trapezoidal cross-section configuration, as shown inFIGS.25and26, whose sides are bounded by groove surfaces170,173and175and hub surface176wherein corner void178in the acute angle formed by groove surfaces173and175. When o-ring seal25is placed in groove127, it can be kept in place by crest177of groove127. In situations when the system pressure within hub11is negative, or a vacuum, corner void178can further provide room for o-ring seal25to move or be drawn into instead of being drawn into void space174. As shown inFIG.26, as the pressure in void space174increases, resulting in protrusion128advancing axially from recess129, pressure bypass groove227can allow pressure from within hub11, traveling through passageway172disposed between hub11and door12, to channel past groove contact surface175thereby allowing seal contact pressure to act on seal groove surface170and hub surface176. As system pressure increases and the distance between protrusion128and recess129increases, pressure bypass groove227allows pressure to act on the posterior surface of the o-ring seal25thus maintaining contact with seal groove surface170and hub surface176and, thus, retaining system pressure therein. As the distance between protrusion128and recess129increases due to increases in system pressure, the movement of seal groove surface170and hub surface171remains axial and the separation distance therebetween remains constant thereby minimizing extrusion of the o-ring seal25into void region175. In other words, even as system pressure causes door12to move away from hub11, the overlapping configuration of protrusion128and recess129allows groove surface170to maintain an overlapping configuration with hub surface171wherein the distance separating the two is constant so as to prevent o-ring seal25from extending into void region175. When the system pressure is removed, pressure bypass groove227can allow for the channeling of pressure within seal groove127to pass through void space174and passageway172to hub11thereby resulting in o-ring seal25to revert to the condition shown inFIG.25without damage, that is, to not being pinched between door12and hub11as shown in the prior art seal arrangement shown inFIG.24. Although a few embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications can be made to these embodiments without changing or departing from their scope, intent or functionality. The terms and expressions used in the preceding specification have been used herein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof, it being recognized that the invention is defined and limited only by the claims that follow. | 24,051 |
11859752 | DETAILED DESCRIPTION It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. FIGS.1and2depict pipeline plug100consistent with at least one embodiment of the present disclosure. In some embodiments, pipeline plug100may include plug body101. Plug body101may be generally tubular. In some embodiments, pipeline plug100may include actuation mechanism103. Actuation mechanism103may include fixed head105and movable head107. In some embodiments, fixed head105may be formed as part of or coupled to plug body101. In some embodiments, movable head107may be movable relative to fixed head105by, for example and without limitation, hydraulic pressure, pneumatic pressure, or electromechanically. In some embodiments, actuation mechanism103may be at least partially positioned within plug body101. In some embodiments, pipeline plug100may include seal assembly111. Seal assembly111may be annular or tubular in shape and may be positioned about plug body101. When actuated, seal assembly111may engage the pipeline such that seal assembly111fluidly isolates the section of the pipeline on one side of seal assembly111from the section of pipeline on the other side of seal assembly111. In some embodiments, pipeline plug100may include gripper assembly121. Gripper assembly121may be annular or tubular in shape and may be positioned about plug body101. Gripper assembly121may be used to maintain the position of pipeline plug100within a pipeline. Gripper assembly121may include one or more gripping elements that extend radially outward into engagement with the pipeline when in an actuated position as discussed further herein below. In some embodiments, actuation mechanism103may be used to actuate gripper assembly121and, in some embodiments, seal assembly111. In some embodiments, movement of movable head107may longitudinally compress gripper assembly121and, in some embodiments, seal assembly111as further described below. FIG.3depicts gripper assembly121consistent with at least one embodiment of the present disclosure. In some embodiments, gripper assembly121may include actuator plate131and bowl141. Actuator plate131and bowl141may be compressed longitudinally together by actuation mechanism103when gripper assembly121is to be engaged. In some embodiments, gripper assembly121may include circumferential wedge sets151positioned between actuator plate131and bowl141. Each circumferential wedge set151may include first circumferential wedge153aand second circumferential wedge153b. In some embodiments, as shown inFIG.3A, each circumferential wedge set151may be aligned with a corresponding actuator wedge133and a corresponding bowl wedge143. In such embodiments, each circumferential wedge set151may be positioned such that actuator wedge133and bowl wedge143are positioned between first circumferential wedge153aand second circumferential wedge153bsuch that linear compression of the space between actuator plate131and bowl141causes circumferential separation or linear in a substantially circumferential direction separation of first circumferential wedge153aand second circumferential wedge153b. In some such embodiments, first and second circumferential wedges153a,153bmay include actuator faces155a,155b, respectively, and bowl faces157a,157b, respectively. Actuator faces155a,155band bowl faces157a,157bmay abut actuator wedges133and bowl wedges143. In some embodiments, Actuator faces155a,155band bowl faces157a,157bmay be formed at an angle that corresponds with the angle of actuator wedges133and bowl wedges143, referred to herein as a forcing angle. For the purposes of this disclosure, two angles are considered to correspond if the two angles are, for example and without limitation, within 15°. In some embodiments, with reference toFIGS.3,3B, gripper assembly121may include gripper units171positioned between actuator plate131and bowl141. Each gripper unit171may be positioned such that a circumferential wedge set151is positioned circumferentially on either side of gripper unit171. Each gripper unit171may include gripper body173. In some embodiments, each gripper body173may include side faces175positioned to abut against expansion faces159a,159bof circumferential wedge sets151positioned adjacent to gripper body173. Side faces175and expansion faces159a,159bmay be formed at an angle, defined herein as an expansion angle. In such an embodiment, in order to set gripper assembly121, actuator plate131and bowl141may be longitudinally compressed by, for example and without limitation, actuation mechanism103. As actuator plate131and bowl141move closer together, actuator wedges133and bowl wedges143may be biased in between first and second circumferential wedges153a,153bof each circumferential wedge set151thereby forcing first and second circumferential wedges153a,153bapart as shown inFIGS.4,4Adue to the forcing angle formed therebetween. Separation of first and second circumferential wedges153a,153bmay be circumferential or linear in a substantially circumferential direction. As shown inFIG.4B, as first and second circumferential wedges153a,153bof each circumferential wedge set151are forced apart, expansion faces159a,159bof adjacent circumferential wedge sets151move closer together, thereby engaging against side faces175of gripper bodies173positioned therebetween. Due to the expansion angle formed between expansion faces159a,159band side faces175of gripper bodies173, gripper bodies173are forced radially outward and, when positioned within a pipeline, into engagement with the inner wall of the pipeline, thereby holding pipeline plug100in place within the pipeline. In some embodiments, the ratio between the radial expansion of gripper bodies173and the axial movement of actuator plate131and bowl141may be, for example and without limitation, between 0.5 and 3.0. FIG.5depicts a perspective view of actuator plate131consistent with at least one embodiment of the present disclosure that shows actuator wedges133. In some embodiments, actuator plate131may include actuator hub135. Actuator hub135may be a boss positioned radially within actuator wedges133such that each actuator wedge133corresponds with a face of actuator hub135, referred to as actuator hub face136. In some embodiments, actuator hub135may be polygonal with flat actuator hub faces136. In other embodiments, actuator hub faces136may be curved. FIG.6depicts a perspective view of bowl141consistent with at least one embodiment of the present disclosure that shows bowl wedges143. In some embodiments, bowl141may include bowl hub145. Bowl hub145may be a boss positioned radially within bowl wedges143such that each bowl wedge143corresponds with a face of bowl hub145, referred to as bowl hub face146. In some embodiments, bowl hub145may be polygonal with flat bowl hub faces146. In other embodiments, bowl hub faces146may be curved. In such an embodiment, with reference toFIG.3BandFIG.4B, each circumferential wedge set151may abut a face of actuator hub135(and similarly abut bowl hub145, not shown for clarity) such that radial forces exerted on first and second circumferential wedges153a,153bof each circumferential wedge set151is transferred to actuator hub135and bowl hub145. First and second circumferential wedges153a,153bmay abut actuator hub135and bowl hub145during the full range of motion of first and second circumferential wedges153a,153b, i.e. in the unset position shown inFIG.3B, the set position shown inFIG.4B, and any intermediary positions. In some embodiments, with reference toFIG.5, actuator plate131may include actuator ways137positioned on each actuator wedge133. In some embodiments, with reference toFIG.6, bowl141may include bowl ways147positioned on each bowl wedge143. Actuator ways137and bowl ways147may extend circumferentially or linearly in a generally circumferential direction. Actuator ways137and bowl ways147may be positioned to engage alignment grooves161formed in first and second circumferential wedges153a,153bof each circumferential wedge set151as shown inFIG.7. Actuator ways137and bowl ways147may, in some embodiments and without being bound to theory, retain circumferential wedge sets151to gripper assembly121, maintain the orientation of each circumferential wedge set151relative to actuator plate131and bowl141, and limit motion of circumferential wedge sets151to circumferential or substantially circumferential directions during actuation of gripper assembly121. In some embodiments, with reference toFIGS.7,7A,7B, first circumferential wedge153aof each circumferential wedge set151may include first interlock rabbet163a, and second circumferential wedge153bof each circumferential wedge set151may include second interlock rabbet163b. In some embodiments, each of first and second interlock rabbets163a,163bmay include interlock teeth165a,165bpositioned such that interlock teeth165aof first interlock rabbet163aengages interlock teeth165bof second interlock rabbet163b. Interlock teeth165a,165bmay be configured in a ratcheting configuration such that interlock teeth165a,165bdisengage as first and second circumferential wedges153a,153bare separated and engage when first and second circumferential wedges153a,153bare biased toward each other. Interlock teeth165a,165bmay therefore, in some embodiments, maintain gripper assembly121in the set position. In some embodiments, first and second interlock rabbets163a,163bmay be arranged such that a longitudinal force on pipeline plug100may disengage interlock teeth165a,165b, such as, for example and without limitation, it is desired to unset gripper assembly121. In other embodiments, first and second interlock rabbets163a,163bmay be arranged such that a longitudinal force on pipeline plug100may engage interlock teeth165a,165b. In such an embodiment, interlock rabbets163a,163bmay be biased apart by a biasing mechanism such that when the longitudinal force on pipeline plug100is released, interlock teeth165a,165bare disengaged, allowing gripper assembly121to be unset. In some embodiments, one or more of actuator ways137and bowl ways147may interlock with corresponding alignment grooves161such that, in some such embodiments, separation of actuator plate131and bowl141may pull first and second circumferential wedges153a,153bapart, thereby allowing interlock teeth165a,165bto be disengaged. FIG.8depicts a perspective view of gripper unit171consistent with at least one embodiment of the present disclosure. As discussed above, gripper unit171may include gripper body173having side faces175. In some embodiments, gripper unit171may include sliding gripper177. Sliding gripper177may abut gripper body173at radially outward face179of gripper body173. In some embodiments, sliding gripper177may be wedge shaped. In some such embodiments, radially outward face179may be formed at an angle as shown inFIG.8Aor may be curved as shown inFIG.8B(shown as radially outward face179′ of gripper body173′ of gripper unit171′) to correspond with the contour of sliding gripper177(or177′ inFIG.8B). In such an embodiment, longitudinal movement of sliding gripper177relative to gripper body173may cause sliding gripper177to move radially outward from gripper body173. Such longitudinal movement may, in some embodiments, be caused by longitudinal movement of gripper assembly121relative to a pipeline when in the set position. For example,FIG.9shows a cross section of gripper unit171positioned within pipeline10in the set position. (Actuator plate131and bowl141are shown for reference, but, as discussed above, may, in some embodiments, not contact gripper unit171.) Sliding gripper177, is in contact with pipeline10. Longitudinal force exerted on pipeline plug100, such as, for example and without limitation, force caused by a differential fluid pressure across seal assembly111of pipeline plug100, may be transferred to gripper unit171. As shown inFIG.9A, sliding gripper177, in contact with pipeline10, may remain in place. Any longitudinal displacement of gripper body173may, due to the taper (or curvature) of radially outward face179, cause an increase in force exerted between sliding gripper177and pipeline10, thereby increasing the gripping force exerted on pipeline10by gripper assembly121. FIGS.10-12depict gripper assembly221consistent with at least one embodiment of the present disclosure. Similar to gripper assembly121described above, gripper assembly221may include actuator plate231, bowl241, circumferential wedge sets251, and gripper units271. In some embodiments, gripper assembly221may include hoop spring222positioned about gripper bodies273of gripper assembly221. In such an embodiment, hoop spring222may provide a radially inward bias for retracting gripper bodies273. In such embodiments, as shown inFIGS.11,12, circumferential wedges253a,253bof circumferential wedge sets251may be positioned radially within gripper units271. In such embodiments, gripper assembly221may operate substantially similarly to gripper assembly121. However, in such an embodiment, by positioning circumferential wedge sets251radially within gripper units271, the area of sliding grippers277and therefore the contact area between gripper assembly221and a surrounding pipeline is increased. In some embodiments, gripper body273may directly abut bowl241. In some such embodiments, bowl wedges243may be positioned on gripper body273such that circumferential wedge sets251are compressed between actuator wedges233and bowl wedges243formed on gripper body273as circumferential wedge sets251are positioned radially inward of gripper units271. In some embodiments, gripper body273may be mechanically coupled to bowl241by one or more retainers245such that gripper body273is slidable relative to bowl241. In some embodiments, one or more of actuator wedges233may be spring-loaded to actuator plate231. In such an embodiment, wedge spring234may be positioned between actuator wedges233and actuator plate231such that the bias force provided by wedge spring234engages interlock teeth of circumferential wedge sets251. In some such embodiments, the circumferential expansion of each circumferential wedge set251may not rely on forces provided by adjacent circumferential wedge sets. The foregoing outlines features of several embodiments so that a person of ordinary skill in the art may better understand the aspects of the present disclosure. Such features may be replaced by any one of numerous equivalent alternatives, only some of which are disclosed herein. One of ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. One of ordinary skill in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure. | 15,614 |
11859753 | DETAILED DESCRIPTION OF THE DRAWINGS FIG.1Ais a side view of an assembly10for relining a junction12between a main pipeline14and a branch pipeline16according to a first embodiment. The assembly10comprises a seal installation device18which is inserted into the main pipeline14and moved to a location juxtaposing the junction12between the main pipeline14and the branch pipeline16. The seal installation device18is attached at one end to a manipulator20which is used for rotating and aligning the seal installation device18relative to the junction12. On the opposite end of the seal installation device18is attached an extension tube22for accommodating a light curing device24and part of the seal26to be installed at the junction12. The light curing device24is connected to a polymeric sheathing tube28which is used for powering, cooling and conveying the light curing device24. The end of the extension tube22facing away from the seal installation device18is fluidly connected to a pressurized gas supply30and a steel wire32. Pressurized gas is also supplied to the polymeric sheathing tube28. The pressurized gas supply30, which also includes communication cables, and the steel wire32and the polymeric sheathing tube are all led to a truck34which is located outside the main pipeline,14, in the present case above ground. A pulley36is used for directing the wire32through a manhole38. The manhole38, which runs vertically, is used for accessing the main pipeline14running horizontally below ground. The truck34includes a compressor for supplying pressurized gas to the compressed gas supply30and a winch for pulling the wire32. Further, the truck also includes the power supply, cooling air supply and control wires for the light curing device24which are all included in the sheathing tube28. On the opposite side, a cable for powering and controlling the seal installation device18and the manipulator20is connected to the end of the manipulator20opposite the seal installation device18. The cable40is also used for pulling the seal installation device18and the manipulator20, similar to the wire32on the opposite end. The cable40is led up to a compact winching vehicle42via a pulley assembly44. The compact winching vehicle42includes a winch for pulling the cable40and a power and control unit for providing power and controlling the seal installation device18and the manipulator20. The compact winching vehicle42is preferably battery powered. The pulley assembly44is clamped in the main pipeline14and serves as a gentle way of changing the direction of the cable in order for the cable to be directed up through the opposite manhole38′ to the compact winching vehicle42. FIG.1Bis a side view of an assembly10′ for relining a junction12between a main pipeline14and a branch pipeline16according to a second embodiment. The present embodiment is an alternative to the previous embodiment with the difference that the steel wire is omitted and instead a cable40′ is used similar to the opposite side. Consequently, a further pulley assembly44′ is used for guiding the cable40′ at the right angle bend between the manhole38and the main pipeline14. FIG.2Ais a side view of a seal installation device18when being introduced into the main pipeline14. Both the seal installation device18and the manipulator20are typically introduced into the main pipeline14via one of the manholes38. Thereafter, a gripping mechanism46of the manipulator20grips the seal installation device18such that both the manipulator20and the seal installation device18are fixated in relation to each other. The manipulator20comprises expansion members48circumferentially disposed about the central axis of the manipulator20. These expansion members48are expanded in the circumferential direction and clamp the manipulator20and thereby also the seal installation device18in the rotational direction. The expansion members48have wheels and allow the manipulator20and the seal installation device18to move in the longitudinal direction. The location of the junction12is detected by the camera56′ and the antenna56′″. The seal installation device comprises the seal26as previously described. The seal26, comprising a brim portion and a tubular portion, is accommodated juxtaposed an expandable bladder50of the seal installation device. The bladder50, which in the present view is non-expanded, is typically made of a durable polymeric material and comprises a cylindrical part50aand a tubular part Sob. The cylindrical part50aof the bladder encloses a housing52of the seal installation device18having an open structure such as a grid structure and an opening54. The tubular part Sob of the bladder50is inverted into the opening54and extends though the housing52and optionally into the extension hose22. The seal26is placed at the opening54such that the brim portion contacts the cylindrical part50aof the bladder and the tubular portion is inverted into the likewise inverted tubular part Sob of the bladder50. The tubular portion of the seal26bthus extending into the opening54in the housing52. FIG.2Bis a side view of a seal installation device18when rotated by the manipulator within the main pipeline14. Since there is no way of ensuring that the seal installation device18does not rotate when moved through the main pipeline14, the opening54may be misaligned with the branch pipeline16. This cannot be easily corrected using the winching units, and instead the misalignment is determined using a camera56′ on the manipulator20. The manipulator20comprises an outer elongated frame58which is comprising the expansion members48and which thus is fixed in the rotational direction, and an inner elongated frame60which is comprising the gripping mechanism46and which is rotatable in relation the to the outer elongated frame58in order to be able to rotate the seal installation device18as shown by the arrows in order to align the opening54with the branch pipeline16. FIG.2Cis a side view of a seal installation device18when moved in the longitudinal direction within the main pipeline14. The seal installation device18is moved within the pipeline14by using the winching units in the truck and in the winching vehicle, pulling the relevant cable or wire and thereby causing the seal installation device18and the manipulator20to move in either direction as shown by the arrow. The seal installation device18and the manipulator20are held substantially centered in the main pipeline14due to the expansion members. The seal installation device18is thereby moved to the correct longitudinal position in which the opening54is longitudinally aligned with the junction12between the main pipeline14and the branch pipeline16. The distance between the seal26and antenna/camera56′ has been predetermined, thereby the distance to move the installation device is known. FIG.2Dis a side view of a seal installation device18when the bladder inverts the seal26into the branch pipeline16and presses it against the junction12. By applying pressurized gas from the gas supply tube30as shown by the hatched arrow, the tubular part Sob of the bladder is inverted out through the opening54, the cylindrical part5oaof the bladder is expanded towards the inner surface of the main pipeline14, and the seal26is pressed by the bladder5oagainst the junction12, as shown by the arrows. FIG.2Eis a side view of a seal installation device in a pipeline with a branch pipeline. InFIG.2Ethe seal is a sleeve/liner29to be placed around the circumference of the main pipe, and with a branch sleeve going up in the branch so that damage to both the main pipe adjacent the pipe branch may be repaired, i.e., the sleeve/liner is T-shaped. In order to place the T-shaped liner at the junction, the seal installation device is provided with the bladder similar to explained above, and the liner is placed on the outside of the bladder so that when the bladder is inflated the liner comes into contact with the main pipe. InFIG.2Epart of both the bladder and the liner are cut away so that the grid can be seen. The liner may be of glassfiber material or felt material. Epoxy may be placed on the outside of the liner so that there is a layer of epoxy between the liner and the pipe surface. FIG.2Fis a close up of the seal installation device inFIG.2Ein a cross section (the cross section is in a plane parallel to the center axis of the seal installation device).FIG.2Fshows the area around a first end edge of the T-shaped sleeve. FIG.2Gis a close up of the seal installation device inFIG.2Eshowing the area around a second end edge (opposite the first end edge). A gasket27is placed around the outer perimeter of the liner at the first end edge as well as outside the liner at the other end edge of the liner. Alternatively, the gasket may be in continuation of the end edges so that the bladder presses on the gasket directly instead of the liner being between the gasket and the bladder. The gasket is to prevent/reduce liquid flowing into the liner between the liner and the surface of the pipe. The gasket may be of rubber material or of a hydrophile material having affinity for liquid such as water. The gasket may also be an epoxy. A gasket may also be placed at the edge of the branch sleeve (not shown in close up). FIG.3Ais a side view of a seal installation device18, an associated extension22of the seal installation device18and a light curing device24located on the extension22. When not in use, the light curing device24is located in a garage62which forms a small bulge of the extension22at the top of the extension22in order not to interfere with the tubular part Sob of the bladder. The polymeric tube28for powering, cooling and controlling the light curing device24is introduced into the garage62through a pressure tight entry64which will allow the polymeric tube28to enter the extension22and push the light curing device24into the seal installation device18for curing the seal26. The polymeric tube28is driven by a drive mechanism66as well located at the top of the extension22but outside the garage62. FIG.3Bis a rear view of a seal installation device18, an associated extension22of the seal installation device18and a light curing device24located on the extension22. FIG.3Cis a top view of a seal installation device18, an associated extension22of the seal installation device18and a light curing device24located on the extension22. The drive mechanism66comprises a first pair of rollers68and a second pair of rollers70which provide traction for the movement of the polymeric tube28. Each roller of each pair rollers is opposing each other and defines a concave inner surface contacting the polymeric tube28. The first pair of rollers68and a second pair of rollers70are optionally interconnected by cogwheels in order to obtain a synchronized movement of the polymeric tube first pair of rollers68and a second pair of rollers70. FIG.4is a perspective view of a seal installation device18without the bladder. The housing52of the seal installation device18defines a grid structure for allowing the light of the light curing device24to illuminate the seal26. FIG.5Ais a side cutout view of a seal installation device18showing the pivotable plate72. The pivotable plate72has a slightly curved shape or “spoon” shape and is at one end hingedly connected to the seal installation device18opposite the opening54via a hinge74. The opposite end of the pivotable plate72is free. The pivotable plate72is further slidably connected to a linear actuator76which allows the pivotable plate72to pivot between a substantially horizontal orientation and a substantially vertical orientation. The linear actuator76is located opposite the opening54. FIG.5Bis a close-up side view of a seal installation device18in which the pivotable plate72is in the horizontal position. When the linear actuator76is pulled back, the pivotable plate72forms a substantially flat surface opposite the opening54between the hinge74and the actuator76. In this way the light curing device24may pass through the seal installation device18as shown by the arrow from the location of the hinge74to the location of the linear actuator76between the opening54and the pivotable plate72as indicated by the arrow. In this way the complete brim portion26aof the seal26may be cured. FIG.5Cis a close-up side view of a seal installation device18in which the pivotable plate72is in the vertical position. By moving the linear actuator76towards the hinge74, the pivotable plate72is pivoted such that the end opposite of the hinge74is located adjacent the opening54, thereby blocking the access straight through the seal installation device18as shown by the arrows. FIG.5Dis a close-up side view of a seal installation device18in which a light curing device24is moved into the branch pipeline16. When inserted into the seal installation device18, the light curing device24will be directed by the pivotable plate72through the opening54and into the branch pipeline16as shown by the arrow. FIG.5Eis a close-up side view of a seal installation device18in which a light curing device24is moved out of the branch pipeline16. In order to cure the tubular portion26bof the seal26, the light curing device24is lit up and pulled back through the tubular portion26bof the seal26as shown by the arrow. In this way, the seal26is firmly cured towards the junction12due to the contraction of the tubular portion26bduring curing. FIG.5Fis a side view of a seal installation device with a pivotable plate. The seal installation device shown inFIG.5Fmay be used in a case where a liner is to be placed around the circumference of the main pipeline, and where the liner has a seal to be inserted into the branch. Such a situation is illustrated inFIG.2E. In that case the seal installation device is to allow for an illumination for 360°. This is achieved by providing a grid all around the cylindrical wall, i.e., as opposed toFIG.5Athe grid continues along the bottom of the tool. Additionally, the pivotable plate is provided with a grid. Thus, electromagnetic radiation may be emitted out through the bottom and the pivotable plate as well for curing the liner all the way around the main pipe. FIG.5Gis a side view of a seal installation device for a part-liner for repairing localized damage. The seal installation device shown inFIG.5Fdoes not have the pivotable plate, and there is no opening in the seal installation device for direction a light curing device into a branch pipe. Instead, the grid extends with perforations for 360°. FIG.6Ais a perspective view of the manipulator20for rotating the seal installation device18. In the present view, the wheels48′ of the expansion members48are shown, as well as the number of expansion members48which typically will be 3 or 4 in order to be able to center the manipulator20in the main pipeline14. The outer elongated frame58is connected to the inner elongated frame60by a set of cogwheels which is rotatable by a motor within the inner elongated frame60. The inner elongated frame comprises the camera housing56which may include an antenna56″″, a front view camera56′ and a rear view camera56″. The outer and inner elongated frames58,60may be separable for easy cleaning and maintenance. FIG.6Bis a close-up side view of a manipulator20moving within the main pipeline14and detecting the branch pipeline16. The antenna56′″ may be used for the purpose of accurately detecting the position of the branch pipeline16. The antenna56′″ has a length such that when the antenna56′″ is located within the main pipeline14, it is bent, indicating that the branch pipeline16is not yet reached. FIG.6Cis a perspective view of a manipulator20having a camera56′ for inspecting the junction12between the main pipeline and the branch pipeline. When the antenna56′″ reaches the branch pipeline16by moving the seal installation device and the manipulator if required both in rotational and longitudinal directions, the antenna56′″ swings from the bent position to the upright position. Thus, it is detected that the branch pipeline16is at the location of the antenna56′″. The camera56may be swung outwards in order to visually detect the precise location of the antenna in the branch pipeline16, and place it accurate at the junction centerline against the branch pipeline wall. As the distance between the antenna/camera and the opening of the seal installation device is known, the positioning of the seal at the junction may be made very accurate by moving the setup the known distance in the longitudinal direction from the first manhole towards the second manhole. FIG.7Ais a seal installation device18in which the flexible bladder is in a deflated and partially inverted position. In the present view it is clearly illustrated that the tubular part Sob of the bladder50is inverted through the opening54of the seal installation device18and extends out of one end of the seal installation device18, being the end which is connected to the extension (not shown). When the seal installation device18is pressurized during the placement of the seal, the pressure will cause the cylindrical part50aof the bladder50to inflate and the tubular part Sob of the bladder50to invert back as shown by the arrows. FIG.7Bis a seal installation device in which the flexible bladder is in an expanded position. The tubular part Sob of the bladder50has reassumed its expanded and inflated position for being able to apply a pressure on the tubular part of the seal. The bladder is made of a durable and transparent/translucent material. FIG.8Ais a perspective view of a seal26′ for sealing the junction between the main pipeline and the branch pipeline according to a first embodiment. The seal26′ comprises a brim portion26a′ and a tubular portion26b′. The brim portion26a′ is covered by an adhesive78such as epoxy paste in order to seal against the inner surface of the main pipeline. Suitable fiber materials include glass, polyamide, polyester, polyolefin (polypropylene PP or polyethylene PE), polyacrylonitrile (PAN), polysulfone. Also, polyaramin carbon fiber and cellulose may be used. Suitable adhesives are epoxy, polyurethane, vinyl ester and polyester. The material may be woven, non-woven, knitted or warp knitted. FIG.8Bis a perspective view showing the different layers of the tubular portion26b′ of the seal26′. The layers comprise an inner coating80and an outer nonwoven felt82. The fibers, being of the types listed above, are oriented to promote during curing a longitudinal contraction whereas maintaining the outer circumference during curing of the seal26′. FIG.8Cis a perspective view showing the different layers of the brim portion26a′ of the seal26′. The layers are all adhered together and are divided into two main layers, an outer and an inner, which each in turn comprises several sublayers. The main layers have perpendicular machine directions. From the outside, i.e., the surface of the brim portion26a′ which is adapted for facing the inner surface of the main pipeline, the outer layers are: one fleece layer84, one CSM layer86, one CD rowing 90° layer88, one CSM layer90, one MD reinforced 0° layer92, whereas the inner layers are: one MD reinforced 0° layer92′, one CSM layer90′, one CD rowing 90° layer88′, one CSM layer86′, one fleece layer84′. The above layers are oriented such that the reinforcement directions of the layers are such that the main layers do not expand or contract during curing. In the present case, both the upper and lower layers comprise fiber directions extending both in the longitudinal direction as well as in the circumferential direction in order to minimize contraction during curing. In this way the stress applied to the epoxy adhesive will be minimized and the risk of voids substantially eliminated. The layers may be adhered, nailed, sewed, flame bonded or woven. The brim portion may optionally have a coating and different layers and material are feasible in order to achieve a direction dependent movement of the brim portion, such as combinations of glass and felt layers and/or other similar fiber types. The coating may be thermoplastic, polyethylene or PVC. Also, polyamide and thermoplastic urethane are usable. FIG.8Dis a perspective view of a seal showing the curing of the brim portion26a′ of the seal26′ using a light curing device24moving as indicated by the arrow and illuminating the brim portion26a′. It is shown how the light curing device is first curing the brim portion26a′ of the seal26′. In this way the epoxy adhesive adheres to the inner wall of the main pipeline while the brim portion26a′ retains its position without deforming or contracting, as such contraction would induce stress and possibly voids in the adhesive joint. FIG.8Eis a perspective view of a seal showing the curing of the tubular portion26b′ of the seal26′ using a light curing device24. The curing starts by illuminating tubular portion26b′ at its far end. FIG.8Fis a perspective view of a seal26′ showing the contraction of the tubular portion26b′. By curing the tubular portion26b′ from the far end in a direction towards the brim portion26a′, the tubular portion26b′ tends to contract away from the brim portion26a′, thus pulling the brim portion26a′ towards the junction thereby obtaining a firm fixation. FIG.9Ais a perspective view of a seal26″ for sealing the junction between the main pipeline and the branch pipeline according to a second embodiment. The seal26″ comprises similar to the previous embodiment a brim portion26a″ and a tubular portion26b″. The brim portion26a″ does not comprise any adhesive and instead a sealing ring94is used in order to seal against the inner surface of the main pipeline. The sealing ring may be made of e.g., rubber such as foamed rubber, EPDM, natural rubber, nitril rubber or silicone rubber. It may also be based on water expanding materials based on e.g., chloroprene or bentonite. The sealing ring is typically O shaped, however, other shapes are feasible e.g., D, H, U etc. FIG.9Bis a perspective view showing the different layers of the tubular portion26b″ of the seal26″. The layers comprise, similar to the previous embodiment an inner coating80′ and an outer nonwoven felt82′. The fibers are oriented to promote during curing a longitudinal contraction whereas maintaining the outer circumference during curing of the seal26″. FIG.9Cis a perspective view showing the different layers of the brim portion26a″ of the seal26″. The layers are all adhered together and are divided into two main layers, an outer and an inner, which each in turn comprises several sublayers. The inner layers are, similar to the previous embodiment, the outer different. From the outside, i.e., the surface of the brim portion26a″, which is adapted for facing the inner surface of the main pipeline, the outer layers are an outer coating80′ and an inner nonwoven felt82′ similar to the tubular portion26b″. The coating may be thermoplastic, polyethylene or PVC. Also, polyamide and thermoplastic urethane are usable. The inner layers are however similar to the brim of the previous embodiment, namely: one MD reinforced 0° layer92″, one CSM layer90″, one CD rowing 900 layer88″, one CSM layer86″, one PV layer84″. The inner layer is oriented such that the reinforcement directions of the layers are such that the inner layer does not expand or contract during curing, whereas the outer layer will contract due to its composition. In this way a stress is applied in the brim portion26a″ as the outer layer has a tendency to contract during curing and the inner layer maintains a minimized contraction during curing. FIG.9Dis a perspective view of a seal26″ showing the curing of the brim portion26a″ using a light curing device24. As with outer layer contracts during curing, the brim portion26a″ will be subjected to an internal stress which as shown by the arrows causes the curvature of the brim portion26a″ to increase which in turn will cause the brim portion26″ to apply a force towards the inner surface of the main pipeline. This will allow the sealing ring94to apply a permanent sealing pressure onto the inner surface of the main pipeline, thus ensuring that the seal26″ remains fluid tight after curing. FIG.10Ais a cutout view and an associated close-up view of a light curing device24showing the heat sinks within the light curing device24. The view is along the axis of the light curing device24. The light curing device24comprises an outer cover96being of a transparent or translucent material, typically glass, however, also feasible is a rigid polymeric material. The cover96encloses the LED light sources98which are thus protected from mechanical impacts. The LED light sources98provide the light necessary for curing, typically being a blue light. In order to provide cooling for the LED light sources98, the interior of the light curing device24comprises an outer passage100and an inner passage102which are placed in a coaxial relationship. The passages100102comprise heat sinks which are thermally connected to the LED light sources98for removing the heat generated by them. An air flow is caused to pass through the passages100102in order to transport the heat from the heat sinks100102in the passages to the outside. The heat sink comprises thin metal walls allowing good thermal contact with the passing cooling air, preferably using printing technologies in order to obtain very thin walls. FIG.10Bis a top view of a light curing device24. The air enters the light curing device24at the centrally located air entry104and leaves the light curing device24at the same end at the exit106. FIG.10Cis a top cutout view of a light curing device24showing the flow paths within the device. The air entry104is connected to the polymeric sheathing tube (not shown) which delivers cooling air to the light curing device24. The air entry is connected to the inner passage102which extends through the interior of the light curing device24to the opposite end of the light curing device24where the flow is led outwards and reversed in a reversing chamber before being led into the outer passage100. The outer passage100extends outside and separates in relation to the inner passage102from the flow reversing chamber to the air exit106at which the air is simply led to the outside. The air has thereby absorbed the excessive heat generated by the LED light sources98. FIG.10Dis a top view of an alternative embodiment of a light curing device24′ having two inlets104′104″ and a common outlet106′. The air enters the light curing device24′ at any of the two inlets104′104″, whereby the central inlet104′ is connected to an air compressor or similar pressure source and the secondary inlets104″ receives air from the surroundings. All air leaves the light curing device24′ at the common outlet106′. All other features are similar to the previous embodiment of the light curing device described above. FIG.10Eis a top cutout view of the alternative embodiment of a light curing device24′. The central inlet104′ is connected to the inner passage102whereas the secondary inlets104″ are connected to the outer passage100. The inner and outer passages102100are preferably provided with heat sinks (not shown) similar to the previous embodiment. Near the common outlet106′, the inner passage102defines a nozzle95constituting the minimum flow area of the inner passage102. FIG.10Fis a top cutout view of the alternative embodiment of a light curing device24′ showing the flow paths within the device. The inner passage102is as described above connected to an air pressure source (not shown) which causes a stream of air to flow through the inner passage102from the central inlet104′ to the common outlet106′ as shown by the filled arrow. A flow jet will thereby be established by the nozzle95towards the common outlet106′. The flow jet causes entrainment of air through the outlet passage100due to the ejector effect. Thus, air will be sucked in through the secondary inlets104″ and pass through the outer passage100and leave the light curing device24′ through the common outlet106′, as indicated by the non-filled arrows. The ejector effect allows much more air to pass through the light curing device24′ compared to connecting both passages to the air pressure source. As all of the air passing through the inner passage102and the outer passage100contributes to cooling the LEDs, the total cooling effect will be larger. As an alternative/supplement to sucking air into one or more of the secondary inlets, water (or another liquid) may be supplied to the light curing device via a hose. The liquid may enter the light curing device at one or more of the secondary inlets and be atomized by an atomizer nozzle at one or more of the secondary inlets. Such a supply of liquid and subsequent atomizing by an atomizer nozzle may also be provided in any of the following examples of light curing devices with secondary inlets. FIG.10Gis an alternate embodiment of the light curing device24″ in which a stream of air is led above the LEDs98. The present embodiment is similar to the previous embodiment except that the secondary inlets104are located between the cover96and the LEDs98and adjacent the exit106′. Air will be sucked in through the secondary inlet104″, pass through a primary outer passage100′ above the LEDs98. Thereafter the stream will turn and pass through a secondary outer passage100″ in the opposite direction below the LEDs98and finally leave the light curing device24″ through the common outlet106′, as indicated by the non-filled arrows. In this way, both the top and the bottom of the LEDs will be cooled. The ejector effect is used similar to the previous embodiment and illustrated by the filled arrow allowing much more air to pass through the light curing device24″ compared to connecting both passages to the air pressure source. FIG.10His an alternate embodiment of the light curing device24′″ in which the outer passage100pass above the LEDs98. The present embodiment is similar to the previous embodiment except that the secondary inlet104″ is located adjacent the central inlet104′ and the outer passage100does not pass below the LEDs98. Air will be sucked in through the secondary inlets104″, pass through the outer passage100above the LEDs98. Thereafter the stream will leave the light curing device24′ through the common outlet106′, as indicated by the non-filled arrows. The ejector effect is used similar to the previous embodiment and illustrated by the filled arrow allowing much more air to pass through the light curing device24′″ compared to connecting both passages to the air pressure source. FIG.10Ishows an alternate embodiment of the light curing device24{circumflex over ( )} (FIG.10Iis a cross section which is parallel to the center axis going through the central inlet104′ and the common outlet106′). In the present embodiment, the secondary passage104Vfluidly connects the central inlet with the outer passage so that during operation of the light curing device, the air flow is led from the central inlet104′ to the outer passage via the secondary passage104w. The central inlet104′ is at an inlet end of the light curing device24{circumflex over ( )}, and it is connected to an air pressure source (not shown) which causes a stream of air to flow into the central inlet104′. The common outlet106′ is at an outlet end of the light curing device24{circumflex over ( )}. The secondary passage is closer to the inlet end than the outlet end. At the other end of the outer passage (opposite the secondary passage) is a third passage, which leads the air flow from the outer passage to the common outlet. The LEDs are in thermal contact with a thermal conductive material constituting a heat sink (the solid shown as hatched areas with a different hatching than the cover96), i.e., the LEDs may be mounted on a PCB (printed circuit board), which may have a surface abutting or in proximity to the heat sink. The light curing device has an exit heat-transfer region at the third passage (proximate the outlet end) such that the air flow passes through the exit heat transfer region on the way from the outer passage to the common outlet. A heat-transfer region is to be understood as a part of the light curing device where the air flow through the device comes in contact with a surface of the heat sink. For example, inFIG.10I, the heat sink forms part of the wall of the third passage104™. The light curing device may have an entry heat-transfer region at the secondary passage (proximate the inlet end) such that the air flow passes through the entry heat-transfer region on the way from the central inlet to the outer passage. The heat sink may comprise fins such that the air flow passes through the fins on the way from the central inlet to the outer passage. For example, the fins may be located in the exit heat-transfer region (outside the central passage). Similarly, fins may extend from the heat sink such that the air passes through the fins on the way from the outer passage to the common outlet. The fins may extend radially or angularly. It is contemplated that the heat transfer from the heat sink to the air flow may be greater at the exit heat transfer region than at the entry heat transfer region, i.e., such that the air flow is not heated (or heated to a less degree) at the entry heat transfer region before it flows over the LEDs in the outer passage. This can be achieved by making the surface area of the heat sink greater at the exit heat transfer region than at the entry heat transfer region. Or by having more fins in the exit heat transfer region than at the entry heat transfer region. FIG.10Jis an alternate embodiment of the light curing device24win which the outer passage100pass above and below the LEDs98. The present embodiment is similar to the previous embodiment except that the outer passage100does pass both above and below the LEDs98. Air will be sucked in through the secondary inlets104″ and104″ and pass through the outer passage100both above the LEDs98and below the LEDs98in a primary outer passage100′ and a secondary outer passage100″ constituting two parallel streams. Thereafter the parallel streams of air will leave the light curing device24′ through the common outlet106′, as indicated by the non-filled arrows. The ejector effect is used similar to the previous embodiment and illustrated by the filled arrow allowing much more air to pass through the light curing device24IV compared to connecting both passages to the air pressure source. FIG.10Kis an alternate embodiment of the light curing device24vin which the nozzle95is located near the central inlet104′ and the secondary inlet104″ is located. In the present embodiment, the outer passage and the inner passage102essentially form a common passage for a stream of air for cooling the LEDs98, whereby the central inlet104′ is connected to high pressured air and the secondary inlet104″ entrains air from the surroundings using the ejector effect. The ejector effect is used similar to the previous embodiment and illustrated by the filled arrow allowing much more air to pass through the light curing device24wcompared to connecting both passages to the air pressure source. As a supplement to a nozzle in the beginning of the light curing device, an additional nozzle for entrainment may be provided at the end of the light curing device, i.e., a path may lead compressed fluid to the end where it goes into the additional nozzle such that air from outside may be entrained via secondary inlets. FIG.10Lis an alternate embodiment of the light curing device2similar to the previous embodiment, however, there exist two secondary inlets104″104′″ located at the central inlet104′ and the common outlet106′, respectively. The outer passage100extending from one of the secondary inlets104′″ is passing outside the LEDs98whereas the other secondary inlet104″ is passing below the LEDs98and form a common passage with the inner passage102. The secondary inlets104″104′″ entrains air from the surroundings using the ejector effect. FIG.10Mis an alternate embodiment of the light curing device24vsimilar to the previous embodiment, however, there is only a secondary inlet at the common outlet106′ and the secondary inlet at the central inlet104′ is closed. FIG.10Nis a set of coupled light curing devices24in a pipeline14having a small diameter. The distance between the individual light curing devices24are set to a small distance enabling an even distribution of light inside the pipeline. FIG.10Ois a set of coupled light curing devices24in a pipeline14having a medium diameter. The distance between the individual light curing devices24are set to a standard distance enabling an even distribution of light inside the pipeline. FIG.10Pis a set of coupled light curing devices24in a pipeline14having a large diameter. The distance between the individual light curing devices24are set to a large distance enabling an even distribution of light inside the pipeline. FIG.11Ais a perspective view of a pulley assembly including a cable. The pulley assembly is used for changing the direction of the cable without any damage to the cable, i.e., when passing the cable from the manhole to the main pipeline. The pulley assembly comprises a pulley108for accommodating a cable. The pulley108is connected to a frame110which comprises fasteners112for fastening the pulley at the junction between a main pipeline and a manhole. The pulley assembly comprises removable pins114in order to prevent the cable from slipping out of the pulley108. Further, the pulley assembly comprises a connector116for being able to connect a control wire for controlling the fasteners112. Preferably, the cable for controlling and pulling the seal installation device is guided via the pulley108. In an advantageous embodiment, the cables are mounted on the pulley108before the pulley assembly is introduced into the manhole. FIG.11Bis a perspective view of plug120associated with a cable118. The cable118may be used together with the pulley assembly and seal installation device described above. The cable comprises an outer polymeric coating and beneath the coating a Kevlar sheath124with load bearing capabilities. The Kevlar sheath124allows the seal installation device to be pulled into the main pipeline using the cable118. The Kevlar sheath124also protects the underling wires122. The wires122provide power and communication between the user interface on the ground and the seal installation device/manipulator inside the main pipeline. The Kevlar sheath124is connected to the plug120by an epoxy joint126within the plug120allowing the Kevlar to cross link with the epoxy and form a very firm bond. FIG.11Cis a cutout view of a cable118showing the Kevlar sheath124enclosing the wires122. FIG.11Dis a cutout view of a cable in a pulley108. In order to prevent the cable118from slipping out of the pulley108, the pulley comprises the above mentioned pins114and additionally a channel128in the pulley wheel for accommodating the cable118. FIG.12Ais a rear perspective view of an overpressure valve130. The overpressure valve130is typically positioned at the end of the extension of the seal installation device and is used for relieving the seal installation device from excessive pressure during the light curing as the cooling air gas used for cooling the LED light sources is released into the seal installation device, and optionally for supplying air to the seal installation device during the expansion of the bladder. The overpressure valve130is electrically controlled and comprises one or more pressure sensors which are typically located in the garage of the light curing device (not shown) but may also be located on the side of the overpressure valve130which is connected to the extension and facing the seal installation device. However, the pressure sensor may also be located in the bladder or at the light curing device in order for the overpressure valve130to react quicker to pressure fluctuations. The reference numeral132denotes the valve cone which is motor driven and movable in an axial direction through a hole in a plate in order to adjust the aperture between the hole and the cone. The air is evacuated through the aperture between the cone and the hole. FIG.12Bis a front perspective view of an overpressure valve130. The overpressure valve130is typically clamped to the extension of the seal installation device, however, other fastening means may be used. The overpressure valve130comprises a gas outlet134for releasing air from the seal installation device, a gas inlet136for receiving air from a compressor, and a control cable inlet138for controlling the overpressure valve130. The overpressure valve130is configured such that it releases air through the gas outlet134when the pressure inside the seal installation device increases beyond a set pressure. The set pressure should be sufficient for maintaining the bladder in an expanded position but considerably less than the expected rupture pressure of the bladder. FIG.13A-Iare various views of a coupling part140. The coupling part140is used e.g., for coupling the extension of the seal installation device to the seal installation device proper. The coupling part140comprises a first part142which may form part of the seal installation device and a second part144which may form part of the extension. The first part142comprises a circumferential bulge146and a pin148whereas the second part144comprises an arc shaped slot. When connected, the second part144covers part of the first part142. The first part142and the second part144are interconnected by causing the pin148to enter the arc shaped slot150, turning the parts142144in relation to each other until the pin reaches the end of the slot. Thereafter the locking ring152is applied. The locking ring152is inserted between the bulge146of the first part and the second part in order to prevent the first and second parts from being separated by rotation without first removing the locking ring152. FIG.14is a side view of a bus system154. The bus system154is established between a master156located at one end of the main pipeline, e.g., at a first manhole, and a slave158located at the opposite end of the main pipeline, e.g., at a second manhole. Normally, the master156is located in the truck and the slave158in the separate electrical powered winching vehicle, however, various setups are feasible including the use of two electrical powered winching vehicle of which one is master and the other is slave. Each of the master156and the slave158comprises a separate CAN bus160160′, separate 48V power supplies162162′ and separate 24V power supplies164,164′. The bus154further comprises nodes166a-gwhich constitute parts of the seal installation system which are requiring power and/or control. The nodes166may be e.g., the light curing device including the drive system, the pulley assembly, the seal installation device and the manipulator. The nodes are interconnected by the cable168which also interconnects the master156and the slave158for providing redundancy and ability to control the installation from both locations. FIG.15Ais a perspective view of a gelling station170and a seal installation device18. The gelling station170is used for gelling the brim portion of the seal in order for the epoxy adhesive coating to be more easily and securely applied before the seal installation device18enters the main pipeline and the seal is applied at the junction between the main pipeline and the branch pipeline. The epoxy coating adheres the brim portion to the main pipeline at the junction. The seal installation device18is fastened to a holder172of the gelling station170. The holder172of the gelling station170grips the seal installation device18at the gripping mechanism46. The gelling station170further comprises a LED panel174which is rotationally mounted via a movable arm176to a motor178of the gelling station170. The motor178is located adjacent the holder172and the movable arm176has an L shape allowing the LED panel174to rotate about the seal installation device18as shown by the arrow, maintaining a constant distance to the seal installation device18. FIG.15Bis a cut-out view of a seal installation device18including a seal26. The seal26has been placed on the bladder50of the seal installation device18and where the tubular portion26bhas been inverted into the opening54of the seal installation device18. The brim portion26arests on the bladder50. The seal26has been impregnated by a suitable curable resin. FIG.15Cis a cut-out view of a seal installation device18including a seal26and a stopper180. The stopper180is applied on top of the opening54for covering the tubular portion26bof the seal. In this way, no light will reach the tubular portion26bof the seal which is thus protected from the light of the LED panel174. The tubular portion26bshould not be gelled, since it must be very flexible in order to invert properly, and gelling the tubular portion26bwould have no purpose since no epoxy coating will be applied. FIG.15Dis a cut-out view of a seal installation device18and gelling station170in operation. In order to achieve a proper gelling of the brim portion26a, it must be irradiated by a predefined amount of light sufficient for achieving a partial curing of the resin in the brim portion26afor allowing the brim portion26ato remain substantially flexible while establishing a semi-solid gel-like surface for applying the epoxy coating. It is evident that the amount of light irradiated is crucial since too much light will yield a full curing of the resin causing the brim portion to be hardened. The LED panel174is set to a constant intensity and the motor170is adjusted to perform a rotational movement of the LED panel174over the brim part26aof the seal for irradiating the complete brim portion26aevenly corresponding to the predefined amount of light for yielding a proper gelling of the brim portion26a. The LED panel174is preferably emitting a blue curing light of a known intensity. After the gelling is completed, the epoxy coating is applied and the installation of the seal may start. The above described embodiments describe specific realizations according to the present invention showing specific features, however, it is apparent to the skillful individual that the above described embodiments may be modified, combined or aggregated to form numerous further embodiments. It now follows a list of the reference numerals used in the figures and description: 10. Assembly12. Junction14. Main pipeline16. Branch pipeline18. Seal installation device20. Manipulator22. Extension tube24. Light curing device26. Seal28. Polymeric tube30. Gas supply tube32. Steel wire34. Truck36. Pulley38. Manhole40. Cable42. Vehicle44. Pulley assembly46. Gripping mechanism48. Expansion member/Wheels50. Bladder52. Housing54. Opening56. Camera58. Outer elongated frame60. Inner elongated frame62. Garage64. Entry66. Drive mechanism68. First pair of rollers70. Second pair of rollers72. Pivotable plate74. Hinge76. Linear actuator78. Adhesive80. Coating82. Felt84. PV86. CSM88. CD rowing90. CSM92. MD rowing94. Sealing ring96. Cover98. LED100. Outer passage (heat sink)102. Inner passage (heat sink)104. Entry106. Exit108. Pulley110. Frame112. Fasteners114. Pins116. Connector118. Cable120. Plug122. Wires124. Keviar sheath126. Epoxy128. Channel130. Overpressure valve132. Valve cone134. Gas outlet136. Gas inlet138. Control cable inlet140. Connector142. First part144. Second part146. Bulge148. Pin150. Arc shaped slot152. Locking ring154. Bus system156. Master158. Slave160. CAN bus162. 24 V DC164. 12 V DC166a-g. Nodes168. Cable170. Gelling station172. Holder174. LED panel176. Arm178. motor180. Stopper Points Now follows a set of points which constitute aspects of the present invention which may be considered independently patentable and as such the following sets form basis for possible future sets of claims: First set of points characterizing the invention:1. A seal for being installed onto a junction between a branch pipeline and a main pipeline, said seal comprising a tubular portion defining a longitudinal direction between a first opening and a second opening, and a brim portion attached to said tubular portion at said first opening and extending radially outwardly from said tubular portion defining a straight axial direction and a curved peripheral direction and comprising an outer layer for facing said main pipeline and an inner layer attached to said outer layer for facing away from said main pipeline, said seal being made to minimize contraction of said brim portion in said axial direction and of said first and second openings of said tubular portion during curing whereas allowing contraction of said outer layer of said brim portion in said peripheral direction and/or said tubular portion in said longitudinal direction during curing.2. The seal according to point 1, wherein said outer layer and said inner layer have fibers which are oriented in different directions, preferably random directions and/or perpendicular directions.3. The seal according to any of the preceding points, wherein said outer layer of said brim portion comprises a resin impregnated layer for facing said main pipeline, and/or, said inner layer comprises a resin impregnated layer for facing away from said main pipeline, said resin impregnated layer preferably being made of fleece, such as PET, PP, PE, glass or most preferably PAN.4. The seal according to any of the preceding points, wherein said outer layer and/or said inner layer comprises one or more sublayers of CSM.5. The seal according to any of the preceding points, wherein said tubular portion comprises a felt material.6. The seal according to any of the preceding points, wherein said brim portion and said tubular portion are impregnated by a light curable resin.7. The seal according to any of the preceding points, wherein said outer layer of said brim portion is stitched and/or adhered onto said inner layer of said brim portion, preferably at edges of said layers, and/or, said brim portion and said tubular portion are stitched and/or adhered together.8. The seal according to any of the preceding points, wherein said brim portion is provided with a sealing ring for facing said main pipeline, said sealing ring preferably comprising one or more of a rubber ring, more preferably a hollow rubber ring, and optionally including a metal wire or rigid plastic filament and optionally being hydrophilic and/or a paste, optionally being hydrophilic.9. The seal according to point 8, wherein said outer layer comprise fibers predominantly directed in random direction and said inner layer comprises fibers predominantly directed in said circumferential direction.10. The seal according to any of the preceding points, wherein said brim portion is provided with a sealant layer, preferably an adhesive such as epoxy, for facing said main pipeline.11. The seal according to point 10, wherein said epoxy layer extends on said brim portion outwardly from said first opening covering only a part of said brim portion between said first opening and an outer periphery of said brim portion, such as between 50% and 90% of said axial and peripheral direction between said first opening and said outer periphery of said brim portion.12. The seal according to any of the points 10-11, wherein said outer layer and said inner layer comprise fibers predominantly directed and substantially equally distributed in said axial direction and said peripheral direction, respectively.13. A method of installing a seal onto a junction between a branch pipeline and a main pipeline, said method comprising the following steps:providing seal comprising a tubular portion defining a longitudinal direction between a first opening and a second opening, and a brim portion attached to said tubular portion at said first opening and extending radially outwardly from said tubular portion defining a straight axial direction and a curved peripheral direction and comprising an outer layer for facing said main pipeline and an inner layer attached to said outer layer for facing away from said main pipeline, said seal being made to minimize contraction of said brim portion in said axial direction and of said first and second openings of said tubular portion during curing whereas allowing contraction of said outer layer of said brim portion in said peripheral direction and/or said tubular portion in said longitudinal direction during curing,positioning said seal onto said junction between said branch pipeline and said main pipeline such that said brim part is located in and contacting said main pipeline about said junction and said tubular part extends into and contacting said branch pipeline, andcuring said brim portion and subsequently curing said tubular part, thereby introducing a contraction force between said first and second openings of said tubular part and/or between said brim portion and said main pipeline.14. The method according to point 13, wherein said tubular part is cured in a direction from said second opening towards said first opening.15. The method according to point 13 or 14, further comprising the step of gelling said outer layer of said brim portion of said seal preferably by exposing said outer layer of said brim portion to radiation and thereafter applying an adhesive to said outer layer of said brim portion before said seal is positioned onto said junction.16. A gelling station comprising a holder for holding a seal installation device including a seal, said gelling station comprising a light source rotationally mounted to said holder via an arm and a motor for allowing said light source to rotate partially about said seal installation device at constant distance to a brim portion of said seal when mounted to said holder.17. A method of gelling a brim portion of a seal on a seal installation device, said gelling station comprising a holder for holding said seal installation device and a light source mounted to said holder via an arm and a motor, said method comprising the step of rotating said light source partially about said seal installation device at constant distance to said brim portion of said seal while irradiating said brim portion of said seal. Second set of points characterizing the invention:1. A seal installation device for installing a seal onto a junction between a branch pipeline and a main pipeline, said seal installation device comprising:an elongated housing having a cylindrical wall extending between a first end and a second end of said housing, said cylindrical wall defining a grid structure and an opening located between said first end and said second end,a pivotable plate having a curved shape being located within said housing adjacent said opening, said pivotable plate defining a first edge which is hingedly attached to said cylindrical wall opposite said opening and a second edge opposite said first edge, said pivotable plate being pivotable between a first position in which said second edge is located at said cylindrical wall opposite said opening and a second position in which said second edge is located at said opening, andan inflatable, expandable and flexible bladder enclosing said grid structure of said cylindrical wall, said flexible bladder defining an inflated position and a deflated position, said flexible bladder having a first cylindrical part extending between said first end of said cylindrical wall and said second end of said cylindrical wall and, when said flexible bladder defining said inflated position, being capable of applying a pressure force onto said main pipeline, and a second cylindrical part extending from said first cylindrical part at said opening and, when said flexible bladder defining said inflated position, being capable of applying a pressure force onto said branch pipeline and, when said flexible bladder defining said deflated position, to be stored in an inverted shape within said grid structure.2. The seal installation device according to point 1, wherein said flexible bladder is light transparent or light translucent, preferably for UV light and/or visible light.3. The seal installation device according to any of the preceding points, wherein said cylindrical wall of said elongated housing defines a circumferential direction and a longitudinal direction, said cylindrical wall comprises a first circumferential protrusion, the first circumferential protrusion defining a pin, the seal installation device further comprising a coupling part comprising a second circumferential protrusion, for being fitted adjacent the first circumferential protrusion, and an are shaped slot extending from a start point on the first end and/or at the second end along the radial direction and along the longitudinal direction to an extreme point adjacent the second circumferential protrusion, and further to an end point being located between the start point and the extreme point in the longitudinal direction, the pin being capable of being guided by the are shaped slot from the start point via the extreme point to the end point, the seal installation device further comprising a locking ring capable of being inserted between the first circumferential protrusion and the second circumferential protrusion for securing the coupling part and the elongated housing in a fixed position relative to each other when the pin is located at the end point.4. The seal installation device according to any of the preceding points, wherein said flexible bladder is made of silicone.5. The seal installation device according to any of the preceding points, wherein said first end of said elongated housing is provided with a protective tubing for protecting said second cylindrical part of said bladder when in said deflated position.6. The seal installation device according to any of the preceding points, wherein said pivotable plate is connected to a sliding profile extending in and slideable in a longitudinal direction of said housing.7. The seal installation device according to point 6, wherein said sliding profile is driven by a mandrel in turn driven by a motor, optionally via a gear.8. The seal installation device according to any of the preceding point, wherein said first end and/or said second end comprises a connector, said connector comprising a gas supply vent for supplying pressurization gas to said bladder, a motorized controllable pressure relief valve for relieving said flexible bladder of excessive pressurized gas and a data cable for allowing data communication through said connector.9. The seal installation device according to any of the preceding points, wherein said seal installation device comprises an extension at said first end in form of a flexible hose, said hose optionally being adapted for accommodating a light curing device.10. A method of installing a seal onto a junction between a branch pipeline and a main pipeline, said method comprising providing a seal installation device comprising:an elongated housing having a cylindrical wall and extending between a first end and a second end of said housing, said cylindrical wall defining a grid structure and defining an opening through said cylindrical wall located between said first end and said second end,a pivotable plate having a curved shape and being located within said housing adjacent said opening, said pivotable plate defining a first edge which is hingedly attached to said cylindrical wall opposite said opening and a second edge opposite said first edge, andan inflatable, expandable and flexible bladder enclosing said grid structure of said cylindrical wall, said flexible bladder having a first cylindrical part extending between said first end of said cylindrical wall and said second end of said cylindrical wall, and a second cylindrical part extending from said first cylindrical part at said opening, said flexible bladder defining a deflated position and said second cylindrical part is stored in an inverted shape within said grid structure, said method further comprising the steps of:causing said flexible bladder to assume an inflated position in which said first cylindrical part applies a pressure force onto said main pipeline and said second cylindrical part applies a pressure force onto said branch pipeline,pivoting said movable plate to assume a first position in which said second edge is located at said cylindrical wall opposite said opening,inserting a light curing device into said seal installation device and lightcuring said main pipeline, pivoting said pivotable plate to assume a second position in which said second edge islocated at said opening, and inserting a light curing device into said sealinstallation device and light curing said branch pipeline,11. The method according to point 10, wherein said flexible bladder is expanded by using pressurized gas, preferably air or steam.12. The method according to any of the points 10-11, wherein said method further comprising the initial step of positioning said seal installation device adjacent said junction such that said opening of said housing is facing said branch pipeline.13. The method according to any of the points 10-12, wherein said branch pipeline is cured in a direction from a position distant from said junction towards said junction.14. A connector for use in a seal installation device including a flexible bladder, said connector comprising a gas supply vent for supplying pressurization gas to said bladder, a motorized controllable pressure relief valve for relieving said flexible bladder of excessive pressurized gas and a data cable for allowing data communication through said connector.15. A method of supplying compressed gas to a flexible bladder of a seal installation device by using a connector comprising a gas supply vent for supplying pressurization gas to said bladder, a motorized controllable pressure relief valve for relieving said flexible bladder of excessive pressurized gas and a data cable for allowing data communication with and through said connector, said method comprising the steps of:receiving pressurized gas by said gas supply vent for causing said flexiblebladder to inflate, andrelieving said flexible bladder of excessive pressurized gas by using said motorized controllable pressure relief valve controlled by said data cable. Third set of points characterizing the invention:1. A light curing assembly including a light curing device and a drive mechanism for driving said light curing device through a pipeline, said drive mechanism being coupled to a seal installation device or to a tubing connected to a seal installation device said drive mechanism comprising:a flexible polymeric sheathing tube connected at one end to said light curing device and defining a curved outer surface, said polymeric sheathing tube being capable of pushing and pulling said light curing device,a first pair of rollers located on opposite sides of said sheathing tube, each roller of said first pair of rollers defining a concave peripheral surface contacting said curved outer surface of said sheathing tube and defining a curvature corresponding to said curved outer surface of said sheathing tube, said first pair of rollers being mutually interconnected, anda second pair of rollers located on opposite sides of said sheathing tube and adjacent said first pair of rollers, each roller of said second pair of rollers defining a concave peripheral surface contacting said curved outer surface of said sheathing tube and defining a curvature corresponding to the outer surface of said sheathing tube, said second pair of rollers being mutually interconnected.2. The light curing assembly according to point 1, wherein said first pair of rollers being mutually interconnected by means of a cog wheel and/or said second pair of rollers being mutually interconnected by means of a cog wheel.3. The light curing assembly according to any of the preceding points, wherein said first pair of rollers being divided into one driving roller and one idle roller.4. The light curing assembly according to point 3, wherein said idle roller of said first pair of rollers being spring loaded towards said driving roller of said first pair of rollers.5. The light curing assembly according to any of the preceding points, wherein said second pair of rollers being divided into one driving roller and one idle roller.6. The light curing assembly according to point 5, wherein said idle roller of said second pair of rollers being spring loaded towards said driving roller of said second pair of rollers.7. The light curing assembly according to any of the preceding points, wherein said flexible and substantially non-elastic polymeric sheathing tube is made of PVC, PP, PE, or preferably PEX or any combinations of the above.8. The light curing assembly according to any of the preceding points, wherein said flexible and substantially non-elastic polymeric sheathing tube includes electrical wiring for providing power to said light curing device and/or for providing data communication with said light curing device.9. The light curing assembly according to any of the preceding points, wherein said flexible polymeric sheathing tube is capable of supplying compressed gas, preferably air, to said light curing device.10. The light curing assembly according to any of the preceding points, wherein said first pair of rollers and said second pair of rollers are mutually interconnected by a cog wheel for ensuring a synchronized rotation of said rollers.11. The light curing assembly according to any of the preceding points, wherein said first pair of rollers and/or said second pair of rollers being driven by an electrical motor, optionally via a gear box.12. The light curing assembly according to any of the preceding points, wherein said concave peripheral surfaces of said first pair of rollers and/or said second pair of rollers being provided with a high friction surface, such as a raw metal surface, optionally coated by rubber.13. The light curing assembly according to any of the preceding points, wherein said first pair of rollers and/or said second pair of rollers being driven by a dual direction drive.14. A method of curing a pipeline by using a light curing assembly, said light curing assembly including a light curing device and a drive mechanism, said drive mechanism being coupled to a seal installation device or to a tubing connected to a seal installation device, said drive mechanism comprising:a flexible polymeric sheathing tube connected at one end to said light curing device and defining a curved outer surface,a first pair of rollers located on opposite sides of said sheathing tube, each roller of said first pair of rollers defining a concave peripheral surface contacting said curved outer surface of said sheathing tube and defining a curvature corresponding to said curved outer surface of said sheathing tube, said first pair of rollers being mutually interconnected, anda second pair of rollers located on opposite sides of said sheathing tube and adjacent said first pair of rollers, each roller of said second pair of rollers defining a concave peripheral surface contacting said curved outer surface of said sheathing tube and defining a curvature corresponding to the outer surface of said sheathing tube, said second pair of rollers being mutually interconnected, said method further comprising the step of pushing said light curing device into said pipeline by rotating said rollers in a first direction and pulling said light curing device back from said pipeline by rotating said rollers in a second direction being opposite said first direction.15. The method according to point 14, further comprising any of the features according to any of the points 1-13. Fourth set of points characterizing the invention:1. A manipulator for positioning and rotating a seal installation device within a main pipeline for aligning said seal installation device with a branch pipeline, said manipulator comprising:an outer elongated frame defining a longitudinal direction and extending between a first end and an opposite second end, said outer elongated frame comprising wheels circumferentially disposed about said outer elongated frame for contacting said main pipeline and defining a rotational axis being perpendicular to said longitudinal direction for allowing said manipulator to move in said longitudinal direction within said pipeline, andan inner elongated frame defining a front end and an opposite rear end, said front end comprising a gripping mechanism for gripping said seal installation device, said inner elongated frame defines a smaller diameter than said outer elongated frame and said inner elongated frame and said outer elongated frame defining a mutually overlapping section.2. The manipulator according to point 1, wherein said outer elongated frame is capable of defining a contracted position in which said wheels defines a first periphery about said outer elongated frame, and an expanded position in which said wheels defines a second periphery about said outer elongated frame, said first periphery being smaller than said second periphery.3. The manipulator according to point 2, wherein said outer elongated frame comprises a plurality of skids, said skids comprising said wheels, said plurality of skids preferably being between 3 and 5 skids, such as 4, said skids being capable of assuming said contracted position and said expanded position.4. The manipulator according to any of the preceding points, wherein said outer elongated frame comprises a camera at said second end and/or said inner elongated frame comprise a camera at said rear end.5. The manipulator according to any of the preceding points, wherein said manipulator further comprises a first wire connected to said second end and/or said rear end for moving said manipulator within said main pipeline.6. The manipulator according to any of the preceding points, further comprising a second wire connected to said seal installation device for moving said manipulator within said main pipeline.7. The manipulator according to any of the preceding points, wherein said inner elongated frame comprises a camera at said front end.8. The manipulator according to point 7, wherein said camera being pivotable.9. The manipulator according to point 8, wherein said camera being pivotable along two axles being perpendicular to said longitudinal direction.10. The manipulator according to any of the points 7-9, wherein said camera comprises a spring for detecting said branch pipeline.11. The manipulator according to any of the preceding points, wherein said inner elongated frame being located within said outer elongated frame, said front end extending beyond said first end and said rear end extending beyond said second end.12. The manipulator according to any of the preceding points, wherein said manipulator is driven by an electrical motor.13. The manipulator according to any of the preceding points, wherein said outer and said inner elongated frame preferably being interconnected by a set of cogwheels within said mutual overlapping section of said frames.14. The manipulator according to any of the preceding points, wherein said inner elongated frame comprises a flexible antenna extending in a radial direction for accurately detecting the position of said branch pipeline, said flexible antenna preferably constituting a spring.15. A method of positioning and rotating a seal installation device, said method comprising providing a manipulator comprising:an outer elongated frame defining a longitudinal direction and extending between a first end and an opposite second end, said outer elongated frame comprising wheels circumferentially disposed about said cylindrical housing and defining a rotational axis being perpendicular to said longitudinal direction, andan inner elongated frame defining a front end and an opposite rear end, said front end comprising a gripping mechanism for gripping said seal installation device, said inner elongated frame defines a smaller diameter than said outer elongated frame and said inner elongated frame and said outer elongated frame defining a mutually overlapping section, said method comprising the steps of:gripping said seal installation device using said gripping mechanism,causing said wheels to contact said main pipeline,moving said manipulator in said longitudinal direction within said pipeline,androtating said inner elongated frame relative to said outer elongated framecausing said seal installationdevice to be aligned with a branch pipeline. Fifth set of points characterizing the invention:1. An assembly for installing a lining tube in a pipeline using a seal installation device, said pipeline extending between a first end and a second end, said assembly comprising:a first motorized winching vehicle for being positioned at said first end of said pipeline and comprising a first control unit and a first winching unit controlled by said first control unit, said first winching unit including a first cable connectable to a first end of said seal installation device, anda second motorized winching vehicle for being positioned at said second end of said pipeline and comprising a second control unit and a second winching unit controlled by said second control unit, said second winching unit including a second cable connectable to a second end of said seal installation device, said first control unit and said second control unit establishing mutual communication for synchronizing said first winching unit and said second winching unit.2. The assembly according to point 1, wherein said first cable is communicating with and powering said seal installation device, whereas said second cable constituting a pulling cable such as a steel wire, and said first control unit and said second control unit establishing mutual communication via wireless communication or via a separate communication wire.3. The assembly according to point 1, wherein both said first cable and said second cable being capable of communicating with and powering said seal installation device, said first control unit and said second control unit establishing mutual communication via said first cable, said seal installation device and said second cable.4. The assembly according to any of the preceding points, wherein said first cable and/or said second cable comprises a pair of data communication wires for establishing data communication between said first control unit and said second control unit using a digital communication protocol, and wherein said first cable and/or said second cable comprises a at least two and preferably three power transmission wires.5. The assembly according to any of the preceding points, wherein said first cable and/or said second cable comprises an outer polymeric sheath and at least one sheath of a load transmitting material, such as Kevlar sheath, and wherein said sheath preferably is fixated to a plug housing by a cross-linked adhesive joint, such as an epoxy joint.6. The assembly according to any of the preceding points, wherein said first motorized winching vehicle constitutes an electrically powered vehicle, preferably a battery powered vehicle and/or said second motorized winching vehicle constitutes a truck, and/or said winching units being driven by servo motors.7. The assembly according to any of the preceding points, wherein said first cable and/or said second cable establishes data communication with and/or provides power to said seal installation device, such as a pressure relief valve, a pressure sensor, a driving motor for a light curing device, a position sensor, a velocity sensor, an operating motor for said seal installation device, a rotation motor for said seal installation device or a clamping motor for clamping said seal installation device.8. The assembly according to any of the preceding points, wherein said first motorized winching vehicle and/or said second motorized winching vehicle comprises a user interface.9. The assembly according to any of the preceding points, further comprising a pulley assembly for protecting and redirecting said first cable and/or said second cable within said main pipeline, said pulley assembly comprising:a rod shaped housing defining a first end and an opposite second end, said rod shaped housing including an actuator and a plurality of expanders, said expanders being operable by using said actuator between a contracted position in which said rod shaped housing defines a first outer periphery for allowing said pulley assembly to move within said main pipeline, and an expanded position in which said rod shaped housing defines a second outer periphery being larger than said first outer periphery for allowing said pulley assembly to be clamped within said main pipeline, anda pulley for accommodating said first cable and/or said second cable, said pulley being mounted at said first end of said housing, said pulley defining a circumferential groove for receiving said first cable and/or said second cable, said pulley further including locking pins for securing said first cable and/or said second cable to said pulley.10. A method of installing a lining tube in a pipeline using a seal installation device, said pipeline extending between a first end and a second end, said assembly comprising:a first motorized winching vehicle comprising a first control unit and a first winching unit controlled by said first control unit, said first winching unit including a first cable connectable to a first end of said seal installation device, anda second motorized winching vehicle comprising a second control unit and a second winching unit controlled by said second control unit, said second winching unit including a second cable connectable to a second end of said seal installation device, said method comprising the steps of:positioning said first motorized winching vehicle at said first end of said pipeline,positioning said second motorized winching vehicle at said second end of said pipeline,connecting said first cable to said first end of said seal installation device,connecting said second cable to said second end of said seal installation device, andestablishing mutual communication between said first control unit and said second control unit forsynchronizing said first winching unit and said second winching unit.11. A cable comprising an outer polymeric sheath encapsulating at least one Kevlar sheath, which in turn circumferentially encloses a bundle comprising at least one power line and at least one communication line, said cable defining an end comprising a plug housing, wherein said Kevlar sheath is fixated to said plug housing by a cross-linked adhesive joint, such as an epoxy joint.12. A method of producing a cable by:providing a bundle comprising at least one power line and at least one communication line, circumferentially enclosing said bundle with at least one Kevlar sheath, encapsulating said Kevlar sheath with an outer polymeric sheath, and fixate said Kevlar sheath to a plug housing by a cross-linked adhesive joint, such as an epoxy joint, at a cable end.13. A pulley assembly for protecting and redirecting a cable within a pipeline, said pulley assembly comprising:A rod shaped housing defining a first end and an opposite second end, said rod shaped housing including an actuator and a plurality of expanders, said expanders being operable by using said actuator between a contracted position in which said rod shaped housing defines a first outer periphery for allowing said pulley assembly to move within said pipeline, and an expanded position in which said rod shaped housing defines a second outer periphery being larger than said first outer periphery for allowing said pulley assembly to be clamped within said pipeline, anda pulley for accommodating said cable, said pulley being mounted at said first end of said housing, said pulley defining a circumferential groove for receiving said cable, said pulley further including locking pins for securing said cable to said pulley.14. The assembly according to point 13, wherein said actuator comprises a scissor mechanism and/or said circumferential groove defines a circumferential indentation being deeper than the diameter of said cable.15. A method of protecting and redirecting a cable within a pipeline by using a pulley assembly, said pulley assembly comprising:a rod shaped housing defining a first end and an opposite second end, said rod shaped housing including an actuator and a plurality of expanders, anda pulley for accommodating said cable, said pulley being mounted at said first end of said housing, said pulley defining a circumferential groove and locking pins, said method comprising the steps of:receiving said cable in said circumferential groove,securing said cable to said pulley by using said locking pins,introducing said pulley assembly into said pipeline in a contracted position in which said rod shaped housing defines a first outer periphery for allowing said pulley assembly to move within said pipeline, andclamping said rod shaped housing within said pipeline by operating said actuator for causing said expanders to assume said expanded position in which said rod shaped housing defines a second outer periphery being larger than said first outer periphery. Sixth set of points characterizing the invention:1. A light curing device for use in curing of pipelines, said light curing device comprising a housing defining:a transparent cylindrical outer cover defining a first end and an opposite second end,a first end piece covering said first end of said transparent cylindrical cover, said first end piece defining a cooling fluid inlet and a cooling fluid outlet,a second end piece covering said second end of said transparent cylindrical cover, said second end piece defining a fluid reversing chamber,an inner heat sink defining a central fluid passage extending from said cooling fluid inlet to said fluid reversing chamber,an outer heat sink coaxially enclosing said inner heat sink and defining an outer passage between said outer heat sink and said inner heat sink, said outer passage being separated from said inner passage and extending from said fluid reversing chamber to said cooling fluid inlet, and,a plurality of light sources located between said outer heat sink and said transparent outer cover.2. The light curing device according to point 1, wherein said cooling fluid inlet is connected to a flexible polymeric sheathing tube defining a curved outer surface and being capable of supplying cooling fluid to said cooling fluid inlet.3. The light curing device according to point 2, wherein said polymeric sheathing tube has a sufficient rigidity for being capable of pushing and pulling said light curing device.4. The light curing device according to any of the points 2-3, wherein said light curing device further includes a drive mechanism for driving said housing through a pipeline, said drive mechanism being coupled to a seal installation device or to a tubing connected to said seal installation device, said drive mechanism comprising:a first pair of rollers located on opposite sides of said sheathing tube, each roller of said first pair of rollers defining a concave peripheral surface contacting said curved outer surface of said sheathing tube and defining a curvature corresponding to said curved outer surface of said sheathing tube, said first pair of rollers being mutually interconnected, anda second pair of rollers located on opposite sides of said sheathing tube and adjacent said first pair of rollers, each roller of said second pair of rollers defining a concave peripheral surface contacting said curved outer surface of said sheathing tube and defining a curvature corresponding to the outer surface of said sheathing tube, said second pair of rollers being mutually interconnected.5. The light curing device according to any of the points 2-4, wherein said polymeric sheathing tube includes electrical power wirings for providing electrical power to said light sources.6. The light curing device according to any of the points 2-5, wherein said polymeric sheathing tube includes communication wirings for providing communication with said light sources or other devices associated with said light curing device such as a temperature sensor or a pressure sensor.7. The light curing device according to any of the preceding points, wherein said light sources are located on said outer heat sink.8. The light curing device according to any of the preceding points, wherein said cooling fluid inlet is centrally located on said first end piece, whereas said cooling fluid outlet is located off centre or circumferentially about said fluid inlet on said first end piece.9. The light curing device according to any of the preceding points, wherein said light sources emit light primarily within the visual spectrum, such as blue light.10. The light curing device according to any of the preceding points, wherein said light sources constituting LEDs, LECs, and/or OLEDs.11. The light curing device according to any of the preceding points, wherein said inner heat sink and/or said outer heat sink is manufactured using metal printing technologies.12. The light curing device according to any of the preceding points, wherein said inner heat sink and/or said outer heat sink is made of aluminum.13. The light curing device according to any of the preceding points, wherein said cooling fluid is compressed air.14. The light curing device according to any of the preceding points, wherein said inner heat sink and/or said outer heat sink comprises a heat pipe or a Peltier element, and/or said light curing device is provided with additional cooling via a stream of air between said outer cover and said light sources.15. A method of cooling a light curing device, said light curing device comprising a housing defining:a transparent cylindrical outer cover defining a first end and an opposite second end,a first end piece covering said first end of said transparent cylindrical cover, said first end piece defining a cooling fluid inlet and a cooling fluid outlet,a second end piece covering said second end of said transparent cylindrical cover, said second end piece defining a fluid reversing chamber,an inner heat sink defining a central fluid passage extending from said cooling fluid inlet to said fluid reversing chamber,an outer heat sink coaxially enclosing said inner heat sink and defining an outer passage between said outer heat sink and said inner heat sink, said outer passage being separated from said inner passage and extending from said fluid reversing chamber to said cooling fluid inlet, and,a plurality of light sources located between said outer heat sink and said transparent outer cover, said method comprising the step of causing a cooling fluid to pass through said housing from said cooling fluid inlet to said cooling fluid outlet via said central fluid passage, said fluid reversing chamber and said outer fluid passage. Seventh set of points characterizing the invention:1. An apparatus for curing a liner of a pipeline, said liner including a resin which is curable by exposure to electromagnetic radiation of a specific wavelength or a specific wavelength range, said apparatus comprising: a housing defining opposite first and second ends, an outer wall of a substantially cylindrical configuration, and an inner wall defining a substantially unobstructed through-going passage extending longitudinally through said housing between said first and second ends,a pair of power supply wires for the supply of electrical power to said apparatus and extending from said first end of said housing,a plurality of LED's irradiating electromagnetic radiation of said specific wavelength or said specific wavelength range, said plurality of LED's being positioned and substantially evenly distributed at said outer wall of said housing, said plurality of LED's being connected through an electronic circuit to said pair of power supply wires, and said plurality of LED's being connected in thermal conductive relationship to heat dissipating elements freely exposed at said inner wall of said housing in said through-going passage of said housing for allowing a stream of cooling fluid to pass through said passage for dissipating heat from said heat dissipating elements and cooling said LED's, characterized in thatsaid housing defines an innermost wall dividing said substantially unobstructed through-going passage into an inner passage centrally located within said substantially unobstructed through-going passage and extending substantially between said first and second ends, and, an outer passage defined between said inner wall and said innermost wall and coaxially enclosing said inner passage.2. The apparatus according to point 1, wherein said housing defines a centrally located inlet for receiving pressurized gas, said inlet being in fluid communication with said inner passage at said first end.3. The apparatus according to point 2, wherein said housing is closed at said second end and said through-going passage defines a flow reversing chamber at said second end for establishing fluid communication between said first passage and said second passage.4. The apparatus according to point 3, wherein said housing defines an outlet at said first end, said outlet being in fluid communication with said outer passage and is preferably located off center or circumferentially about said housing.5. The apparatus according to point 2, wherein said housing defines an outlet at said second end, said outlet being in fluid communication with said outer passage and said inner passage at said second end, said housing preferably defining a secondary inlet located off center or circumferentially about said housing at said first end and in fluid communication with said outer passage.6. The apparatus according to point 5, wherein said innermost wall defines a nozzle adjacent said outlet or adjacent said inlet, said nozzle defining a minimum flow area of said inner passage for establishing a jet from said inner passage towards said outlet.7. The apparatus according to any of the previous points, wherein said apparatus further comprising an outer cover extending between said opposite first and second end, enclosing said outer wall and establishing an outermost passage in fluid communication with said outer passage and/or forming part of said outer passage.8. The apparatus according to any of the points 2-7, wherein said cooling fluid inlet is connected to a flexible polymeric sheathing tube defining a curved outer surface and being capable of supplying cooling fluid to said cooling fluid inlet, said polymeric sheathing tube preferably having a sufficient rigidity for being capable of pushing and pulling said apparatus, said polymeric sheathing tube preferably includes communication wirings for providing communication with said LED's or other devices associated with said apparatus such as a temperature sensor or a pressure sensor.9. The apparatus according to point 8, wherein said apparatus further includes a drive mechanism for driving said housing through a pipeline, said drive mechanism being coupled to a seal installation device or to a tubing connected to said seal installation device, said drive mechanism comprising:a first pair of rollers located on opposite sides of said sheathing tube, each roller of said first pair of rollers defining a concave peripheral surface contacting said curved outer surface of said sheathing tube and defining a curvature corresponding to said curved outer surface of said sheathing tube, said first pair of rollers being mutually interconnected, anda second pair of rollers located on opposite sides of said sheathing tube and adjacent said first pair of rollers, each roller of said second pair of rollers defining a concave peripheral surface contacting said curved outer surface of said sheathing tube and defining a curvature corresponding to the outer surface of said sheathing tube, said second pair of rollers being mutually interconnected.10. The apparatus according to any of the preceding points, wherein said plurality of LED's being connected in thermal conductive relationship to further heat dissipating elements freely exposed at said innermost wall of said housing in said inner passage of said housing for allowing a stream of cooling fluid to pass through said inner passage for dissipating heat from said additional heat dissipating elements and cooling said LED's.11. The apparatus according to any of the preceding points, wherein said outer wall of said housing being composed of a set of curved or planar surface elements, each of said curved or planar surface elements extending longitudinally between said first and said second ends of said housing, said surface elements being of identical configuration, preferably said plurality of LED's being arranged at said curved or planar surface elements for allowing irradiation of said electromagnetic radiation radially from said curved or planar surface elements, more preferably each of said curved or planar surface elements constituting an outer surface component of a housing element, said housing element comprising a finned heat dissipation element arranged opposite to said curved or planar surface element.12. The apparatus according to any of the preceding points, further comprising first and second end housing components protruding beyond said outer wall of said housing and serving to prevent physical contact between said outer wall of said housing and said liner.13. The apparatus according to any of the preceding points, further comprising co-operating first and second connectors provided at said first and second ends, respectively, for allowing said apparatus to be connected to an identical apparatus for providing an assembly of apparatuses comprising a number of apparatuses such as 2-12, e.g. 3-8, such as 4-6 individual apparatuses, preferably, said first and second connectors when joint together providing a cardanic linking or a ball-and-socket joint between any two apparatuses of said assembly.14. An apparatus for curing a liner of a pipeline, said apparatus comprising a housing defining:a first enda second endan inner heat sink defining an inner passage extending from an inlet at said first end to an outlet at said second end, said inner passage defines a nozzle adjacent said outlet, said nozzle defining a minimum flow area of said inner passage for establishing a jet from said inner passage towards said outlet,an outer heat sink coaxially enclosing said inner heat sink and defining an outer passage separated from said inner passage and extending from an inlet at said first end to an outlet at said second end, anda plurality of light sources located on said outer heat sink opposite said outer passage.15. A method of curing a liner of a pipeline, said liner including a resin, which is curable by exposure to electromagnetic radiation of a specific wavelength or a wavelength range, said method comprising:providing an apparatus according to any of the preceding points,said method further comprising moving said apparatus within said liner while supplying a stream of cooling fluid through said inner passage and/or said outer passage and supplying electrical power to said LED's through said pair of power supply wires for irradiating electromagnetic radiation of said specific wavelength or said specific wavelength range onto said liner for causing said resin to cure, andadjusting the velocity of movement of said apparatus through said liner so as to cause a complete curing of said resin. Eight set of points characterizing the invention:1. A light curing device for curing a liner of a pipeline, said liner including a resin which is curable by exposure to electromagnetic radiation of a specific wavelength or a specific wavelength range, said light curing device comprising:an inlet end having a central inlet for leading an air flow into said light curing device, and an outlet end having a common outlet opposite said central inlet for leading said air flow out of said light curing device,a pair of power supply wires for the supply of electrical power to said apparatus and extending from said inlet end of said housing,a plurality of LEDs for irradiating electromagnetic radiation of said specific wavelength or said specific wavelength range, said plurality of LEDs being connected through an electronic circuit to said pair of power supply wires,a transparent cylindrical outer cover for covering said plurality of LEDs for protection said plurality of LEDs against mechanical impact,an outer passage between said plurality of LEDs and said transparent cylindrical outer cover for allowing an air flow to pass through said outer passage for dissipating heat from said heat dissipating elements and cooling said LEDs,said outer passage being in fluid communication with said central inlet via a secondary passage, and said outer passage being in fluid communication with said common outlet inlet via a third passage for providing said air flow between said central inlet and said common outlet,said light curing device further comprising a heat sink being in thermal conductive relationship with said plurality of LEDs such that heat dissipate from said plurality of LEDs to said heat sink,said heat sink defining an exit heat transfer region at said third passage such that heat dissipate from said heat sink to said air flow after said air flow having passed said plurality of LEDs.2. The light curing device according to point 1, said heat sink defining an entry heat transfer region at said secondary passage such that heat dissipate from said heat sink to said air flow before said air flow passing said plurality of LEDs.3. The light curing device according to point 1, said heat sink consisting of a single heat transfer region constituted by said exit heat transfer region.4. The light curing device according to any of points 1-3, said exit heat transfer region comprising fins.5. The light curing device according to any of points 2 or 4, said entry heat transfer region comprising fins.6. The light curing device according to any of points 1 or 3, said heat sink having fins exclusively at exit heat transfer region.7. The light curing device according to any of points 1-6, said exit heat transfer region being defined such that the heat transfer from said heat sink to said air flow being greater at said exit heat transfer region than at said entry heat transfer region. Ninth set of points characterizing the invention:1. A light curing device for curing a liner of a pipeline, said liner including a resin which is curable by exposure to electromagnetic radiation of a specific wavelength or a specific wavelength range, said light curing device comprising:an inlet end having a central inlet for leading a first fluid flow into said light curing device, and an outlet end having an outlet opposite said central inlet for leading said first fluid flow out of said light curing device,a pair of power supply wires for the supply of electrical power to said apparatus and extending from said inlet end of said housing,a plurality of LEDs for irradiating electromagnetic radiation of said specific wavelength or said specific wavelength range, said plurality of LEDs being connected through an electronic circuit to said pair of power supply wires,a transparent cylindrical outer cover for covering said plurality of LEDs for protection said plurality of LEDs against mechanical impact,a heat sink being in thermal conductive relationship with said plurality of LEDs such that heat dissipate from said plurality of LEDs to said heat sink,a second inlet adjacent said inlet end for leading a second fluid flow into said light curing device, and an atomizer nozzle adjacent said second inlet for atomizing said second fluid flow. Tenth set of points characterizing the invention:1. An assembly with a seal installation device comprising:an elongated housing having a cylindrical wall extending between a first end and a second end of the housing, the cylindrical wall having a grid structure with a plurality of perforations for emitting electromagnetic radiation such as light from within the housing, the plurality of perforations consisting of perforations extending around the whole circumference of the cylindrical wall for emitting electromagnetic radiation substantially omnidirectional onto a pipeline during use of the assembly, and an inflatable, expandable and flexible bladder enclosing the grid structure of the cylindrical wall, the flexible bladder defining an inflated position and a deflated position, the flexible bladder having a cylindrical part extending between the first end of the cylindrical wall and the second end of the cylindrical wall and being capable of, when the flexible bladder defining the inflated position, to apply a pressure force onto the pipeline. Eleventh set of points characterizing the invention:1. An assembly wherein the seal installation device comprising:an elongated housing having a cylindrical wall extending between a first end and a second end of the housing, the cylindrical wall having an opening located between the first end and the second end, and a first grid structure with a first plurality of perforations for emitting electromagnetic radiation from within the housing, the installation device further comprising a pivotable plate having a curved shape being located within the housing adjacent the opening, the pivotable plate defining a first edge which is hingedly attached to the cylindrical wall opposite the opening and a second edge opposite the first edge, the pivotable plate being pivotable between a first position in which the second edge is located at the cylindrical wall opposite the opening and a second position in which the second edge is located at the opening,the pivotable plate comprising a second grid structure with a second plurality of perforations for emitting electromagnetic radiation through the area of the housing occupied by the pivotable plate. | 102,500 |
11859754 | DETAILED DESCRIPTION In the following detailed description, certain specific details are set forth in order to provide a thorough understanding of various disclosed implementations and embodiments. However, one skilled in the relevant art will recognize that implementations and embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, and so forth. In other instances, related well known features or processes have not been shown or described in detail to avoid unnecessarily obscuring the implementations and embodiments. For the sake of continuity, and in the interest of conciseness, same or similar reference characters may be used for same or similar objects in multiple figures. A pipeline profiler that provides direct measurements of a pipeline profile on the topography of the Earth's surface is described herein. The pipeline profiler may be used to measure a pipeline profile of onshore or offshore pipelines transporting hydrocarbon products. The pipeline profiler may be launched into the pipeline network during scraping activities to avoid inducing disturbances to production of products. The pipeline profile obtained from the measurements made by the pipeline profiler may be used in field models to improve accuracy of the models, predict the flow regime in the pipelines at different scenarios, optimize scraping frequency of the pipelines to minimize production upsets, and identify bottlenecks in the pipeline network. FIGS.1and2show one illustrative implementation of a pipeline profiler100that may be used to obtain direct measurements of a pipeline profile. Pipeline profiler100includes a profiler body104, which in the illustrated example is an elongated body, such as a generally cylindrical body. Profiler body104may be made of a metal or a metal alloy or other material that can withstand the environment of use. A plurality of mechanical arms108are attached radially about profiler body104. In the illustrated example, four mechanical arms108are attached radially about profiler body104. In general, two to eight mechanical arms108may be attached radially about profiler body104. Mechanical arms108may be evenly spaced apart along a circumference of profiler body104. Each mechanical arm108includes two linearly adjustable arms112a,112barranged to form an angle bracket shape. The term “linearly adjustable arm” means that the length of the arm is adjustable in a linear direction. The outer ends of linearly adjustable arms112a,112bare coupled together by a hinge joint116, which is located at the corner of the angle bracket shape. The inner ends of linearly adjustable arms112a,112bare coupled to profiler body104at two axially spaced apart positions by pivot joints120a,120b. Each mechanical arm108carries a distance measuring wheel (or odometer)124at hinge joint116. The lengths of linearly adjustable arms112a,112bare adjustable to position hinge joint116and odometer124at a desired radius from an axial centerline of profiler body104. Referring toFIG.3, in one example, linearly adjustable arm112amay include a cylinder128aand a rod132areceived inside cylinder128a. Rod132ais slidable relative to cylinder128ato extend or shorten the length of linearly adjustable arm112a. A flange134amay be formed at an end of cylinder128afor attaching linearly adjustable arm112ato profiler body104(inFIGS.1and2). Flange134amay include a hole135ato receive a pin. A coupling136ais formed at an end of rod132athat extends outside of cylinder128a. A compression spring144ais arranged to bias rod132ain an outward direction. In one example, such arrangement may include a collar140aon an outer diameter of cylinder128aat a position intermediate between the ends of cylinder128aand a shoulder146aat the transition between rod132aand coupling136a. The arrangement may include disposing compression spring144aon linearly adjustable arm112aand between collar140aand shoulder146a. Spring144awill abut collar140aat one end and shoulder146aat another end. In the rest state (uncompressed state) of spring144a, linearly adjustable arm112ahas the longest length (or the extension length of rod132aout of cylinder128ais maximum). The length of linearly adjustable arm112acan be shortened by applying a force to displace rod132ainto cylinder128aand compress spring144a. Cylinder128aand rod132a, as well as flange134aand collar140a, may be made of a metal or a metal alloy or other material that can withstand the environment of use. Linearly adjustable arm112b(inFIGS.1and2) may have a similar structure to linearly adjustable arm112a. As shown inFIG.4, linearly adjustable arm112bmay include a cylinder128band a rod132breceived inside cylinder128band slidable relative to cylinder128a, a coupling136bformed at an end of rod132bextending outside of cylinder128b, and a compression spring144barranged to bias rod132bin an outward direction. Spring144bmay be arranged between a collar140bon cylinder128band a shoulder146bbetween rod132band coupling136b, as previously described for linearly adjustable arm112a(inFIG.3). In the rest state of spring144b, linearly adjustable arm112bhas the longest length (or the extension length of rod132bout of cylinder128bis maximum). The length of linearly adjustable arm112bcan be shortened by applying a force to displace rod132binto cylinder128band compress spring144b. A flange134bmay be formed at an end of cylinder128bfor attaching linearly adjustable arm112bto profiler body104(inFIGS.1and2). Flange134bmay include a hole135bto receive a pin. Cylinder128band rod132b, as well as flange134band collar140b, may be made of a metal or a metal alloy or other material that can withstand the environment of use. Returning toFIG.3, coupling136aincludes two spaced apart flanges148adefining a slot152athat is aligned with rod132aand cylinder128aalong an axial axis of linearly adjustable arm112a. Flanges148ahave holes156athat are aligned in a direction transverse to the axial axis of linearly adjustable arm112a. Slot152ahas a width to accommodate an axial thickness of odometer124(inFIGS.1and2). Similarly, as shown inFIG.4, coupling136bincludes two spaced apart flanges148bdefining a slot152bthat is aligned with rod132band cylinder128balong an axial axis of linearly adjustable arm112b. Flanges148bhave holes156bthat are aligned in a direction transverse to the axial axis of linearly adjustable arm112b. Slot152bhas a width to accommodate coupling flanges148aof linearly adjustable arm112a, as shown inFIG.5. Flanges148aof linearly adjustable arm112acan be disposed in slot152bsuch that holes156ain flanges148aand holes156bin flanges148bare aligned. FIG.6shows odometer124disposed in an opening formed by slots152aand152b. Odometer124has a central hole that can be aligned with holes156a,156b(inFIGS.3and4) in flanges148a,148b. A hinge pin160is inserted through the holes in flanges148a,148band the central hole in odometer124, forming a hinge joint (116inFIGS.1and2). Hinge pin160is secured in place, e.g., by means of a fastener. Hinge pin160allows linearly adjustable arms112a,112bto pivot relative to each other. When odometer124contacts a surface, such as an inner wall of a pipeline, odometer124can roll along the surface by rotating about hinge pin160. Spacers164may be provided on hinge pin160and between flanges148aand odometer124to reduce friction between adjacent surfaces of odometer124and flanges148a. Spacers164may be made of antifriction material. FIG.7shows linearly adjustable arms112a,112bpivoted relative to each other at hinge joint116to form the angle bracket shape of mechanical arm108. For illustrative purposes, two example positions of mechanical arm108resulting in different distances between odometer124and a datum162are shown inFIG.7. The position indicated by dashed lines may be the full length of each of linearly adjustable arms112a,112b, i.e., the rest state of compression springs144a,144b. The position indicated by solid lines may be a shortening of the length of at least one of linearly adjustable arms112a,112band compression of the respective compression spring, as previously explained. Returning toFIGS.1and2, pipeline profiler100includes a device172mounted on profiler body104to measure a horizontal angle (or azimuth) of profiler body104as profiler body104traverses a pipeline. Pipeline profiler100includes a device176mounted on profiler body104to measure a vertical angle (or inclination) of profiler body104as profiler body104traverses a pipeline. Azimuth is measured with respect to true north. Inclination is measured with respect to the vertical. Device172may be, for example, a tri-axis MEMS gyroscope, which will sense the angular rotation of profiler body104around three orthogonal axes. The z axis of the gyroscope may be aligned with the axial axis of profiler body104. Device176may be, for example, a tri-axis accelerometer, which will measure linear acceleration of profiler body104in three axes. The z axis of the accelerometer may be transverse to the axial axis of profiler body104. In some cases, devices172and176may be integrated into an inertial measurement unit (IMU) that can be mounted within profiler body104. Referring toFIG.8, profiler body104may contain an electronics module including, for example, a signal processing circuit180, a data storage circuit184, and a power source188. Signal processing circuit180may include a processor and memory. Signal processing circuit180may be configured with, for example, CMOS, microcontroller, digital signal processor (DSP), field programmable gate array (FGPA), application-specific integrated circuit (ASIC), complex programmable logic device (CPLD), or a system-on-chip (SoC). Signal processing circuit180may receive signals representative of measured distance from odometer124, signals representative of the azimuth of profiler body104from device172, and signals representative of the inclination of profiler body104from device176. Signal processing circuit180may process the signals and store the measurement data contained in the processed signals in data storage circuit184. Data storage circuit184may be any non-transitory computer-readable storage medium. Signal processing circuit180and data storage circuit184are powered by power source188, which may be a battery or supercapacitor. Signal processing circuit180may manage distribution of power. Pipeline profiler100includes a coupling192at an end of profiler body104to use in forming a joint between profiler body104and a pig.FIG.9shows profiler body104coupled to a pig196by a flexible joint200. Joint200may be a universal joint, for example, to allow bending of the joint along a curvature of a pipeline. In one example, pig196is a utility pig that is used to clean a pipeline bore. In the illustrated example, pig196includes seal cups204,208mounted on a pig body (or mandrel)212. Seal cups204,208seal against an inside diameter of a pipeline and scrape debris off the inner wall surface of the pipeline while moving through the pipeline. Pig196is only one example of utility pig and is not intended to be limiting. For example, seal discs may be used instead of or in addition to seal cups. In addition, wire bristles and other elements to scrape debris from a surface of a pipe may be carried by pig body212. Pig196is illustrated as a mandrel pig. Other types of utility pigs, such as foam pigs and solid cast pigs, may be used instead of mandrel pigs. In other cases, pipeline profiler100may be coupled to a pig other than a utility pig. Referring toFIG.10, pig196and pipeline profiler100can be inserted into a pipeline216via a pipeline pig launcher220, which would be located at a pumping station. Pig196will be propelled along pipeline216by fluid pressure in pipeline216, pulling pipeline profiler100along.FIGS.11and12show pig196and pipeline profiler100in a section of pipeline216. As pig196is propelled along pipeline216, seal cups204,208engage the inner wall220of pipeline196and scrape debris from the inner wall. Seal cups204,208will also push the debris along pipeline216. Odometers124of pipeline profiler100roll along inner wall220of pipeline216with motion of pig196. Springs144a,144bcarried by mechanical arms108of pipeline profiler100bias odometers124into contact with inner wall220of pipeline216. The angle bracket shape of the mechanical arms108means that mechanical arms108will not recline back to be flat against profiler body104as pipeline profiler100is pulled along the pipeline by pig196. In addition, the slim profile of profiler body104and the long mechanical arms108with the spring-loaded adjustable arms allow pipeline profiler100to be more flexible and adaptable to the inner profile of the pipeline. As odometers124roll along inner wall224of pipeline216, odometers124generate distance measurement signals that are received by the electronics module inside profiler body104of pipeline profiler. Simultaneously, devices172,176measure azimuth and inclination of profiler body104and generate corresponding measurement signals that are received by the electronics module. The electronics module stores the measurement data. Pig196and pipeline profiler100can be retrieved from a pig receiver (228inFIG.10) at a pumping station. After retrieving pipeline profiler100from the pig receiver, the measurement data stored inside pipeline profiler100are retrieved and processed on a computer. Using the launch point of pig196as datum, the pipeline profile can be calculated from the measurement data (distance measurements, azimuth measurements, and inclination measurements) using either curvature radius method or minimum curvature method. The output will be x, y, z coordinates along the pipeline. Curvature radius and minimum curvature methods are known in the drilling art, e.g., in the context of determining borehole trajectories. FIG.13shows an example of a pipeline profile232that may be generated using data collected by the pipeline profiler. Pipeline profile232begins at a platform236, passes through a tie-in platform244, and ends at a plant248. Pipeline profile232, platforms236,244, and plant248are shown relative to a seabed240. Platform236may be, for example, a structure with wells, pipelines of the wells, and surface equipment for the wells. Tie-in platform244may be, for example, a structure that connects pipelines of several platforms into a larger pipeline that routes the fluid production to the plant. The detailed description along with the summary and abstract are not intended to be exhaustive or to limit the embodiments to the precise forms described. Although specific embodiments, implementations, and examples are described herein for illustrative purposes, various equivalent modifications can be made without departing from the spirit and scope of the disclosure, as will be recognized by those skilled in the relevant art. | 14,871 |
11859755 | DETAILED DESCRIPTION Overview The disclosed aspects, details, and embodiments herein may be used in various combinations with other pipe inspection, cleaning, locating, and related apparatus, systems, and methods in additional embodiments. For example, additional details and examples that may be used in conjunction with the disclosures herein are detailed in co-assigned patent applications including: U.S. Pat. No. 6,545,704, issued Apr. 7, 1999, entitled VIDEO PIPE INSPECTION DISTANCE MEASURING SYSTEM; U.S. Pat. No. 5,939,679, issued Aug. 17, 1999, entitled VIDEO PUSH CABLE; U.S. Pat. No. 6,831,679, issued Dec. 14, 2004, entitled VIDEO CAMERA HEAD WITH THERMAL FEEDBACK LIGHTING CONTROL; U.S. Pat. No. 6,862,945, issued Mar. 8, 2005, entitled CAMERA GUIDE FOR VIDEO PIPE INSPECTION SYSTEM; U.S. Pat. No. 6,908,310, issued Jun. 21, 2005, entitled SLIP RING ASSEMBLY WITH INTEGRAL POSITION ENCODER; U.S. Pat. No. 6,958,767, issued Oct. 25, 2005, entitled VIDEO PIPE INSPECTION SYSTEM EMPLOYING NON-ROTATING CABLE STORAGE DRUM; U.S. Pat. No. 7,009,399, issued Mar. 7, 2006, entitled OMNIDIRECTIONAL SONDE AND LINE LOCATOR; U.S. Pat. No. 7,136,765, issued Nov. 14, 2006, entitled A BURIED OBJECT LOCATING AND TRACING METHOD AND SYSTEM EMPLOYING PRINCIPAL COMPONENTS ANALYSIS FOR BLIND SIGNAL DETECTION; U.S. Pat. No. 7,221,136, issued May 22, 2007, entitled SONDES FOR LOCATING UNDERGROUND PIPES AND CONDUITS; U.S. Pat. No. 7,276,910, issued Oct. 2, 2007, entitled A COMPACT SELF-TUNED ELECTRICAL RESONATOR FOR BURIED OBJECT LOCATOR APPLICATIONS; U.S. Pat. No. 7,288,929, issued Oct. 30, 2007, entitled INDUCTIVE CLAMP FOR APPLYING SIGNAL TO BURIED UTILITIES; U.S. Pat. No. 7,298,126, issued Nov. 20, 2007, entitled SONDES FOR LOCATING UNDERGROUND PIPES AND CONDUITS; U.S. Pat. No. 7,332,901, issued Feb. 19, 2008, entitled LOCATOR WITH APPARENT DEPTH INDICATION; U.S. Pat. No. 7,336,078, issued Feb. 26, 2008, entitled MULTI-SENSOR MAPPING OMNIDIRECTIONAL SONDE AND LINE LOCATORS; U.S. Pat. No. 7,443,154, issued Oct. 28, 2008, entitled MULTI-SENSOR MAPPING OMNIDIRECTIONAL SONDE AND LINE LOCATOR; U.S. Pat. No. 7,498,797, issued Mar. 3, 2009, entitled LOCATOR WITH CURRENT-MEASURING CAPABILITY; U.S. Pat. No. 7,498,816, issued Mar. 3, 2009, entitled OMNIDIRECTIONAL SONDE AND LINE LOCATOR; U.S. Pat. No. 7,518,374, issued Apr. 14, 2009, entitled RECONFIGURABLE PORTABLE LOCATOR EMPLOYING MULTIPLE SENSOR ARRAYS HAVING FLEXIBLE NESTED ORTHOGONAL ANTENNAS; U.S. Pat. No. 7,557,559, issued Jul. 7, 2009, entitled COMPACT LINE ILLUMINATOR FOR LOCATING BURIED PIPES AND CABLES; U.S. Pat. No. 7,619,516, issued Nov. 17, 2009, entitled SINGLE AND MULTI-TRACE OMNIDIRECTIONAL SONDE AND LINE LOCATORS AND TRANSMITTER USED THEREWITH; U.S. patent application Ser. No. 12/704,808, filed Feb. 12, 2010, entitled PIPE INSPECTION SYSTEM WITH REPLACEABLE CABLE STORAGE DRUM; U.S. Pat. No. 7,733,077, issued Jun. 8, 2010, entitled MULTI-SENSOR MAPPING OMNIDIRECTIONAL SONDE AND LINE LOCATORS AND TRANSMITTER USED THEREWITH; U.S. Pat. No. 7,741,848, issued Jun. 22, 2010, entitled ADAPTIVE MULTICHANNEL LOCATOR SYSTEM FOR MULTIPLE PROXIMITY DETECTION; U.S. Pat. No. 7,755,360, issued Jul. 13, 2010, entitled PORTABLE LOCATOR SYSTEM WITH JAMMING REDUCTION; U.S. Pat. No. 7,825,647, issued Nov. 2, 2010, entitled METHOD FOR LOCATING BURIED PIPES AND CABLES; U.S. Pat. No. 7,830,149, issued Nov. 9, 2010, entitled AN UNDERGROUND UTILITY LOCATOR WITH A TRANSMITTER A PAIR OF UPWARDLY OPENING POCKETS AND HELICAL COIL TYPE ELECTRICAL CORDS; U.S. Pat. No. 7,863,885, issued Jan. 4, 2011, entitled SONDES FOR LOCATING UNDERGROUND PIPES AND CONDUITS; U.S. Pat. No. 7,948,236, issued May 24, 2011, entitled ADAPTIVE MULTICHANNEL LOCATOR SYSTEM FOR MULTIPLE PROXIMITY DETECTION; U.S. Pat. No. 7,969,419, issued Jun. 28, 2011, entitled PRE-AMPLIFIER AND MIXER CIRCUITRY FOR A LOCATOR ANTENNA; U.S. patent application Ser. No. 13/189,844, filed Jul. 25, 2011, entitled BURIED OBJECT LOCATOR SYSTEMS AND METHODS; U.S. Pat. No. 7,990,151, issued Aug. 2, 2011, entitled TRI-POD BURIED LOCATOR SYSTEM; U.S. Pat. No. 8,013,610, issued Sep. 6, 2011, entitled HIGH Q SELF-TUNING LOCATING TRANSMITTER; U.S. Pat. No. 8,035,390, issued Oct. 11, 2011, entitled OMNIDIRECTIONAL SONDE AND LINE LOCATOR; U.S. patent application Ser. No. 13/346,668, Jan. 9, 2012, entitled PORTABLE CAMERA CONTROLLER PLATFORM FOR USE WITH PIPE INSPECTION SYSTEM; U.S. Pat. No. 8,106,660, issued Jan. 31, 2012, entitled SONDE ARRAY FOR USE WITH BURIED LINE LOCATOR; U.S. Pat. No. 8,203,343, issued Jun. 19, 2012, entitled RECONFIGURABLE PORTABLE LOCATOR EMPLOYING MULTIPLE SENSOR ARRAYS HAVING FLEXIBLE NESTED ORTHOGONAL ANTENNAS; U.S. patent application Ser. No. 13/584,799, filed Aug. 13, 2012, entitled BURIED OBJECT LOCATOR SYSTEMS AND METHODS; U.S. Pat. No. 8,248,056, issued Aug. 21, 2012, entitled A BURIED OBJECT LOCATOR SYSTEM EMPLOYING AUTOMATED VIRTUAL DEPTH EVENT DETECTION AND SIGNALING; U.S. Pat. No. 8,264,226, issued Sep. 11, 2012, entitled SYSTEMS AND METHODS FOR LOCATING BURIED PIPES AND CABLES WITH A MAN PORTABLE LOCATOR AND A TRANSMITTER IN A MESH NETWORK; U.S. patent application Ser. No. 13/647,310, filed Oct. 8, 2012, entitled PIPE INSPECTION SYSTEM APPARATUS AND METHODS; U.S. Pat. No. 8,289,385, issued Oct. 16, 2012, entitled PUSH-CABLE FOR PIPE INSPECTION SYSTEM; U.S. patent application Ser. No. 13/769,202, Feb. 15, 2013, entitled SMART PAINT STICK DEVICES AND METHODS; U.S. patent application Ser. No. 13/774,351, Feb. 22, 2013, entitled DOCKABLE TRIPODAL CAMERA CONTROL UNIT; U.S. patent application Ser. No. 13/787,711, Mar. 6, 2013, entitled DUAL SENSED LOCATING SYSTEMS AND METHODS; U.S. patent application Ser. No. 13/793,168, filed Mar. 11, 2013, entitled BURIED OBJECT LOCATORS WITH CONDUCTIVE ANTENNA BOBBINS; U.S. Pat. No. 8,395,661, issued Mar. 12, 2013, entitled PIPE INSPECTION SYSTEM WITH SELECTIVE IMAGE CAPTURE; U.S. patent application Ser. No. 13/826,112, Mar. 14, 2013, entitled SYSTEMS AND METHODS INVOLVING A SMART CABLE STORAGE DRUM AND NETWORK NODE FOR TRANSMISSION OF DATA; U.S. Pat. No. 8,400,154, issued Mar. 19, 2013, entitled LOCATOR ANTENNA WITH CONDUCTIVE BOBBIN; U.S. patent application Ser. No. 13/851,951, Mar. 27, 2013, entitled DUAL ANTENNA SYSTEMS WITH VARIABLE POLARIZATION; U.S. patent application Ser. No. 13/894,038, May 14, 2013, entitled OMNI-INDUCER TRANSMITTING DEVICES AND METHODS; U.S. patent application Ser. No. 13/925,636, Jun. 24, 2013, entitled MODULAR BATTERY PACK APPARATUS, SYSTEMS, AND METHODS INCLUDING VIRAL DATA AND/OR CODE TRANSFER; U.S. patent application Ser. No. 14/027,027, Sep. 13, 2013, entitled SONDE DEVICES INCLUDING A SECTIONAL FERRITE CORE STRUCTURE; U.S. Pat. No. 8,547,428, issued Oct. 1, 2013, entitled PIPE MAPPING SYSTEM; U.S. Pat. No. 8,564,295, issued Oct. 22, 2013, entitled METHOD FOR SIMULTANEOUSLY DETERMINING A PLURALITY OF DIFFERENT LOCATIONS OF THE BURIED OBJECTS AND SIMULTANEOUSLY INDICATING THE DIFFERENT LOCATIONS TO A USER; U.S. patent application Ser. No. 14/033,349, filed Sep. 20, 2013, entitled PIPE INSPECTION WITH SNAP ON PIPE GUIDES; U.S. Pat. No. 8,540,429, issued Sep. 24, 2013, entitled SNAP ON PIPE GUIDE; U.S. patent application Ser. No. 14/077,022, filed Nov. 11, 2013, entitled WEARABLE MAGNETIC FIELD UTILITY LOCATOR SYSTEM WITH SOUND FIELD GENERATION; U.S. Pat. No. 8,587,648, issued Nov. 19, 2013, entitled SELF-LEVELING CAMERA HEAD; U.S. patent application Ser. No. 14/136,104, Dec. 20, 2013, entitled ROTATING CONTACT ASSEMBLIES FOR SELF-LEVELING CAMERA HEADS; U.S. patent application Ser. No. 14/148,649, Jan. 6, 2014, entitled MAPPING LOCATING SYSTEMS AND METHODS; U.S. Pat. No. 8,635,043, issued Jan. 21, 2014, entitled application Ser. No. 14/203,485, filed Mar. 10, 2014, entitled PIPE INSPECTION CABLE COUNTER AND OVERLAY MANAGEMENT SYSTEM; U.S. patent application Ser. No. 14/207,527, Mar. 12, 2014, entitled ROTATING CONTACT ASSEMBLIES FOR SELF-LEVELING CAMERA HEADS; U.S. patent application Ser. No. 14/207,502, Mar. 12, 2014, entitled GRADIENT ANTENNA COILS FOR USE IN LOCATING SYSTEMS; U.S. patent application Ser. No. 14/214,151, Mar. 14, 2014, entitled DUAL ANTENNA SYSTEMS WITH VARIABLE POLARIZATION; U.S. patent application Ser. No. 14/216,358, Mar. 17, 2014, entitled SMART CABLE STORAGE DRUM AND NETWORK NODE SYSTEM AND METHODS; U.S. Pat. No. 8,717,028, issued May 6, 2014, entitled SPRING CLIPS FOR USE WITH LOCATING TRANSMITTERS; U.S. Pat. No. 8,773,133, issued Jul. 8, 2014, entitled ADAPTIVE MULTICHANNEL LOCATOR SYSTEM FOR MULTIPLE PROXIMITY DETECTION; U.S. Pat. No. 9,703,002, issued Jul. 13, 2014, entitled UTILITY LOCATOR SYSTEMS AND METHODS; U.S. patent application Ser. No. 14/446,145, Jul. 29, 2014, entitled UTILITY LOCATING SYSTEMS WITH MOBILE BASE STATION; U.S. Pat. No. 8,841,912, issued Sep. 23, 2014, entitled PRE-AMPLIFIER AND MIXER CIRCUITRY FOR A LOCATOR ANTENNA; U.S. patent application Ser. No. 14/935,878, Nov. 7, 2014, entitled INSPECTION CAMERA DEVICES AND METHODS WITH SELECTIVELY ILLUMINATED MULTISENSOR IMAGING; U.S. patent application Ser. No. 14/557,163, Dec. 1, 2014, entitled ASYMMETRIC DRAG FORCE BEARING; U.S. Pat. No. 8,908,027, issued Dec. 9, 2014, entitled ASYMMETRIC DRAG FORCE BEARING FOR USE WITH PUSH-CABLE STORAGE DRUM; U.S. Pat. No. 8,970,211, issued Mar. 3, 2015, entitled PIPE INSPECTION CABLE COUNTER NAD OVERLAY MANAGEMENT SYSTEM; U.S. patent application Ser. No. 14/642,596, filed Mar. 9, 2015, entitled PIPE CLEARING CABLES AND APPARATUS; U.S. Pat. No. 8,984,698, issued Mar. 24, 2015, entitled LIGHT WEIGHT SEWER CABLE; U.S. patent application Ser. No. 14/709,301, filed May 11, 2015, entitled PIPE MAPPING SYSTEMS AND METHODS; U.S. Pat. No. 9,041,794, issued May 26, 2015, entitled PIPE MAPPING SYSTEMS AND METHODS; U.S. Pat. No. 9,057,754, issued Jun. 16, 2015, entitled ECONOMICAL MAGNETIC LOCATOR APPARATUS AND METHOD; U.S. patent application Ser. No. 14/746,590, Jun. 22, 2015, entitled THERMAL EXTRACTION ARCHITECTURES FOR CAMERA AND LIGHTING DEVICES; U.S. Pat. No. 9,066,446, issued Jun. 23, 2015, entitled THERMAL EXTRACTION ARCHITECTURE FOR CAMERA HEADS, INSPECTION SYSTEMS, AND OTHER DEVICES AND SYSTEMS; U.S. patent application Ser. No. 14/749,545, Jun. 24, 2015, entitled ADJUSTABLE VARIABLE RESOLUTION INSPECTION SYSTEMS AND METHODS; U.S. patent application Ser. No. 14/797,760, Jul. 13, 2015, entitled HAPTIC DIRECTIONAL FEEDBACK HANDLES FOR LOCATING DEVICES U.S. patent application Ser. No. 14/798,177, filed Jul. 13, 2015, entitled MARKING PAINT APPLICATOR FOR USE WITH PORTABLE UTILITY LOCATOR; U.S. Pat. No. 9,081,109, issued Jul. 14, 2015, entitled GROUND-TRACKING DEVICES FOR USE WITH A MAPPING LOCATOR; U.S. Pat. No. 9,082,269, issued Jul. 14, 2015, entitled HAPTIC DIRECTIONAL FEEDBACK HANDLES FOR LOCATION DEVICES; U.S. Pat. No. 9,080,992, issued Jul. 14, 2015, entitled ADJUSTABLE VARIABLE RESOLUTION INSPECTION SYSTEMS AND METHODS; U.S. patent application Ser. No. 14/800,490, Jul. 15, 2013, entitled UTILITY LOCATOR DEVICES, SYSTEMS, AND METHODS WITH SATELLITE AND MAGNETIC FIELD SONDE ANTENNA SYSTEMS; U.S. Pat. No. 9,085,007, issued Jul. 21, 2015, entitled MARKING PAINT APPLICATOR FOR PORTABLE LOCATOR; U.S. Pat. No. 9,134,255, issued Sep. 15, 2015, entitled PIPE INSPECTION SYSTEM WITH SELECTIVE IMAGE CAPTURE; U.S. patent application Ser. No. 14/949,868, Nov. 23, 2015, entitled BURIED OBJECT LOCATORS WITH DODECAHEDRAL ANTENNA NODES; U.S. Pat. No. 9,207,350, issued Dec. 8, 2015, entitled BURIED OBJECT LOCATOR APPARATUS WITH SAFETY LIGHTING ARRAY; U.S. patent application Ser. No. 14/970,362, Dec. 15, 2015, entitled COAXIAL VIDEO PUSH-CABLES FOR USE IN INSPECTION SYSTEMS; U.S. Pat. No. 9,222,809, issued Dec. 29, 2015, entitled PORTABLE PIPE INSPECTION SYSTEMS AND APPARATUS; U.S. patent application Ser. No. 15/006,119, Jan. 26, 2016, entitled SELF-STANDING MULTI-LEG ATTACHMENT DEVICES FOR USE WITH UTILITY LOCATORS; U.S. patent application Ser. No. 15/434,056, Feb. 16, 2016, entitled BURIED UTILITY MARKER DEVICES, SYSTEMS, AND METHODS; U.S. patent application Ser. No. 15/050,267, filed Feb. 22, 2016, entitled SELF-LEVELING CAMERA HEAD; U.S. Pat. No. 9,277,105, issued Mar. 1, 2016, entitled SELF-LEVELING CAMERA HEAD; U.S. Pat. No. 9,341,740, issued May 17, 2016, entitled OPTICAL GROUND TRACKING APPARATUS, SYSTEMS, AND METHODS; U.S. patent application Ser. No. 15/187,785, Jun. 21, 2016, entitled BURIED UTILITY LOCATOR GROUND TRACKING APPARATUS, SYSTEMS, AND METHODS; U.S. Pat. No. 9,372,117, issued Jun. 21, 2016, entitled OPTICAL GROUND TRACKING APPARATUS, SYSTEMS, AND METHODS; U.S. patent application Ser. No. 15/225,623, Aug. 1, 2016, entitled SONDE-BASED GROUND-TRACKING APPARATUS AND METHODS; U.S. patent application Ser. No. 15/225,721, filed Aug. 1, 2016, entitled SONDES AND METHODS FOR USE WITH BURIED LINE LOCATOR SYSTEMS; U.S. Pat. No. 9,411,066, issued Aug. 9, 2016, entitled SONDES AND METHODS FOR USE WITH BURIED LINE LOCATOR SYSTEMS; U.S. Pat. No. 9,411,067, issued Aug. 9, 2016, entitled GROUND-TRACKING SYSTEMS AND APPARATUS; U.S. patent application Ser. No. 15/247,503, Aug. 25, 2016, entitled LOCATING DEVICES, SYSTEMS, AND METHODS USING FREQUENCY SUITES FOR UTILITY DETECTION; U.S. Pat. No. 9,927,546, issued Aug. 29, 2016, entitled PHASE SYNCHRONIZED BURIED OBJECT LOCATOR APPARATUS, SYSTEMS, AND METHODS; U.S. Pat. No. 9,435,907, issued Sep. 6, 2016, entitled PHASE SYNCHRONIZED BURIED OBJECT LOCATOR APPARATUS, SYSTEMS, AND METHODS; U.S. patent application Ser. No. 15/264,355, Sep. 13, 2016, entitled HIGH BANDWIDTH VIDEO PUSH-CABLES FOR PIPE INSPECTION SYSTEMS; U.S. Pat. No. 9,448,376, issued Sep. 20, 2016, entitled HIGH BANDWIDTH PUSH-CABLES FOR VIDEO PIPE INSPECTION SYSTEMS; U.S. Pat. No. 9,465,129, issued Oct. 11, 2016, entitled IMAGE-BASED MAPPING LOCATING SYSTEM; U.S. Pat. No. 9,468,954, issued Oct. 18, 2016, entitled PIPE INSPECTION SYSTEM WITH JETTER PUSH-CABLE; U.S. patent application Ser. No. 15/331,570, Oct. 21, 2016, entitled KEYED CURRENT SIGNAL UTILITY LOCATING SYSTEMS AND METHODS; U.S. Pat. No. 9,477,147, issued Oct. 25, 2016, entitled SPRING ASSEMBLIES WITH VARIABLE FLEXIBILITY FOR USE WITH PUSH-CABLES AND PIPE INSPECTION SYSTEMS; U.S. patent application Ser. No. 15/339,766, Oct. 31, 2016, entitled GRADIENT ANTENNA COILS AND ARRAYS FOR USE IN LOCATING SYSTEMS; U.S. patent application Ser. No. 15/345,421, Nov. 7, 2016, entitled OMNI-INDUCER TRANSMITTING DEVICES AND METHODS; U.S. Pat. No. 9,488,747, issued Nov. 8, 2016, entitled GRADIENT ANTENNA COILS AND ARRAYS FOR USE IN LOCATING SYSTEM; U.S. Pat. No. 9,494,706, issued Nov. 15, 2016, entitled OMNI-INDUCER TRANSMITTING DEVICES AND METHODS; U.S. patent application Ser. No. 15/360,979, Nov. 23, 2016, entitled UTILITY LOCATING SYSTEMS, DEVICES, AND METHODS USING RADIO BROADCAST SIGNALS; U.S. patent application Ser. No. 15/369,693, Dec. 5, 2016, entitled CABLE STORAGE DRUM WITH MOVABLE CCU DOCKING APPARATUS; U.S. patent application Ser. No. 15/376,576, filed Dec. 12, 2016, entitled MAGNETIC SENSING BURIED OBJECT LOCATOR INCLUDING A CAMERA; U.S. Pat. No. 9,521,303, issued Dec. 13, 2016, entitled CABLE STORAGE DRUM WITH MOVEABLE CCU DOCKING APPARATUS; U.S. Pat. No. 9,523,788, issued Dec. 20, 2016, entitled MAGNETIC SENSING BURIED OBJECT LOCATOR INCLUDING A CAMERA; U.S. patent application Ser. No. 15/396,068, filed Dec. 30, 2016, entitled UTILITY LOCATOR TRANSMITTER APPARATUS AND METHODS; U.S. patent application Ser. No. 15/425,785, filed Feb. 6, 2017, entitled METHOD AND APPARATUS FOR HIGH-SPEED DATA TRANSFER EMPLOYING SELF-SYNCHRONIZING QUADRATURE AMPLITUDE MODULATION (QAM); U.S. Pat. No. 9,571,326, issued Feb. 14, 2017, entitled METHOD AND APPARATUS FOR HIGH-SPEED DATA TRANSFER EMPLOYING SELF-SYNCHRONIZING QUADRATURE AMPLITUDE MODULATION (QAM); U.S. patent application Ser. No. 15/457,149, Mar. 13, 2017, entitled USER INTERFACES FOR UTILITY LOCATORS; U.S. patent application Ser. No. 15/457,222, Mar. 13, 2017, entitled SYSTEMS AND METHODS FOR LOCATING BURIED OR HIDDEN OBJECTS USING SHEET CURRENT FLOW MODELS; U.S. patent application Ser. No. 15/457,897, Mar. 13, 2017, entitled UTILITY LOCATORS WITH RETRACTABLE SUPPORT STRUCTURES AND APPLICATIONS THEREOF; U.S. patent application Ser. No. 14/022,067, Mar. 21, 2017, entitled USER INTERFACES FOR UTILITY LOCATORS; U.S. Pat. No. 9,599,449, issued Mar. 21, 2017, entitled SYSTEMS AND METHODS FOR LOCATING BURIED OR HIDDEN OBJECTS USING SHEET CURRENT FLOW MODELS; U.S. patent application Ser. No. 15/470,642, Mar. 27, 2017, entitled UTILITY LOCATING APPARATUS AND SYSTEMS USING MULTIPLE ANTENNA COILS; U.S. patent application Ser. No. 15/470,713, Mar. 27, 2017, entitled UTILITY LOCATORS WITH PERSONAL COMMUNICATION DEVICE USER INTERFACES; U.S. patent application Ser. No. 15/483,924, Apr. 10, 2017, entitled SYSTEMS AND METHODS FOR DATA TRANSFER USING SELF-SYNCHRONIZING QUADRATURE AMPLITUDE MODULATION (QAM); U.S. patent application Ser. No. 15/485,082, Apr. 11, 2017, entitled MAGNETIC UTILITY LOCATOR DEVICES AND METHODS; U.S. patent application Ser. No. 15/485,125, Apr. 11, 2017, entitled INDUCTIVE CLAMP DEVICES, SYSTEMS, AND METHODS; U.S. Pat. No. 9,625,602, issued Apr. 18, 2017, entitled SMART PERSONAL COMMUNICATION DEVICES AS USER INTERFACES; U.S. patent application Ser. No. 15/497,040, Apr. 25, 2017, entitled SYSTEMS AND METHODS FOR LOCATING AND/OR MAPPING BURIED UTILITIES USING VEHICLE-MOUNTED LOCATING DEVICES; U.S. Pat. No. 9,632,199, issued Apr. 25, 2017, entitled INDUCTIVE CLAMP DEVICES, SYSTEMS, AND METHODS; U.S. Pat. No. 9,632,202, issued Apr. 25, 2017, entitled ECONOMICAL MAGNETIC LOCATOR APPARATUS AND METHOD; U.S. Pat. No. 9,634,878, issued Apr. 25, 2017, entitled SYSTEMS AND METHODS FOR DATA SYNCHRONIZING QUADRATURE AMPLITUDE MODULATION (QAM); U.S. Pat. No. 9,638,824, issued May 2, 2017, entitled QUAD-GRADIENT COILS FOR USE IN LOCATING SYSTEMS; U.S. patent application Ser. No. 15/590,964, May 9, 2017, entitled BORING INSPECTION SYSTEMS AND METHODS; U.S. Pat. No. 9,651,711, issued May 16, 2017, entitled HORIZONTAL BORING INSPECTION DEVICE AND METHODS; U.S. patent application Ser. No. 15/623,174, Jun. 14, 2017, entitled TRACKABLE DIPOLE DEVICES, METHODS, AND SYSTEMS FOR USE WITH MARKING PAINT STICKS; U.S. patent application Ser. No. 15/185,018, Jun. 17, 2016, entitled RESILIENTLY DEFORMABLE MAGNETIC FIELD TRANSMITTER CORES FOR USE WITH UTILITY LOCATING DEVICES AND SYSTEMS; U.S. patent application Ser. No. 15/626,399, Jun. 19, 2017, entitled SYSTEMS AND METHODS FOR UNIQUELY IDENTIFYING BURIED UTILITIES IN A MULTI-UTILITY ENVIRONMENT; U.S. Pat. No. 9,684,090, issued Jun. 20, 2017, entitled NULLED-SIGNAL LOCATING DEVICES, SYSTEMS, AND METHODS; U.S. Pat. No. 9,696,447, issued Jul. 4, 2017, entitled BURIED OBJECT METHODS AND APPARATUS USING MULTIPLE ELECTROMAGNETIC SIGNALS; U.S. Pat. No. 9,696,448, issued Jul. 4, 2017, entitled GROUND-TRACKING DEVICES FOR USE WITH A MAPPING LOCATOR; U.S. patent application Ser. No. 15/670,845, Aug. 7, 2017, entitled HIGH FREQUENCY AC-POWERED DRAIN CLEANING AND INSPECTION APPARATUS AND METHODS; U.S. patent application Ser. No. 15/681,250, Aug. 18, 2017, entitled ELECTRONIC MARKER DEVICES AND SYSTEMS; U.S. patent application Ser. No. 15/681,409, filed Aug. 20, 2017, entitled WIRELESS BURIED PIPE AND CABLE LOCATING SYSTEMS; U.S. Pat. No. 9,746,572, issued Aug. 29, 2017, entitled ELECTRONIC MARKER DEVICES AND SYSTEMS; U.S. Pat. No. 9,746,573, issued Aug. 29, 2017, entitled WIRELESS BURIED PIPE AND CABLE LOCATING SYSTEMS; U.S. patent application Ser. No. 15/701,247, Sep. 11, 2017, entitled PIPE INSPECTION SYSTEMS WITH SELF-GROUNDING PORTABLE CAMERA CONTROLLER; U.S. Pat. No. 9,769,366, issued Sep. 19, 2017, entitled SELF-GROUNDING TRANSMITTING PORTABLE CAMERA CONTROLLER FOR USE WITH PIPE INSPECTION SYSTEMS; U.S. patent application Ser. No. 15/728,250, Oct. 9, 2017, entitled OPTICAL GROUND TRACKING APPARATUS, SYSTEMS, AND METHODS FOR USE WITH BURIED UTILITY LOCATORS; U.S. patent application Ser. No. 15/728,410, Oct. 9, 2017, entitled PIPE INSPECTION SYSTEM WITH JETTER PUSH-CABLE; U.S. Pat. No. 9,784,837, issued Oct. 10, 2017, entitled OPTICAL GROUND TRACKING APPARATUS, SYSTEMS, AND METHODS; U.S. patent application Ser. No. 15/785,330, Oct. 16, 2017, entitled SYSTEMS AND METHODS OF USING A SONDE DEVICE WITH A SECTIONAL FERRITE CORE STRUCTURE; U.S. Pat. No. 9,791,382, issued Oct. 17, 2017, entitled PIPE INSPECTION SYSTEM WITH JETTER PUSH-CABLE; U.S. Pat. No. 9,798,033, issued Oct. 24, 2017, entitled SONDE DEVICES INCLUDING A SECTIONAL FERRITE CORE; U.S. patent application Ser. No. 15/805,007, filed Nov. 6, 2017, entitled PIPE INSPECTION SYSTEM CAMERA HEADS; U.S. patent application Ser. No. 15/806,219, Nov. 7, 2017, entitled MULTI-CAMERA PIPE INSPECTION APPARATUS, SYSTEMS AND METHODS; U.S. patent application Ser. No. 15/811,264, Nov. 13, 2017, entitled SPRING ASSEMBLIES WITH VARIABLE FLEXIBILITY FOR USE WITH PUSH-CABLES AND PIPE INSPECTION SYSTEMS; U.S. patent application Ser. No. 15/811,361, Nov. 13, 2017, entitled OPTICAL GROUND TRACKING APPARATUS, SYSTEMS, AND METHODS; U.S. Pat. No. 9,824,433, issued Nov. 21, 2017, entitled PIPE INSPECTION SYSTEM CAMERA HEADS; U.S. Pat. No. 9,829,783, issued Nov. 28, 2017, entitled SPRING ASSEMBLIES WITH VARIABLE FLEXIBILITY FOR USE WITH PUSH-CABLES AND PIPE INSPECTION SYSTEMS; U.S. Pat. No. 9,835,564, issued Dec. 5, 2017, entitled MULTI-CAMERA PIPE INSPECTION APPARATUS, SYSTEMS, AND METHODS; U.S. Pat. No. 9,841,503, issued Dec. 12, 2017, entitled OPTICAL GROUND TRACKING APPARATUS, SYSTEMS, AND METHODS; U.S. patent application Ser. No. 15/846,102, Dec. 18, 2017, entitled SYSTEMS AND METHODS FOR ELECTRONICALLY MARKING, LOCATING, AND VIRTUALLY DISPLAYING BURIED UTILITIES; U.S. patent application Ser. No. 15/866,360, Jan. 9, 2018, entitled TRACKED DISTANCE MEASURING DEVICE, SYSTEMS, AND METHODS; U.S. patent application Ser. No. 15/870,787, Jan. 12, 2018, entitled MAGNETIC FIELD CANCELING AUDIO SPEAKERS FOR USE WITH BURIED UTILITY LOCATORS OR OTHER DEVICES; U.S. Provisional Patent Application 62/620,959, Jan. 23, 2018, entitled RECHARGEABLE BATTERY PACK ONBOARD CHARGE STATE INDICATION METHODS AND APPARATUS; U.S. Pat. No. 9,880,309, issued Jan. 30, 2018, entitled UTILITY LOCATOR TRANSMITTER APPARATUS AND METHODS; patent application Ser. No. 15/889,067, Feb. 5, 2018, entitled UTILITY LOCATOR TRANSMITTER DEVICES, SYSTEMS, AND METHODS WITH DOCKABLE APPARATUS; U.S. Pat. No. 9,891,337, issued Feb. 13, 2018, entitled UTILITY LOCATOR TRANSMITTER DEVICES, SYSTEMS, AND METHODS WITH DOCKABLE APPARATUS; U.S. patent application Ser. No. 15/919,077, Mar. 12, 2018, entitled PORTABLE PIPE INSPECTION SYSTEMS AND METHODS; U.S. Pat. No. 9,914,157, issued Mar. 13, 2018, entitled METHODS AND APPARATUS FOR CLEARING OBSTRUCTIONS WITH A JETTER PUSH-CABLE APPARATUS; U.S. patent application Ser. No. 15/922,703, Mar. 15, 2018, entitled SELF-LEVELING INSPECTION SYSTEMS AND METHODS; U.S. patent application Ser. No. 15/925,643, Mar. 19, 2018, entitled PHASE-SYNCHRONIZED BURIED OBJECT TRANSMITTER AND LOCATOR METHODS AND APPARATUS; U.S. patent application Ser. No. 15/925,671, Mar. 19, 2018, entitled MULTI-FREQUENCY LOCATING SYSTEMS AND METHODS; U.S. Pat. No. 9,924,139, issued Mar. 20, 2018, entitled PORTABLE PIPE INSPECTION SYSTEMS AND APPARATUS; U.S. patent application Ser. No. 15/936,250, Mar. 26, 2018, entitled GROUND TRACKING APPARATUS, SYSTEMS, AND METHODS; U.S. Pat. No. 9,927,368, issued Mar. 27, 2018, entitled SELF-LEVELING INSPECTION SYSTEMS AND METHODS; U.S. Pat. No. 9,927,545, issued Mar. 27, 2018, entitled MULTI-FREQUENCY LOCATING SYSTEM AND METHODS; U.S. Pat. No. 9,928,613, issued Mar. 27, 2018, entitled GROUND TRACKING APPARATUS, SYSTEMS, AND METHODS; U.S. Provisional Patent Application 62/656,259, Apr. 11, 2018, entitled GEOGRAPHIC MAP UPDATING METHODS AND SYSTEMS; U.S. patent application Ser. No. 15/954,486, filed Apr. 16, 2018, entitled UTILITY LOCATOR APPARATUS, SYSTEMS, AND METHODS; U.S. Pat. No. 9,945,976, issued Apr. 17, 2018, entitled UTILITY LOCATOR APPARATUS, SYSTEMS, AND METHODS; U.S. patent application Ser. No. 15/960,340, Apr. 23, 2018, entitled METHODS AND SYSTEMS FOR GENERATING INTERACTIVE MAPPING DISPLAYS IN CONJUNCTION WITH USER INTERFACE DEVICES; U.S. Pat. No. 9,959,641, issued May 1, 2018, entitled METHODS AND SYSTEMS FOR SEAMLESS TRANSITIONING IN INTERACTIVE MAPPING SYSTEMS; U.S. Provisional Patent Application 62/686,589, filed Jun. 18, 2018, entitled MULTI-DIELECTRIC COAXIAL PUSH-CABLES; U.S. Provisional Patent Application 62/688,259, filed Jun. 21, 2018, entitled ACTIVE MARKER DEVICES FOR UNDERGROUND USE; U.S. Provisional Patent Application 62/726,500, filed Sep. 4, 2018, entitled VIDEO PIPE INSPECTION SYSTEMS, DEVICES, AND METHODS INTEGRATED WITH NON-VIDEO DATA RECORDING AND COMMUNICATION FUNCTIONALITY; U.S. patent application Ser. No. 16/144,878, filed Sep. 27, 2018, entitled MULTIFUNCTION BURIED UTILITY LOCATING CLIPS; U.S. patent application Ser. No. 16/178,494, filed Nov. 1, 2018, entitled THREE-AXIS MEASUREMENT MODULES AND SENSING METHODS; U.S. Provisional Patent Application 62/756,538, filed Nov. 6, 2018, entitled ROBUST AND LOW COST IMPEDANCE CONTROLLED SLIP RINGS; U.S. Provisional Patent Application 62/768,760, filed Nov. 16, 2018, entitled PIPE INSPECTION AND/OR MAPPING CAMERA HEADS, SYSTEMS, AND METHODS; U.S. Provisional Patent Application 62/777,045, filed Dec. 7, 2018, entitled MAP GENERATION BASED ON UTILITY LINE POSITION AND ORIENTATION ESTIMATES; U.S. Provisional Patent Application 62/794,863, filed Jan. 21, 2019, entitled HEAT EXTRACTION ARCHITECTURE FOR COMPACT VIDEO HEADS; U.S. Provisional Patent Application 62/824,937, filed Mar. 27, 2019, entitled LOW COST AND HIGH PERFORMANCE SIGNAL PROCESSING IN A BURIED OBJECT LOCATOR SYSTEM; and U.S. patent application Ser. No. 16/382,136, filed Apr. 11, 2019, entitled GEOGRAPHIC MAP UPDATING METHODS AND SYSTEMS. The content of each of the above-described patents and patent applications is incorporated by reference herein in its entirety. The above applications may be collectively denoted herein as the “co-assigned applications” or “incorporated applications.” In one aspect this disclosure relates to cable handling device for inspection of pipes or cavities. The cable handling device may include a housing for at least partially enclosing one or more cables or hoses at least one coupling mechanism integrally attached to the housing, and a coupling control for coupling and decoupling the one or more cables or hoses. The cable handling device allows a user to deploy and/or retract one or more cables and/or hoses. The cable handling device may be used to deploy various tools into a pipe or cavity for inspection and/or cleaning. For instance, in some embodiments a cable may be attached to a camera assembly and the camera may be deployed into a pipe or cavity to provide images to a user display so that a user can inspect the inside of the pipe and/or cavity. In some embodiments a user may also deploy a flex-shaft. A flex-shaft is an elongate mechanical apparatus with a hollow flexible outer structure and an inner rotating element for transmitting power. A common example is a speedometer cable or a rotary tool cable such as provided with Dremel tools. A flex-shaft provides a flexible shaft that allows rotational power to be supplied at one end and transmitted to a rotationally operated mechanism at the other end. In the plumbing context a flex shaft may be used to transmit power to a cutting mechanism inserted into a pipe or cavity, although it has other uses such as in plumbers' snakes, hand or motor powered energy transmission, and the like. One exemplary plumbing flex shaft is sold by Ridge Tool as a Ridgid™ FlexShaft™ device. In some embodiments, the cutting mechanism may be a blade, a cutting string, a chain knocker, or another cutting device known on the art. In some embodiments the user may deploy a hose attached to a nozzle or jetter to supply pressurized water or other fluid through the nozzle or jetter. The cable handling device allows a user to deploy and/or retract multiple cables at once more quickly and conveniently than by just using their hands. The cable handling device keeps one or more cables and/or hoses together inside the cable handling device making the one or more cables and/or hoses easier to manage. In some embodiments a user simply inserts one or more cables into the cable handling device either by threading the one or more cables or hoses through the device, or in some embodiments, by opening a hinged door and inserting the one or more cables and/or hoses. A coupling mechanism such as one or more triggers, levers, or other controls may be provided to allow a user to clamp the one or more cables and/or hoses inside the cable handling device allowing the cables/hoses to be deployed or retracted from a pipe or cavity together. Once the user has reached the desired location in the pipe or cavity, which can be determined by viewing images provided by the camera, using a location device such as a GPS coupled to the camera, measuring the distance length of the one or more cables and/or hoses deployed, or using other location determining devices or methods understood by those skilled in the art, the user can then release the one or more triggers or controls to allow one or more of the cables and/or hoses to move independently from the cable handling device and/or the other of the one or more cables and/or hoses. This allows a user to deploy the one or more cables and/or hoses at different locations inside the pipe and/or cavity. In one embodiment, a user inserts a cable attached to a camera and a flex-shaft attached to a cutting mechanism into the cable handling device. The user then deploys the two cables simultaneously into a pipe or cavity by using a trigger to couple the two cables and then using their hands attached to the cable handling device and pushing the device and thus the cables into the pipe. The cable handling device may also be configured to automatically deploy one or more cables and/or hoses when the trigger is activated using a motorized feeding element which may include wheels. The user may desire to have one of the cables deployed ahead of the other and, therefore, insert the cables into the cable handling device in the desired configuration. For instance, the user may want the camera to be ahead of the cutting device and may insert the cables into the cable handling device in such a way as to achieve the desired configuration. In this manner, the user can view the camera images without the cutting device obstructing the user's view. If more of the cables needs to be deployed, the user release the trigger and pulls the cable handling device back independent of the two cables. The user can repeat the sequence until the desired location inside the pipe has been reached. Once the two cables are deployed, the user may desire to pull the camera back and push the cutting device forward to allow an obstruction to be removed by the cutting device while protecting the camera cable and camera from being damaged by the cutting device. By releasing the one or more triggers, the user can move the cables independently from each other and from the cable handling device. The user may then continue the process by reconfiguring the cables inside the cable handling device as desired, and further deploying the cables into the pipe by using the trigger to inspect other locations in the pipe. When the user is done with the cables/tools inside the pipe, the trigger is activated to clamp the cables and the user manually pulls back on the cable handling device thus pulling the cables back with it. Then the trigger is released allowing the device to be pushed forward independent of the cables so that the trigger can be used again to clamp the cables and the user can continue to retract the cables as desired. In some embodiments the device may have an automatic feeder direction control allowing the cable to be retracted. In some embodiments, dampening or noise cancellation could be provided to reduce noise and vibration when the flex-shaft is transmitting power to a cutting mechanism in order to provide better imaging by reducing possible distortions created by the camera being near the flex-shaft. In some embodiments, coupling mechanism may be a trigger or other control and may include other controls such as speed control, control lock, direction control, etc. A trigger may be provided to control one or multiple cables, or multiple triggers may be provided to control one or more cables individually. In another embodiment, the cable handling device deploys or retracts one or more cables and/or hoses by attaching various clips, clamps, and pipe guides along desired locations of the one or more cables and/or hoses to provide, among other things, cable management, cable steering and/or cable protection. As an example, a pipe guide may have an opening through the center allowing the camera cable and cable to be inserted snugly into the opening. Another cable or hose, for example a flex-shaft with a cutting mechanism attached, can be inserted into one of the outside channels. The pipe guide can be attached at the desired location along the cables, or along the camera assembly, depending on the size of pipe guide used. Cable clips and clamps simply clamp one or more cables together, typically by twisting or with a provided tightening mechanism. It is often desirable to locate the clamp or pipe guide near or on the camera assembly to allow the camera and any other attached cables or hoses to be easily pushed and guided into a pipe or cavity. Guides have the added advantage over clips or clamps because they are often designed to permit axial movement while restraining both lateral and angular movement. In another embodiment, a cutting mechanism, as an example, a chain knocker is provided a the end of a flex-shaft. The flex-shaft attaches using a pair of set screws that bite on the flexible shaft. The chain mount may have a shaft collar that is a larger diameter than the sheathing on the flexible shaft. In another embodiment, the plastic material forming the pipe guide could be shaped and formed in such a way that it creates a flexure, so that the flex-shaft sheath can be “snapped in,” but the chain mount would still crash on an undersized bore. This would allow the flex-shaft to be attached without removing the chain if the chain knocker. In some embodiments, multiple bores could be added to allow two or more flex-shafts to be used. Alternatively, the bores could be of a different size and include a lip configured to accept an installed captive sleeve to provided adaptation to various sizes of sheathing, hose, etc. Cleaning could be provided as well, by implementing a capture O-ring in the supplemental bore, to wipe the flex-shaft sheathing pulled back into the O-ring. In another embodiment, the disclosure relates to a configuration wherein the cable handling device works in conjunction with remotely controlled clamps dispersed along desired locations of the one or more cables and/or hoses to provide, among other things, cable management, cable steering and/or cable protection. In another embodiment, a camera and a flex cable with a chain knocker attached at the end may be clamped together with a remote controlled clamp being placed behind the camera assembly as shown inFIG.13A. The chain knocker could be positioned behind the camera assembly so that when the camera is moved forward or backwards in a pipe or cavity, the flex-shaft and chain knocker would be moved as well. Once a desired location is reached, LEDs located in the camera head could be modulated to send an optical signal to a receiving sensor located in the clamp, to unclamp the flex-shaft allowing it to be move independent of the camera. The flex-shaft and chain knocker could then be moved forward to allow the flex-shaft to be powered and the chain knocker to rotate to clear any obstructions without damaging the camera which is now behind the chain knocker. The clamp could then be sent another optical signal to again clamp the flex-shaft to the camera cable so the flex-shaft and chain knocker could again be deployed or retracted as desired. In another embodiment, the remote controlled clamp could be located on or near the camera head as shown inFIG.13B. The diameter of the distal side of the clamp could be smaller than the diameter of the chain proximal side end cap, thereby preventing the chain knocker from ever being pulled near the camera cable, thus preventing damage to the camera cable from the chain knocker. In another embodiment, as an alternative to optically controlling the remote controlled clamp, a transmitter/transceiver could be provided on or near the camera head as shown inFIG.13C. The transmitter/transceiver could be configured to send control signals to a receiving sensor in the clamp. The transmitted signals could be wireless, electromagnetic, radio, Bluetooth, BLE (Bluetooth Low Energy), etc. Various frequency schemes could be provided, included but not limited to, 400 Hz, 512 Hz, 32 kHz. In another embodiment, the transmitted signal to control the remote clamp could be provided by an electromagnetic Sonde or other type of location Sonde or beacon. Alternatively, the remote controlled clamp could be integrated with a three-axis magnetometer capable of communicating with a second sensor located with the camera, wherein the second sensor is configured to modulate an electromagnetic signal that can be received by the three-axis magnetometer and used to control the opening and closing of the remote controlled clamp. In another embodiment, a cable handling device including a coupling mechanism and a motorized feeder, may include a rocker switch configured to control the direction (forward or backward), and speed of one or more cables or hoses, either simultaneously or individually, as they are deployed or retracted during pipe cleaning or inspection. In one embodiment, the rocker switch may configured as a dual side-by-side rocker switch which can be controlled by hand, wherein each one of the dual switches controls the individual feeding direction of a cable or hose depending on if the individual switches are put into the forward, reverse, or neutral direction, and controls the speed of feeding the cable or hose depending on how far forward or reverse the switches are relative to the neutral position. In another embodiment, the rocker switch may be a single rocker switch, wherein the switch is configured to have seven positions, wherein the switch can be put completely or partially into any of six positions in order to control the direction and/or speed of feeding of one and/or two cables and/or hoses. In another embodiment, a dual drum-reel management system allows a user to transport and/or use two drum-reels at a time using only one hand. Two-drum reels can be coupled together in a side-by-side configuration. Cables and/or hoses for inspecting and/cleaning pipes or cavities are typically stored and deployed from a rotating drum-reel which may include a handle for carrying/transporting the drum-reel. Users, which may be plumbers or utility workers, often need to carry specific equipment for inspecting and/or cleaning pipes or cavities. As an example, this equipment may include a flex-shaft cable for providing rotating power to a rotating tool and a camera cable connected to a camera for providing images and/or video for performing inspections and cleaning of the pipes and/or cavities. The flex-shaft cable is typically stored and deployed from a first drum-reel and the camera cable is typically stored and deployed from a second drum-reel. If a user needs to carry and/or transport both drum-reels at once, two hands are required, one for each-drum reel. Often other tools will be carried by a user by hand which creates a “not enough hands” situation if both hands are already occupied carrying the two drum-reels. Users may also use high pressure jetter hoses which can be stored and deployed from a drum-reel, as well as other equipment that may be stored and/deployed from a drum-reel, e.g. electrical cables. In some embodiments, the drum-reel may include feet to stabilize it in certain positions. The drum-reel may also include one or more wheels to allow it to be easily moved to/from a desired location. In another embodiment, a first smaller diameter drum-reel can be docked inside a second larger diameter drum-reel, thereby allowing a user to carry both drum-reels using a single handle. The first drum-reel may be configured to remain docked inside the second drum-reel, may be configured to be removed for maintenance or replacement, or may be configured to be docked or undocked as desired. In some embodiments, a door may be provided for each drum-reel case, and in other embodiments the second larger drum-reel case may have a door that closes over both the first and second drum-reels. In this configuration the first smaller drum-reel case can be configured with or without a door. In another embodiment, a cable handling device configured to deploy or retract one or more cables and/or hoses may be attached to a drum-reel. The cable handling device may be configured attached to a drum-reel in a fixed position (FIG.22B), or configured to be docked with a coupling mechanism that allows the cable handling device to be attached or removed from the drum-reel as needed (FIG.22A). In some embodiments, a cleaning element can be attached to one or both drum-reels, thereby allowing one or more cables and or hoses to be cleaned as they are being deployed or retracted on and off the drum reel or reels. In one embodiment, a drum for a flex-shaft cable may include a drive shaft centered in the center of the drum-reel. The drive-shaft is accessible on the outside of the drum-reel, or if provided on the outside of the case of the drum reel, thereby allowing rotating power to be coupled to the drive shaft. When supplied with rotational power, the power will be transferred from the drive shaft to the flex-shaft cable via one or more gears. In other embodiments, there maybe one or more drive shafts which may be configured on different locations, as desired. By way of example only, examples are shown inFIG.23B. In one embodiment, rotational power for a flex-shaft cable may be provided by an external motor, as an example, a motorized drill as shown inFIG.23A. In another embodiment, power may be provided by a motor integrated with the drum-reel, as shown inFIG.23C. In one embodiment, one or more batteries may be removably attached to a drum-reel or a drum-reel case, as shown inFIGS.20A and20B. The one or more batteries may provide power to a motor, a camera, or any other equipment requiring battery power. In another embodiment, a drive-shaft may be provide for supplying rotational power to one or more gears internal to a drum-reel, wherein the one or more gears rotate, the drum-reel rotates, thereby allowing a cable and/or hose to be stored on (wound) or deployed from (unwound) the drum-reel. It is noted that as used herein, the term “exemplary” means “serving as an example, instance, or illustration.” Any aspect, detail, function, implementation, and/or embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects and/or embodiments. Example Embodiments FIG.1is an example of a typical system100which may be used for deploying or retracting one or more cables and/or hoses110into a pipe or cavity120, manually by user130by hand140. The one or more of the cables and/or hoses110may be a cable110attached to a camera assembly150, and one or more of the cables and/or hoses110may be a flex-shaft110for providing power to a cutting tool160, which may be used to clear an obstruction170in the pipe or cavity120. Optionally, one or more of the cables and/or hoses110may be a hose110which provides pressurized water or other fluid through a nozzle or jetter (not shown). The cutting tool160and/or pressurized water or other fluid forced through the nozzle or jetter (not shown) may be used to clear an obstruction170in the pipe or cavity120. Optionally, one or more cables and/or hoses may be deployed from and stored on drum-reels180. FIG.2illustrates details of an exemplary embodiment of an inspection and obstruction cleaning system200including a cable handling device210being held by a user130and being used to deploy or retract two cables110into a pipe or cavity120allowing the pipe or cavity120to be inspected and cleaned as necessary. One or more of the cables and/or hoses110may be a push-cable including a camera assembly150and one or more of the cables and/or hoses110may be a flex-shaft for providing power to a cutting tool160, which may be used to clear an obstruction170in the pipe or cavity120. The camera assembly150may include a flexible guide spring attached to an imaging device which may include additional sensors, electronics, and/or memory. Optionally, one or more of the cables and/or hoses110may be a hose which provides pressurized water or other fluid through a nozzle or jetter (not shown). The cutting tool160and/or pressurized water or other fluid forced through the nozzle or jetter (not shown) may be used to clear an obstruction170in the cavity or pipe120. Optionally, one or more cables and/or hoses may be deployed from and stored on drum-reels180. FIG.3Aillustrates details of an exemplary embodiment300of a cable handling device210which has a housing310and a channel320through openings at opposite ends of the housing310. The openings allow one or more cables or hoses110to be inserted through the channel320from one end to the other so that the one or more cables or hoses110may be coupled to the cable handling device210. A coupling control330may be provided to activate an internal coupling mechanism (not shown) inside the cable handling device210. FIG.3Billustrates details of an exemplary embodiment300of a cable handling device210which includes a door340which may include at least one hinge350and a latching mechanism360. Door340may be opened allowing one or more cables or hoses110to be inserted into channel320and then secured by closing door340and then securing the door340with latching mechanism360. The one or more cables or hoses110may be coupled to the cable handling device210by using a coupling control330to activate an internal coupling mechanism (not shown) inside the cable handling device210. The door340may be made of a material that is non-transparent or transparent, or may include one or more windows, thus allowing a user to see the sections of the one or more cables and/or hoses110inside the cable handling device210when the door340is closed. FIG.4Aillustrates details of an exemplary embodiment400of a cable handling device210with handles410and a coupling control in the form of a single trigger420. The trigger420allows a user to actuate movements of at least one cable and/or hose in a forward or backward direction by using the trigger420. Trigger420may be used as coupling control330to activate an internal coupling mechanism (not shown) inside the cable handling device210to engage one or more cables and/or hoses placed in the cable handling device210, thus facilitating deployment or retraction of at least one cable or hose into or out of a pipe or cavity by applying a manual or automatic force in the desired direction, i.e. deployment or retraction. When trigger420is released, it allows cable handling device210to move independently of the one or more cables and/or hoses. Trigger420may also include integrated speed and/or direction control to control the speed and/or direction of deployment or retraction of the one or more cables and/or hoses. Optionally, speed and/or direction control may be separate controls not associated with the trigger420. Additionally, one or more triggers420may include a locking mechanism to allow one or more triggers420to be locked in an on or off position or any position in between. FIG.4Billustrates details of an exemplary embodiment400of a cable handling device210, with coupling controls in the form of a two triggers420(piggy backed) one in front of the other as shown, or in another configuration, e.g. side by side, etc. FIGS.5A,5B and5Care some examples of clutch mechanisms that are well known in the art.FIGS.5A,5B and5Crepresent a mechanical clutch, a magnetically controlled clutch and a disk type clutch, respectively. It would be understood by those of ordinary skill in the art that some embodiments could use a single clutch or multiple clutches to clamp one or more cables or hoses, and that the clutching mechanism could be various other well known clutching or clamping mechanisms and could be in many different configurations. Clutches are well known in the art, and may include, by limited example only, friction type clutches with single or multiple plates, centrifugal clutches or flywheel type clutches. Clutch forces may be applied to one or more plates causing the plates to apply pressure against another surface or plate and used to secure one or more cables and/or hoses. The clutch force applied could be electromagnetic, pneumatic, manual pressure, or any other clutch type forces known in the prior art. The clutch could be completely released to allow the one or more cables and/or hoses to move freely, or could have a reduced force applied, thereby allowing the one or more cables and/or clutches to move by slipping a desired amount. The embodiments herein could be implemented with a single clutch or multiple clutches. The single or multiple clutches could be used to control (couple) a single cable and/or hose or multiple cables and/or hoses. The single or multiple clutches could be controlled by a single coupling control and/or multiple coupling controllers. FIG.6illustrates details of an exemplary embodiment600of a cable handling device with door340open to show a view of a wheels610which are controlled by an internal coupling mechanism (not shown) via a coupling control trigger420. When trigger420is activated it causes the wheels610to engage with at least one cable and/or hose110and locks the wheels610so they can not rotate thereby allowing a user to apply force to the handles410of the cable handling device600so that the at least one cable and/or hose can be deployed or retracted into or out of a pipe or cavity. When the trigger420is released it allows the one or more cables and/or hoses to move freely by disengaging the internal coupling mechanism (not shown) thereby allowing the wheels to rotate freely and the allowing the cable handling device210to move independently of the at least one cable and/or hose. FIG.7illustrates details of an exemplary embodiment700of a cable handling device210that includes a motorized feeder. Cable handling device700may include a motor710for rotating one or more wheels610to provide automatic feeding of one or more cables and/hoses for deployment or retraction into or out of a pipe or cavity. The motor710may be powered by a battery720which may be rechargeable and/or detachable, or another power supply. The trigger420is used to turn the motor710and thus the wheels610on or off. Trigger420may also provide speed control and/or directional control to the motorized wheels for deployment or retraction into or out of a pipe or cavity. FIGS.8A,8B,8C,8D,8E and8Fillustrate details of exemplary embodiments800of cable/hose clips and pipe guides, as known in the prior art.FIG.8Ashows a screw type clamp810with a hand screw820which when tightened closes clamps830which secure cables/hoses110.FIG.8Bshows a U-bolt type clamp840with a two ended threaded U-bolt850. When nuts860are tightened against the top side of bar870, it causes the bottom side of the bar870to tighten against one or more cables/hoses110, thereby securing them. In some exemplary embodiments, the cable clamps may be powered by one or more batteries (not shown). FIGS.8C and8Dillustrate details of exemplary embodiments of cable/hose guides880and885which have similar but different shapes and features as known in the prior art. A first cable/hose110is threaded and secured through a center channel890of the guides880and885, and additional cables/hoses are guided along one or more channels895. FIGS.9A,9B and9Cillustrate details of an exemplary embodiment900of a pipe guide910integrated with a cable/hose stop920. In this example, cable110is a push-cable which is used to push or pull a camera head930into or out of a pipe or cavity during deployment or retraction of the camera head930. As the camera head930is being pushed into a pipe or cavity via the push cable110, another cable110which in this example is a flex-shaft being used to supply rotational power to a chain knocker940is also pushed into the pipe or cavity. Push cable110which is attached to the camera via a spring. The spring fits snuggly into cable guide910which is attached to cable stop920. As cable guide910is moved forward the stationary cable stop920pushes again the proximal end of the chain knocker causing the flex-shaft110and the chain knocker940to be moved the same distance and at the same speed as the push cable, thereby allowing the push cable to deploy the chain knocker940. In this type of deployment no power should be supplied to the chain knocker940. As the push-cable is being pushed, the guide-stop prevents the chain knocker940from moving backwards towards the camera930. A typical chain knocker940may include a pair of set screws which when tightened allow the chain end-caps to be secured against the flex-shaft110, thereby allowing the chain knocker940to remain in place. FIG.9Bshows the chain knocker940ready to cut/clear a pipe or cavity blockage. The chain knocker940is in a open position caused by power being supplied to the flex-shaft110. At this time the flex-shaft110and the chain knocker940can be moved freely forward ahead of the camera930, thereby, preventing damage to the camera930while power is being supplied to the chain knocker940in order to facilitate cutting of a blockage (e.g. tree roots, debris, etc.). FIG.9Cshows a different view of a pipe guide910integrated with a cable/hose stop920using a slightly different shaped pipe guide910. In some exemplary embodiments, cable/hose stop920may be removable attached to pipe guide910via a clamp or other mechanism. The pipe guide may be designed to fit snuggly around a specific diameter cable/hose110, or shim tubes with collars may be inserted between the cable/hose100and the pipe guide to achieve the desired fit. FIGS.9D and9Eillustrate details of exemplary embodiments800of pipe guides896and897which may include one or more closed guides950dispersed among the guide channels895and used as a guide-stop to prevent a chain knocker940(not shown) from moving backwards towards the camera930(not shown). FIG.10illustrates details of an exemplary embodiment1000of a cable/hose cleaner. A clamp1010with and adjustable tightening screw1020can be tightened causing cleaning elements (e.g. sponges, cloth, etc.)1030to come in contact with one or more cables/hoses110which will be wiped off as they are drawn through the cleaning elements1030. FIG.11illustrates details of an exemplary embodiment1100of a cable handling device210being held by a user130and being used to deploy or retract two cables110into a pipe or cavity120allowing the pipe or cavity120to be inspected and cleaned as necessary. One or more of the cables and/or hoses110may be a camera assembly150and one or more of the cables and/or hoses110may be a hose for providing pressurized water or other fluid through a nozzle or jetter1100. The pressurized water or other fluid forced through the nozzle or jetter1100may be used to clear an obstruction170in the cavity or pipe110. Optionally, one or more cables and/or hoses may be deployed from and stored on drum-reels180. In one exemplary embodiment, video images and/or data may be shown on a display1120with an integrated radio transceiver (not shown) that may receive image data wirelessly from a transceiver1130integrated with the camera assembly150and/or a transceiver1140integrated with an optional drum-reel180. This provides a user130with visual information from the camera assembly150that can be used to steer the camera assembly150and/or the nozzle or jetter1110to aid in locating an obstruction170and removing it with pressurized water or fluid from the nozzle or jetter1110. In some embodiments, the obstruction170may be removed using a cutting tool powered by an electrical cable110or a flex-shaft110. FIGS.12A and12Bare illustrations of embodiments1200of a cable handling device210being used to deploy a cable or hose into a pipe or cavity (not shown) manually. InFIG.12Aa user130grabs the handles410with their hands140, exerts pressure on the trigger (not shown) which activates an internal coupling mechanism (not shown) inside the cable handling device210. The user130then uses the handles410to push the one or more cables and/or hoses110into a pipe or cavity (not shown). Since the coupling mechanism is engaged via the trigger, as the user130exerts force on the handles in a forward direction away from their body as shown by the arrow, the one or more cables and/or hoses move in the same direction. As shown inFIG.4B, once the user130has pushed the one or more cable/and/or hose forward, they can then release the trigger which releases the coupling mechanism from the one or more cables and/or hoses, thereby allowing the cable handling device210to be pulled back towards the user130without affecting the position of the one or more cables and/or hoses110. A user can then repeat the process to deploy the desired amount of the one or more cables and/or hoses into the pipe or cavity. The one or more cables and/or/hoses110may be retracted from the pipe or cavity by exerting pressure on the trigger and pulling the one or more cables and/or hoses out of the pipe or cavity. The trigger can be released to allow the cable handling device210to be pushed forward independent of the one or more cables and/or hoses and then the trigger can again be activated to repeat the process until the desired amount of the one or more cables and/or hoses has been retracted from the pipe or cavity. FIG.13Aillustrates details of an exemplary embodiment1300using a remote controlled clamp1310and1320to provide clamping of a camera cable110attached at the distal end to a camera assembly150and/or to a flex-shaft110connected to a chain knocker940. Clamp1310which includes an optical sensor is attached securely to the camera cable110in a position behind the camera assembly150. The camera includes LED's which can be modulated to transmit a signal which can be received by the sensor in clamp1310. Clamp1310is communicably coupled to clamp1320. The modulated signal from the LEDs can be received by the sensor in clamp1310and used to control the opening and closing of clamp1320. FIG.13Billustrates details of an exemplary embodiment which includes a steering stick1330to help steer the camera assembly1310into a desired position. InFIG.13Bclamp1310is located proximal to the camera assembly150. Clamp1320is a smaller diameter than the base side of the chain knocker940so that the chain knocker940stops when it comes in contact with clamp1320. Clamp1310which includes a sensor is attached securely to the camera cable110in a position behind the camera assembly150. The camera includes LED's which can be modulated to transmit a signal which can be received by the sensor in clamp1310. Clamp1310is communicably coupled to clamp1320. The modulated signal from the LEDs can be received by the sensor in clamp1310and used to control the opening and closing of clamp1320. FIG.13Cillustrates details of an exemplary embodiment which include an additional transmitter1340for transmitting control signals to open or close clamp1320via the sensor included with clamp1310. In this exemplary embodiment, transmitter1340may be configured to send a wireless radio signal. FIG.14Aillustrates details of an exemplary embodiment1400of a cable handling device210with a dual-rocker seven-position push switch1410. Two cables and/or hoses110left and110right can be controlled with dual-rocker seven-position push switch1410which includes a left side rocker switch and a right side rocker switch configuration via a first motorized cable or hose feed element and/or a second motorized cable or hose feed element, wherein the switch is configured to control a forward feeding direction or a backward feeding direction of the one or more cables or hoses110via the first motorized cable or hose feed element and/or the second motorized cable or hose feed element which may be implemented using several motorized wheels610,FIG.14B. The motors710for powering the wheels610may be internal or external to the cable handling device210. FIG.14Bis a cross-section illustration of an exemplary embodiment1400of a cable handling210device with a single-rocker seven-position switch1420. Door340is open to better show motorized wheels610which can be used to deploy and retract cables and/or hoses110in either together or individually in a forward or backward direction using a single-rocker seven-position push switch1420. FIG.15Ais an illustration of an embodiment of a dual-rocker seven-position push switch1410which includes a side by side left and right rocker switch configuration. The left rocker switch and the right rocker switch rock around an axis1550and have a neutral position, a forward position, and a backward position for feeding at least one of a first cable and a second cable in a forward direction (for deploying a cable or hose) or a backward direction (for retracting a cable and/or hose). When both the left rocker switch and the right rocker switch are in a neutral position (not moved to either side of the axis1550) the motorized wheels610,FIG.14Bwill remain inactive. When both the left rocker and right rocker switch are in the forward position, that is, when switch corners1510and1530, respectively, are pushed down simultaneously, both the left cable or hose110,FIG.14Band the right cable or hose110will be simultaneously fed forward (deployed), and when the left rocker switch and the right rocker switch are in the backward position1520and1540, respectively, both the left cable or hose110and the right cable or hose110will be fed in the backward direction (retracted). If either the left rocker or right locker switch are moved independently of each other, they will control a single cable or hose depending on the switch or direction chosen. For example, moving the left rocker switch in the forward direction1510will deploy the left cable (move it in a forward direction), and moving the left rocker switch backward1520will retract the left cable (move it in a backward direction). Moving the right rocker switch forward1530will deploy the right cable (move it in a forward direction), and moving the right rocker switch backward1540will retract the right cable (move it in a backward direction). FIG.15Bis an illustration of an embodiment1500of a single-rocker seven-position push switch1420that can be used for controlling two motorized cable or hose feed elements (not shown) in order to deploy or retract one or more cables or hoses (not shown). Applying pressure by touch specific points1510,1520,1530and1540on rocker switch1420will cause either of a left cable or a right cable610,FIG.14B, or both, to move in a forward (deployment) or backward (retraction) direction. The single-rocker seven-position push switch1410is configured to tilt forward or backward around an axis1560, or sideways around an axis1570, or a combination thereof. For instance, when switch1410is moved in a forward-left position by pushing on1510, the left cable or hose610,FIG.14Bwill move in a forward (deployment) direction. Other switch positions for controlling the feeding direction of the left cable610or right cable610,FIG.14Bare a backward-left position1520for feeding the left cable or hose in a backward direction, a forward-right position1530for feeding the right cable or hose in the forward direction, a forward position1510and1530for feeding both the left cable or hose and the right cable or hose in a forward direction simultaneously; and a backward position1520and1540for feeding both the left cable or hose and the right cable or hose in a backward direction simultaneously. FIG.16is an illustration of a typical method for transporting drum-reels storing cables or hoses to a pipe or cavity inspection location, as known in the prior art. FIGS.17A and17Bare front and side views, respectively, of an illustration of a dual camera drum system in a side-by-side docked configuration1700.FIG.17Ashows a first drum-reel1710configured for storing and deploying a flex-shaft cable1720. A handle1730is provided for carrying the first drum-reel1710to a desired location. Also shown is a second drum-reel1740configured for storing and deploying a camera cable with an attached camera1750. A handle1760is provided for carrying the second drum-reel1740to a desired location. A docking mechanism not shown is used to removably couple the second drum-reel1740to the first drum-reel1710via a hub1770connected to the first drum-reel1700, thereby, allowing a user to carry both drum-reels to a desired location using only the handle1730of the first drum-reel1710. FIGS.17C and17Dare illustrations of embodiments of docking mechanisms configured with one or more straps1715for use in a dual camera drum system in a side-by-side docked configuration. InFIG.17C, two straps1715are attached on opposite ends of the larger flex-shaft drum-reel1710and are configured to hold the smaller camera-cable drum reel1740in place by using strap connectors1725. In some example embodiments, the strap connectors1725may allow the straps1715to be threaded through the strap connectors1725and tightened, however, in other sample embodiments the strap connectors1725may snap, clip, or hook and loop in place. The straps1715may be cloth and made of a non-flexible material or may be flexible allowing them to stretch to secure the camera-cable drum-reel1740in place. In other embodiments, a single strap1715may be used, as shown inFIG.17D. The single strap1715may be configured as a flexible cord that can stretch, for example a bungee type cord. In this configuration the single strap/cord may be attached to the bottom of the larger flex-shaft drum-reel1710and a prong type clasp1735be provided at the top of the flex-shaft drum-reel1710to allow a clasp or ball1745to hold the camera-drum reel1740in place by being inserted on or into the prong type clasp1735and held in place by tension. FIG.17Eis an illustration of an embodiment of a docking mechanism that is configured with a pedestal1755for placing the camera drum-reel1740on and a hook1765for going through the camera-drum reel handle1760and securing the camera drum-reel1740in place. In some embodiments, wheels1775may be provided on the bottom of flex-shaft drum-reel1710, as well as an extra handle1785for allowing flex-shaft drum-reel1710to be leaned back onto wheels1775(similar to a dolly), and then both drum-reels may be moved to a desired location. In some embodiments, handle1785may be configured to be permanent or may be configured to be detachable. In other embodiments, handle1785may be configured to fold up and down telescopically, or in some other configuration. FIGS.17F and17Gare illustrations of embodiments of docking mechanisms configured with a clamp type latch1795and a wire type latch1796, respectively. Clamp latch1795can be opened and closed by applying pressure in the downward or upward direction to engage and disengage the clamp latch1795or the wire latch1796.FIGS.17F and17Gare example embodiments. It would have been obvious to one skilled in the art that many other latch styles and configurations could be provided, each with its own specific advantages and disadvantages. FIG.17His an illustration of an embodiment of a docking mechanism that is configured with rotating and interlocking male1797and female coupling parts1798. Male coupling part1797has one or more tabs1793that connect with one or more slots1794in female coupling part1798. In some embodiments, the one or both of the coupling parts1797and1798may include pins, surfaces, tabs, or the like, for providing electrical connections between the coupling parts1797and1798. It would have been obvious to one skilled in the art that many other interlocking coupling part styles and configurations could be provided, each with its own specific advantages and disadvantages. FIG.18Ais an inside view illustration of an embodiment1800of a flex-shaft drum-reel system, as known in the prior art. A drum-reel case1810is configured for storing and deploying a flex-shaft cable1820. Typically, the flex-shaft cable1820is wound and stored inside the drum case1810in a single layer on the outer most layer1830, therefore, there is a large amount of empty space1840available within the flex-shaft drum-reel case. A drive shaft1850is provided for supplying rotational power to the flex-shaft cable1820via an external device (not shown). As an example, power to the drive shaft1850can be provided by a motor, for instance a hand-held motorized drill (FIG.23A). The drive shaft1850is typically centered in the middle of the drum-reel case1820and transfers power to the flex-shaft cable1820via one or more gears1860. FIGS.18B and18Care illustrations of embodiments of a dual camera drum system, wherein a flex-shaft drum-reel case1810is configured to allow a camera drum-reel1740to be docked in the center of the flex-shaft drum-reel case1810, as shown inFIG.18C. In this embodiment, the drum-reel case is configured with a partially open middle section, cavity1840, thereby, allowing the camera drum-reel1740to be docked inside cavity1840of the drum-reel case1810as shown inFIG.18C. The flex-shaft drum-reel case1810and the camera drum-reel1740may each have a handle1890and1730, respectively. The handles may be of a single construction, or hinged to allow the handle to fold down, and they may be detachable. The shape of cavity1840will be of a similar shape of the outside of the camera-drum-reel, including any external parts such as the handle1730, thereby allowing the camera drum-reel1740to fit snuggly inside the flex-shaft drum-reel case1810, as shown inFIG.18C. The flex-shaft drum-reel-case may be configured with one or more stabilizing feet1890which allow the drum-reel case to be positioned upright. In some configurations, the camera drum-reel case1740may also include one or more stabilizing feet (not shown). If the camera drum-reel1740is configured with stabilizing feet or other external components, the shape of the cavity1840of the drum-reel case1810would be of a similar shape to the outside shape of the drum-reel case1810including any stabilizing feet or and/or any other external components. In some embodiments, the front of the camera drum-reel1740may be positioned flush, protruding, or recessed relative to the front of the flex-shaft drum-reel case1810when in a docked position. FIG.19Ais an inside view illustration of an embodiment1900of a single drum-reel case1810configured with a flex-shaft cable1820on the outside section of the drum-reel case1810. The drum-reel case1810is shown with the front door1910open, showing an integrated camera drum-reel1740inside the flex-shaft drum-reel case1810. Although the door may include a hinge1920, in this embodiment the camera drum-reel is configured to remain inside of the flex-shaft drum-reel case1810, but may be removed for replacement or maintenance by opening the door1910. The door1910may be configured with various shapes, dimensions and materials. For instance, in some embodiments the inside of the door1910may shaped to be straight or it may be shaped for a portion of the docked camera drum-reel1740to fit into the door1910. In some embodiments, the door1910may be solid and in other embodiments it may be translucent or be configured with a window. One or more handles1880may be provided for carrying both the flex-shaft drum-reel case1810and the camera drum-reel1740at the same time. It would be understood by one reasonably skilled in the art that the handle1740can have many configurations. Although FIGS.19A and19B show that the handle splits into two halves when the door is open, the handle1740could be of a different configuration, as an example the handle1740could be a single piece that does not become two pieces when the door is open. FIG.19Bis an inside view illustration of an embodiment1900of a single drum-reel case1810configured with a flex-shaft drum-reel1810on the outside which includes an opening case which allows a camera drum-reel1740to be docked and stored in the center of the flex-shaft drum-reel case1810. When door1910is open, access to the cavity1840,FIG.18C, is provided. A coupling mechanism (not shown) is provided to allow the camera drum-reel1740to be detachably coupled to the inside of the drum-reel case1810. The shape of the cavity1840will be of a similar shape of the outside of the camera-drum-reel, including any external parts such as the handle1730, thereby allowing the camera drum-reel1740to fit snuggly inside the flex-shaft drum-reel case1810, as shown inFIG.19B. A hinge1920may be provided to connect the door1910to the drum-reel case1810. One or more latching mechanisms1930may be provided to allow door1910to be opened or closed and secured. Flex-shaft cable1820is stored and deployed in a single layer on the top inner portion of flex-shaft drum-reel case1810. FIG.19Cis a cross-section illustration of an embodiment ofFIG.19Bof a camera cable1750attached to a camera assembly stored on a drum-reel1740which is configured inside a flex-shaft drum-reel case1810. Both drum-reels, camera drum-reel1740and flex-shaft drum-reel1810, are enclosed in single flex-shaft drum-reel case1810, thereby allowing both drum-reels to be carried and relocated using a single handle1880. Although the cables and drums are configured to remain inside drum-reel case1810, a latch1930may be provided to allow maintenance access to both drum-reels. As shown, the flex-shaft cable1820is stored (wound) in a single layer on the outer most circumference on the inside of drum-reel case1810. The camera cable1750is stored (wound) in multiple layers around the inner camera drum-reel1740. Both the flex-shaft drum-reel1810and the camera drum-reel1740rotate around a central axis1940when being deployed or retracted. The two drum-reels are configured to work independently of each other. Cable1820is stored and deployed from an outer drum-reel that can rotated around a central axis1940while not affecting the rotation of a second inner drum-reel which itself can rotate around a central axis1940independent of any rotation of the first outer drum-reel, thereby permitting cable camera1750and flex-shaft cable1820to be deployed together or independently from each other. FIGS.20A and20Bare illustrations of embodiments2000of a dual camera drum system integrated with at least one battery2010. InFIG.20A, camera drum-reel1740is configured to be integral with flex-shaft drum-reel1710. One or more batteries2010could be used to power a motor2320(FIG.23), that may be used to power a flex-shaft cable1720. In another embodiment, one or more batteries2010may be used to supply power to a camera attached to a camera cable1750. In some embodiments, at least two batteries2010could be provided to provide redundancy to ensure the camera1750can continue to record if one of the batteries fails. Battery2010may be fixed or detachable, and may be rechargeable. In some embodiments, one or more batteries2010could be configured with various electrical characteristics for powering tools, e.g. an cordless drill, a hand cutting tool, etc. FIG.20Bis an illustration of an embodiment2000of a flex-shaft drum-reel1710configured with a dockable camera drum-reel1750. As shown, camera drum-reel1750is detached from flex-shaft drum-reel1710. Camera1750may be powered by one or more batteries2010via a cable2020. FIGS.21A and21Bare illustrations of embodiments of a dual camera drum system2100integrated with at least one reel counter2110. Reel counter2110, shown in bothFIGS.21A and21B, may be fixed or detachably coupled to camera drum-reel1740. Reel counter2110may be configured to measure the amount of camera cable1750deployed or retracted from camera drum-reel1740.FIG.21Bshows a first reel counter2110, as well as a second reel counter2120. Reel counter2120may be fixed or detachably coupled configured to measure the amount of flex-shaft cable1720deployed or retracted from the flex-shaft drum-reel1810. The location of the reel counters shown inFIGS.21A and21Bis an example only. It would be understood by one or ordinary skill in the art that the location of reel counters2110and2120could be different than shown in the embodiments without changing the intended functionality of the reel counters. FIGS.22A and22Bare illustrations of a dual camera drum system2200configured with a cable handling device210. InFIG.22A, a flex-shaft cable drum-reel1710is shown with a camera drum-reel1740docked inside. Flex-shaft cable1720and camera cable1750are shown coupled within cable handling device210which is docked to cable drum-reel case1710via couplers2210. The type, quantity, and location of docking/coupling components given is an example only and could be changed based on various design considerations. At least one trigger420is provided to allow cable handling device210to deploy or retract at least one of the flex-shaft cable1720and/or the camera cable1750either together or independently. InFIG.22B, a flex-shaft cable drum-reel1710is shown with a camera drum-reel1740docked inside. Flex-shaft cable1720and camera cable1750are shown coupled within cable handling device210which is removably fixed to cable drum-reel case1710via couplers2210. FIG.22Bis an illustration of an embodiment of a dual camera drum system2200configured with a built-in cable handling device. At least one trigger420is provided to allow cable handling device210to deploy or retract at least one of the flex-shaft cable1720and/or the camera cable1750either together or independently. FIG.23Ais an illustration of an embodiment of a dual camera system2300configured using a typical hand-drill2310to provide rotational power to drive shaft1850(not shown), to which it is attached. Rotational power from hand-drill2210supplied drive shaft1850will provide power to flex-shaft cable1720for rotating an attached tool, typically a cutting type of tool, via one or more gears (not shown). FIG.23Bis an illustration of an embodiment of a dual camera system2300showing possible drive shaft1850locations/configurations. WhileFIG.23Bshows possible locations/configurations of drive shaft1850for supplying rotational power to flex-shaft cable1720via one or more gears (not shown), one skilled in the art would appreciate that many other locations/configurations could be used based on design considerations, and could be determined via a minimal amount of experimentation. FIG.23Cis an illustration of an embodiment of a dual camera system2300integrated with a built in motor2320. In one embodiment, motor2320may be provided for supplying rotational power to flex shaft cable1720via one or more gears (not shown). Power for motor2300may be provided externally internally. In some embodiments, power may be provided by one or more batteries (seeFIGS.20A and20B). FIG.24Ais an inside view illustration of an embodiment2400of a flex-shaft drum-reel1810for storing and deploying a flex-shaft cable1820, wherein the flex-shaft drum-reel1810is configured to allow automatic retraction or deployment of the flex-shaft cable1820via a motor (not shown). In one embodiment, a motorized drill (as shown inFIG.23A), may be used to supply rotational power to the flex-shaft cable1820and any tool attached to the distal end of the flex-shaft-cable, e.g. a cutting tool such as a chain knocker, a blade, or any other type of cutting tool requiring rotational power. The motorized drill (as shown inFIG.23A) supplies the rotational power by applying the rotating portion of the drill to the drive shaft1850of the flex-shaft cable1820which in turn supplies rotational power to the flex-shaft cable via gears1860. The same motorized drill (FIG.23A) can be used to feed (deploy) the cable or retract the cable back on to the flex-shaft drum-reel1810by placing the rotation portion of the motorized drillFIG.23Aon a second drive shaft2410. When rotational power is supplied to drive shaft2410, drive shaft2410will rotate a first gear2430which is meshed with a second gear2430which in turn will rotate the flex-shaft drum-reel1810in one of two directions thus causing the flex-shaft cable1820to be retracted onto the flex-shaft drum-reel1810or deployed off of the flex-shaft drum-reel1810. The direction of rotation of the motorized drill (FIG.23A) will determine the direction of rotation of the flex-shaft drum-reel, and in turn, whether the flex-shaft cable is wound around the flex-shaft drum-reel1810(retracted and stored), or wound off of the flex-shaft drum-reel1810(deployed). FIG.24Binside view illustration of an embodiment2400of a flex-shaft drum-reel1810for storing and deploying a flex-shaft cable1820. In this view, the door1910is shown closed but configured as to allow access to drive shafts1850and2430, respectively. In this exemplary embodiment, the location of drive shafts1850and2430is an example only. It would be understood by those of ordinary skill in the art that the drive shafts could be located in other areas on the flex-shaft drum-reel case1810and there may be any number of gear configurations (numbers, placement, etc.), that differ from those shown as1860,2420and2430. The scope of the invention is not intended to be limited to the aspects shown herein but are to be accorded the full scope consistent with the disclosures herein and their equivalents, wherein reference to an element in the singular is not intended to mean “one and only one” unless specifically so stated, but rather “one or more.” Unless specifically stated otherwise, the term “some” refers to one or more. A phrase referring to “at least one of” a list of items refers to any combination of those items, including single members. As an example, “at least one of: a, b, or c” is intended to cover: a; b; c; a and b; a and c; b and c; and a, b and c. The previous description of the disclosed aspects is provided to enable any person skilled in the art to make or use embodiments of the present invention. Various modifications to these aspects will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other aspects without departing from the spirit or scope of the disclosure. Thus, the disclosure is not intended to be limited to the aspects shown herein but is to be accorded the widest scope consistent with the disclosures herein and in the appended drawings. | 83,332 |
11859756 | DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION FIG.1illustrates a cross section through a leak detection element10according to an embodiment of the invention. The leak detection element10is substantially spherical and includes a core12which includes an electromagnetic signal transmitter, in this example a radio frequency transmitter, and associated power supply. The core12may be watertight to prevent water from damaging the electromagnetic signal transmitter, and may comprise a waterproof pouch. Alternatively, the electromagnetic transmitter itself is provided with a waterproof coating, such as a rubber coating. The core is preferably surrounded by an outer layer of foam14. The leak detection element10is preferably buoyant in water. In the embodiment illustrated inFIG.2, the leak detection element10′ further includes attachment means in the form of a socket16shaped to enable releasable attachment to the nozzle18of a hose20. The leak detection elements10,10′ are used to locate leaks in underground pipelines or water mains.FIGS.3ato5billustrate different means for introducing the leak detection element10,10′ into a water main via a fire hydrant, without needing to shut off the water supply. FIGS.3a,3band3cillustrate a hydrant22connected to a water main pipeline24. Water is flowing through the pipeline24in the direction of the arrows. To locate the site of a leak in the pipeline24upstream of the hydrant22, a leak detection element10′ is inserted into the pipeline24through the outlet26of the hydrant22. At first, as shown inFIG.3a, the hydrant valve29remains closed, preventing flow of water from the pipeline24into the outlet26of the hydrant22. As shown inFIG.3b, the outlet26of the hydrant22is then sealed using a hydrant sealing cap28, the cap28having an aperture30therethrough to allow a hose20to freely pass through the sealing cap28. One end of the hose20is connected to a source of pressurised fluid32. The other end of the hose20is provided with a nozzle (not shown) which in turn is connected to a complementary socket16on the leak detection element10′. Once the sealing cap28is in position, the hydrant valve29is opened using an appropriate tool. Turning the hydrant spindle34raises the hydrant valve29, allowing water from the pipeline24to enter the outlet26of the hydrant22. As shown inFIG.3c, after the valve29has been opened the hose is pushed further into the hydrant, past the valve29urging the leak detection element10′ towards the pipeline24. The leak detection element10′ preferably has an outer layer of foam14(seeFIG.2) which allows it to be squashed, aiding entry to the pipeline24. Once the leak detection element10′ is in, or close to, the pipeline24, pressurised fluid from the cylinder32is released into the hose20, causing the leak detection element10′ to separate from the hose20and be released into the pipeline24. At this stage the leak detection element10′ is carried along the pipeline by the water in the pipeline. Mains water is generally at a pressure in the range 2-4 bar. The pressurised fluid must be released at a higher pressure in order to push the leak detection element into the pipeline. In this example the pressurised fluid is at a pressure of approximately 8 bar. The fluid may be water, chlorinated water, or air. FIGS.4aand4billustrate alternative means of introducing the leak detection element10into the pipeline24via a hydrant22. In this example the leak detection element10is not connectable to the hose20. Instead, the leak detection element10is pushed into the outlet26of the hydrant22as shown inFIG.4aand then the hydrant sealing cap26is secured onto the hydrant, with the hose20passing through an opening30therethrough. Once the sealing cap28is in position, the hydrant valve29is opened using an appropriate tool. Turning the hydrant spindle34raises the hydrant valve29, allowing water from the pipeline24to enter the outlet26of the hydrant22. After the hydrant valve29has been opened, pressurised fluid from the cylinder32is released into the hose20, as shown by arrow A inFIG.4b, and this surge of pressurised fluid urges the leak detection element in a downwards direction towards the pipeline. The leak detection element10is then carried along the pipeline by the water flowing in the pipeline. Again, mains water is generally at a pressure in the range 2-4 bar. The pressurised fluid must be released at a higher pressure in order to push the leak detection element into the pipeline. In this example the pressurised fluid is at a pressure of approximately 8 bar. The fluid may be water, chlorinated water, or air. FIGS.5aand5billustrate further alternative means of introducing the leak detection element10into the pipeline24via a hydrant22. In this example a flexible rod21, preferably with an enlarged end portion23is inserted through the opening30in the sealing cap28. The enlarged end portion23is preferably shaped to fit at least partially around the leak detection element. As illustrated inFIG.5b, the rod21is used to manually urge the leak detection element10towards the pipeline24where it is then carried along the pipeline by the water flowing in the direction of the arrows. FIG.6illustrates a water pipeline24installation connected to a hydrant22and the leak detection element10′ locating the site of a leak36located upstream of the hydrant22. In order to detect the location of the leak, the leak detection element10′ is inserted into the pipeline24as described in relation toFIGS.3ato3c. The diameter of the leak detection element10′ is sufficiently small for it to move easily along the interior of the pipeline24, but sufficiently large to prevent it escaping through the wall of the pipeline at the site of the leak36. In a preferred example the leak detection element10,10′ is approximately 70 mm in diameter. Water flows through the pipeline24in the direction of the arrows, towards the leak site36, carrying the leak detection element10′ until the leak detection element10′ reaches the leak36, where it is retained by the water pressure in the pipeline as shown inFIG.4. The leak detection element10′ continually transmits a signal42through the ground40. The transmitted signal42is monitored at ground level by a signal receiver38carried by a user44walking above ground in the vicinity of the buried pipeline24. The signal receiver38preferably provides the user44with an audible and/or visual indicator relating to the intensity of the received signal. A maximum level of signal received by the signal receiver38will indicate that the user44is directly above the site of the leak36. After the location of the leak36has been determined, further action can be taken to repair the leak. FIG.7illustrates a cross-sectional view through the sealing cap28attached to the outlet of a fire hydrant. The sealing cap28is provided with an internal thread48which allows it to be connected to the hydrant outlet26. The sealing cap28has an opening30to allow passage of a hose20or rod21therethrough. The opening30is preferably set an angle to the top of the cap28as this helps guide the hose20or rod21towards the pipeline when the hydrant valve29is open. The angle X is preferably around 30 degrees. The inside of the cap28is also provided with waterproof seals46, for example rubber membranes, around both the internal upper edge of the cap and around the outlet30, this prevents water from the pipeline from escaping through the sealing cap28when the hydrant valve29is opened. The signal receiver38may also be provided with a GPS tracking device which records the movements of the signal receiver as the user follows the transmitted signal from the leak detection element10,10′. This allows the approximate path of the pipeline to the leak to be mapped from above-ground. | 7,794 |
11859757 | DETAILED DESCRIPTION This disclosure generally relates to conduit-based fluid flow systems. Such systems generally include a plurality of separate elements, e.g., conduit sections, valves, diverters, and/or the like are joined together to form a continuous conduit through which fluid, e.g., compressed fluid, flows. In some instances, for ease of explanation, “conduit” or “conduit section” may be used herein to describe an individual element making up the overall system. Furthermore, the term “union” is used to describe a connection or coupling of two (or more) elements (or conduits or conduit sections). Various of the elements can include features that facilitate the union. For instance, and without limitation, separate conduit sections can include flanges, threaded portions, male or female features, seal seats, or the like. Furthermore, for ease of explanation, the fluid conduit will be referred to herein as “conduit”. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. FIG.1depicts a cross-sectional view of an example fluid conduit union100(referred to herein as “the union100”). In some examples, the union100may represent a hammer union. However, the union100is for illustration only and could alternatively or additionally include any type of union that joins two or more sections of conduit together. Without limitation, the union100may be representative of a section of conduit being joined to a valve, two valves being joined together, or any other type of fluid conduit junction. As shown inFIG.1, the union100includes a first conduit section102and a second conduit section104. In some examples, the first conduit section102may be a section of pipe, an inlet or outlet of a valve, or other type of fluid conduit. The first conduit section102and the second conduit section104may be tubular members, such that the first conduit section102and the second conduit104section may together form a fluid passageway extending through the union100. The union100, and components thereof, may be comprised of various types of steel and/or other metal materials. The first conduit section102includes an end106that is configured as a female end such that at least a portion of an end112of the second conduit section104is inserted therein. In some examples, the first conduit section102may include a first end (e.g., end106) configured as a female end and a second end (not shown) configured as a male end. The end106of the first conduit section102includes a beveled surface108. In some examples, the beveled surface108of the end106of the first conduit section102is configured to abut a beveled surface110of the end112of the second conduit section104when the first conduit section102and the second conduit section104are joined to form the union100. While describing various “surfaces” herein, it is to be understood that the various “surfaces” described herein are annular in nature. As shown inFIG.1, at least a portion of the end106of the first conduit section102may surround at least a portion of the end112of the second conduit section104. For example, the end106of the first conduit section102may be configured to at least partially overlap (e.g., axially) the end112of the second conduit section104. The first conduit section102further includes an exterior surface114. The exterior surface114of the first conduit section102includes a threaded portion116located proximate the end106of the first conduit section102. The union100may also include a nut118having threading120that corresponds with the threaded portion of the first conduit section102. For example, the threading of the nut118includes an interior diameter that corresponds with an exterior diameter of the threaded portion116of the first conduit section102. These and other features of the nut118will be described further herein. The first conduit section102also includes an interior surface122defined in part by a first conduit bore124. The first conduit bore124extends along a length of the first conduit section102and provides a fluid passageway through which fluid may flow. As shown inFIG.1, the first conduit section102may also include a first surface126circumscribing an opening127of the first conduit bore124. In some examples, the first surface126is substantially flat and is configured to accommodate a seal between the first surface126and the second conduit section104, as is shown and described further herein. The first conduit section102may also include a cylindrical surface125that, together with the first surface126, forms a seal seat on which a seal may rest or be inserted therein. Furthermore, the first conduit section102includes another beveled surface128(or “interior beveled surface128”) on an interior portion of the first conduit section102. For example, the interior beveled surface128extends from the interior surface122of the first conduit section102towards the exterior surface114of the first conduit section102. In other words, the interior beveled surface128extends between the first surface126and the interior surface122, with a diameter being smaller proximate the interior surface122and greater proximate the first surface126. As such, the interior beveled surface128includes a non-perpendicular angle with respect to the interior surface122. Accordingly, the first conduit bore124has a relatively larger interior diameter proximate the end106and tapers, via the interior beveled surface128to a smaller diameter at the interior surface122. In some examples, the first conduit section102may omit the interior beveled surface128or include multiple bevels (or steps) at the location of the interior beveled surface128. Still further, while the interior surface122is shown as defining a substantially constant diameter, the interior surface122may also be tapered. Similarly, the second conduit section104includes the end112that is configured as a male end such that at least a portion of the second conduit section104is inserted into the first conduit section102. In some examples, the end112of the second conduit section104may be a first end configured as a male end and an opposite, e.g., second end (not shown), may be configured as a female end. As mentioned previously, the second conduit section104includes the beveled surface110located on the end112of the second conduit section104. The beveled surface110extends between a face (140) of the end112of the second conduit section104and an exterior surface130of a flange132. As such, the beveled surface110is configured to abut the beveled surface108proximate the end106of the first conduit section102. As mentioned previously, the second conduit section104also includes a flange132located on the exterior surface130of the second conduit section104and proximate the end112of the second conduit section. The flange132of the second conduit section104is configured to correspond with and abut a surface134of the nut118. Thus, when the threading120on the nut118engages with the threaded portion116of the first conduit section102and the surface134of the nut118abuts the flange132of the second conduit portion104, when the nut118is rotated in a first direction, the nut118draws the first conduit section102and the second conduit section104towards each other, such that the beveled surface108of the first conduit section102seats against the beveled surface110of the second conduit section104. Conversely, when the nut118is rotated in a second direction (opposite the first direction), the nut118allows the first conduit section102and the second conduit section104to be separated. The second conduit section104includes an interior surface136partially defining a second conduit bore138. The second conduit bore138extends along a length of the second conduit section104and provides a fluid passageway through which fluid may flow. As shown inFIG.1, the second conduit section104may also include a second surface140circumscribing an opening142of the second conduit bore138. In some examples, the second surface140is shaped and configured to abut a seal disposed between the first surface126and the second surface140, thereby forming a seal when the nut118is tightened on the union100. The second conduit section104also includes another beveled surface144(or “interior beveled surface”) on an interior portion of the second conduit section104. The interior beveled surface144extends from the interior surface136from the interior surface136of the second conduit section104towards the exterior surface130of the second conduit section104. In other words, the interior beveled surface144extends between the second surface140and the interior surface136. As such, the interior beveled surface144includes a non-perpendicular angle with respect to the interior surface136. Accordingly, the second conduit bore138has a relatively larger interior diameter proximate the end112and tapers, via the interior beveled surface144to a smaller diameter at the interior surface136. In some examples, the second conduit section104may omit the interior beveled surface144or include multiple bevels (or steps) at the location of the interior beveled surface144. Still further, while the interior surface136is shown as defining a substantially constant diameter, the interior surface136may also be tapered. In some examples, the interior beveled surface144is non-perpendicular to a direction of extension of the interior surface136. As shown inFIG.1, the interior beveled surface128of the first conduit section102and the interior beveled surface144of the second conduit section104are arranged to form a recess145having a relatively larger diameter than the diameters of interior surface122and interior surface136. The recess145may reduce turbulent flow that may be created by the seal if the seal were proud to the interior surfaces122and136of the first conduit section102and the second conduit section104. Furthermore, recessing the seal from the interior surfaces122,136may create flow disturbance (such as a dead zone) around the seal and may reduce the amount of abrasion that the seal experiences. However, if the interior beveled surfaces128and144create a recess145that is overly deep, the conduit (102and104) may experience greater abrasive forces. As also illustrated inFIG.1, a coating146is applied to the interior beveled surface128of the first conduit section102and/or the interior beveled surface144of the second conduit section104. In some examples, the coating146is also applied to the first surface126of the first conduit section102and/or the second surface140of the second conduit section104in addition to, or instead of, the interior beveled surface128of the first conduit section102and the interior beveled surface144of the second conduit section104. The coating146may include a hardness that is greater than the hardness of the material used for the conduit sections102,104and may, therefore, resist abrasive forces and/or resist corrosion which may result in a longer usable life, when compared to a non-coated conduit. In some examples, other surfaces of the conduit sections102,104, for example and without limitation, interior surface122and interior surface136may be substantially free of the coating. As used herein, a surface that is “substantially free” of coating may be a surface to which a coating is not directly or intentionally directly applied, but may still be subjected to some hardening. For example, in a spray-coating hardening process, some overspray may occur on surfaces adjacent to or otherwise proximate surfaces intended to be hardened. However, in some examples, interior surface122and interior surface136may be coated in addition to, or instead of, the surfaces described previously. In some examples, the coating146includes a metallic alloy formed from a powdered metal alloy. The powdered metal alloy may include at least one of tungsten carbide, cobalt, or chromium and may include any combination (percentage) of such materials. In some examples, the coating146is a thermal spray coating that is applied using a high velocity air fuel (HVAF) thermal spray process. However, in some examples, the coating146may be applied as a thermal spray via other processes including a high velocity oxygen fuel (HVOF) thermal spray process. Furthermore, the coating146may instead be applied via a plating, diffusion, or physical vapor deposition (PVD) process, among other processes. Other techniques, including but not limited to plasma twin wire arc, may also be used to apply the coating146to the identified surfaces. The process may vary based on the type of material used as the first conduit section102and the second conduit section104and/or the type of material used for the coating146. Any technique that allows for a robust mechanical bond of the coating146to the desired surfaces may be used. By including coating146on the interior beveled surfaces128and144, the union100configuration may reduce wear on the seal by creating flow disturbance around the seal, while increasing the resistance of the interior beveled surfaces128and144to erosive forces caused by pumping a highly abrasive slurry through the union100. In examples, the coating146may include any suitable thickness. By way of example, and not limitation, the coating146may include a thickness between approximately 0.00001 inches and approximately 0.10 inches. In some examples, the coating146may have a thickness between approximately 0.0001 inches and approximately 0.01 inches. Additionally, and/or alternatively, the coating146may have a thickness between approximately 0.001 inches and approximately 0.009 inches. Furthermore, the coating146may be substantially uniform in thickness. Moreover, the coating146may have a suitable surface finish. For instance, the coating146on the interior beveled surfaces128and144may need a particularly smooth finish, e.g., to ensure that the coating146does not include cracks, rough patches, or other inconsistencies that may be particularly disposed to erosion. In examples, a thermal spray technique such as high velocity air fuel may result in a sufficient surface finish, e.g., without subsequent finishing, polishing, or the like. Furthermore, the coating146may be applied to additional or fewer surfaces of the union100than described herein. In some examples, the coating146is applied to the interior beveled surfaces128,144and/or the first surface126and the second surface140as such surfaces may experience the greatest abrasive forces. Furthermore, as the seal may be recessed from edges (204,302) of the interior surfaces122,136in order to extend a usable life of the seal as the interior beveled surfaces128,144and/or the first surface126and the second surface140may experience greater abrasive forces. FIG.2depicts a first perspective cross-sectional view of the union100shown and described with respect toFIG.1. The first perspective view better illustrates aspects of the first conduit section102. For instance, the view shows the first surface126of the first conduit section102circumscribing the opening127of the first conduit bore124. In some examples, the first surface126is shaped and configured to accommodate a seal between the first surface126and the second conduit section104. For example, when inserted into a space202between the first conduit section102and the second conduit section104, a surface of the seal abuts the first surface126and is held securely between the first conduit section102and the second conduit section104. Furthermore, in some examples, the first conduit section102may include an edge204between the interior beveled surface128and the first surface126. In some examples, the edge204includes a radius, chamfer, or other edge break rather than having a straight edge. By including an edge204with a radius, chamfer, or other edge break, the coating146may be applied to the first conduit section102with a more uniform thickness than when applied to a straight edge. FIG.3depicts a second perspective cross-sectional view of the union100shown and described with respect toFIG.1. The second perspective view better illustrates aspects of the second conduit section104. For instance, the view shows the second surface140circumscribing the opening142of the second conduit bore138. In some examples, the second surface140is shaped and configured to accommodate a seal between the first surface126and the second conduit section104. For example, when inserted between the space202between the first conduit section102and the second conduit section104, a surface of the seal abuts the second surface140and is held securely between the first conduit section102and the second conduit section104. Furthermore, in some examples, the first conduit section102may include an edge302between the interior beveled surface144and the second surface140. Similar to edge204, the edge302includes a radius, chamfer, or other edge break rather than having a straight edge. By including an edge302, the coating146may be applied to the second conduit section104with a more uniform thickness than when applied to a straight edge. FIG.4depicts the first perspective cross-sectional view of the union100ofFIG.2, with a seal402inserted into the space202shown and described with respect toFIGS.2-3. In some examples, the seal402includes at least one of the following materials: fluorocarbon, urethane, nitrile butadiene rubber, hydrogenated nitrile butadiene rubber, or other suitable material. As shown inFIG.4, the seal402is at least partially recessed from the edge204of the interior beveled surface128of the first conduit section102such that the first surface126is partially seen. However, in some examples, the seal402may be flush with the edge204of the interior beveled surface128such that the first surface126is not exposed to fluid flow. In either example, coating the first surface126with the coating146may serve to harden the first surface126thereby increasing the ability of the first surface126to resist abrasive forces to which the first surface126may be exposed via fluid flow. Furthermore, if the flow of fluid is directional, only portions of the downstream conduit section (i.e., either the first conduit section102or the second conduit section104) may include the coating146thereon. However, the coating146may be applied to portions of both conduit sections102,104in directional or bi-directional flow scenarios. FIG.5depicts a second perspective cross-sectional view of the union100ofFIG.2, with the seal402inserted into the space202. As shown inFIG.5, the seal402is at least partially recessed from the edge302of the interior beveled surface144of the second conduit section104such that the second surface140is partially seen. However, in some examples, the seal402may be flush with the edge302of the interior beveled surface144such that the second surface140is not exposed to fluid flow. In either example, coating the second surface140with the coating146may serve to harden the second surface140thereby increasing the ability of the second surface140to resist abrasive forces if/when the second surface140is exposed to fluid flow. Furthermore, if the flow of fluid is directional, only portions of the downstream conduit section (i.e., either the first conduit section102or the second conduit section104) may include the coating146thereon. However, the coating146may be applied to portions of both conduit sections102,104in directional or bi-directional flow scenarios. FIG.6depicts an example swing check valve600having a female union end602. The female union end602may include same or similar features as the first conduit section102described previously. For example, the female union end602includes threading604that is configured to correspond with threading associated with a nut that secures the female union end602to a secondary conduit. Furthermore, the female union end602may cooperate with a male union end of a conduit section, e.g., the second conduit section104discussed above, (or another valve) such that the male union end is at least partially inserted into the female union end602. Furthermore, the swing check valve600includes a valve bore606extending along a length of the swing check valve600, thereby forming a fluid passageway. The swing check valve600also includes an interior beveled surface608proximate an end of the female union end602. The interior beveled surface608extends from an interior surface defined by the valve bore towards an exterior surface of the female union end602. The swing check valve600also includes a surface610circumscribing an opening of the valve bore606. In some examples, the interior beveled surface608and/or the surface610may be coated with the coating146, whereas other surfaces may be substantially free of the coating146. Furthermore, the swing check valve600may include an edge612located between the interior beveled surface608and the surface610. The edge612may include a radius, chamfer, or other edge break and may also be coated with the coating146. In some examples, the female union end602may be joined to a male union end similar to the first conduit section102and the second conduit104that form the union100. Accordingly, a seal may be inserted between the female union end602and the male union end and a nut may secure the female union end602to the male union end. FIG.7depicts a male union end702of the swing check valve600. The male union end702may include same or similar features as the second conduit section104described previously. For example, the male union end702includes a flange704that is configured to correspond with a surface of the nut that secures the male union end702to a secondary conduit. Furthermore, the male union end702may cooperate with a female union end of a conduit section, e.g., the first conduit section102discussed above, (or another valve) such that the male union end702is at least partially inserted into the female union end. Furthermore, the swing check valve600includes a valve bore606extending along a length of the swing check valve600, thereby forming a fluid passageway. The swing check valve600also includes an interior beveled surface706proximate an end of the male union end702. The interior beveled surface706extends from an interior surface defined by the valve bore towards an exterior surface of the male union end702. The swing check valve600also includes a surface708circumscribing an opening of the valve bore606. In some examples, the interior beveled surface706and/or the surface708may be coated with the coating146, whereas other surfaces may be substantially free of the coating146. Furthermore, the swing check valve600may include an edge710located between the interior beveled surface706and the surface710. The edge710may include a radius, chamfer, or other edge break and may also be coated with the coating146. In some examples, the male union end702may be joined to a female union end similar to the first conduit section102and the second conduit104that form the union100. Accordingly, a seal may be inserted between the male union end702and the female union end and a nut may secure the male union end702to the female union end. FIG.8depicts an example plug valve800having a female union end802. The female union end802may include same or similar features as the first conduit section102described previously. For example, the female union end802includes threading804that is configured to correspond threading associated with a nut that secures the female union end802to a secondary conduit. Furthermore, the female union end802may correspond with a male union end of conduit (or another valve) such that the male union end is at least partially inserted into the female union end802. Furthermore, the plug valve800includes a valve bore806extending along a length of the plug valve800, thereby forming a fluid passageway. In some examples, the plug valve800may omit the interior beveled surface due to a greater diameter of the valve bore806. In some examples (particularly with conduit of larger relative diameter), the plug valve800may include a radius808between the valve bore806and a surface810that circumscribes an opening of the valve bore806. In some examples, the radius808and the surface810may be coated with the coating146. FIG.9depicts a male union end902of the example plug valve800. The male union end902may include same or similar features as the second conduit section104described previously. For example, the male union end902includes a flange904that is configured to correspond with a surface of the nut that secures the male union end902to a secondary conduit. Furthermore, the male union end902may correspond with a female union end of conduit (or another valve) such that the male union end902end is at least partially inserted into the female union end. Furthermore, the plug valve800includes a valve bore806extending along a length of the plug valve800, thereby forming a fluid passageway. As described previously, the plug valve800may omit the interior beveled surface due to a greater diameter of the valve bore806. In some examples, the plug valve800may include a radius906between the valve bore806and a surface908that circumscribes an opening of the valve bore806proximate an end of the male union end902. In some examples, the radius906and the surface908may be coated with the coating146, whereas other surfaces may be substantially free of the coating. FIG.10illustrates an example method1000of coating portions of the union100. As discussed further herein, the union100may be better suited to resist corrosion, erosion, and/or abrasion than conventional fluid conduit unions and may be cost effective to produce. The method1000shows some example steps for achieving such benefits. It is to be understood, that certain steps of the method1000described herein may be conducted contemporaneously or sequentially. The order in which the operations are described is not intended to be construed as a limitation, and any number of the described steps may be combined in any order and/or in parallel to implement the process. Specifically, at operation1002, the method1000includes providing a first conduit section. In examples described herein, the first conduit section may be the first conduit section102, the second conduit section104, and/or some other conduit and/or valve section. The first conduit section may also define a bore that includes a conduit bore section having an interior beveled surface proximate an end of the first conduit section and a surface circumscribing an opening of the bore. At1004, the method1000includes applying the coating to the desired surfaces. For example, the coating may be applied to the interior beveled surface and/or the surface circumscribing the opening of the bore. In the example ofFIGS.1and2, the operation1004may include applying the coating146to the first surface126, the edge204, and/or the interior beveled surface128. In some instances, the coating146may be a metal alloy powder applied using a thermal spray technique, such as HVAF, HVOF, or other thermal spray technique. Alternatively, the coating146may instead be applied to the above described surfaces via plating, diffusion, PVD, or other processes. In some examples, the coating146can include a metal alloy powder including tungsten carbide. Furthermore, in some examples, the coating146may include a ceramic coating. In some examples, the first conduit section and a second conduit section may be coated contemporaneously. At1006, the method1000includes providing a second conduit section. For example, the second conduit section may be a conduit section configured to be at least partially inserted into the first conduit section provided at operation1002. In the example ofFIGS.1and2, the first conduit section may be the first conduit section102and the second conduit section may be the second conduit section104. In that example, the second conduit section104includes the male union end. As will be appreciated, in other examples, the first conduit section provided at the operation1002may be the second conduit section104, and the second pipe section provided at the operation1006may be either the first conduit section102. Of course, these are for examples only. However, in the context ofFIG.10, the first conduit section and the second conduit section should include corresponding union ends, as described herein. At1008, the method1000includes applying the coating to the desired surfaces of the second conduit section. For example, the coating may be applied to the interior beveled surface and/or the surface circumscribing the opening of the bore. In the example ofFIGS.1and2, the operation1004may include applying the coating146to the second surface140, the edge302, and/or the interior beveled surface144. In some instances, the coating146may be a metal alloy powder applied using a thermal spray technique, such as HVAF, HVOF, or other thermal spray technique. Alternatively, the coating146may instead be applied to the above described surfaces via plating, diffusion, PVD, or other processes. In some examples, the coating146can include a metal alloy powder including tungsten carbide. Furthermore, in some examples, the coating146may include a ceramic coating. In some examples, the first conduit section and the second conduit section may be coated contemporaneously. At1010, the method1000includes assembling the first and second conduit sections. For example, and with reference toFIG.1, the first and second conduit sections102,104may be assembled by inserting the seal402into contact with the first surface126of the first conduit section102, and inserting at least a portion of the end112of the second conduit section104into the first conduit section102such that the beveled surface108of the first conduit section102abuts the beveled surface110of the second conduit section104, thereby forming a seal. The nut118may then be rotated to tighten the connection between the first conduit section102and the second conduit section104. The method1000allows for cost-effective and efficient manufacture of a fluid conduit union, as detailed herein. For instance, because selected surfaces are coated, the union100may be more resistant to corrosion, erosion, and/or abrasion. While the method may include an additional step, e.g., the coating step, compared to conventional fabrication, the coating can meaningfully increase life expectancy of the union100and/or the components thereof. INDUSTRIAL APPLICABILITY The present disclosure provides an improved fluid conduit union (“union”) and methods of making the union. The union may be used in a variety of applications. For example, the union may be used in gas, oil, and fracking applications. The union may be particularly useful in high pressure applications and/or with fluids containing abrasive particles. The disclosed union may be in use for extended periods of time before failing and/or requiring replacement, which can result in a decrease in down time for fluid systems and/or reduce maintenance time and expense. According to some embodiments, a union100may include a coating146on one or more surfaces that are at least partially exposed to fluid flow. By selectively applying the coating to one or more of these surfaces, the useful life of the union may be significantly increased. Moreover, by purposefully excluding the coating from other surfaces, deleterious effects can be avoided. While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof. | 31,951 |
11859758 | DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS To make the foregoing objectives, features, and advantages of the present invention clear and easy to understand, a detailed description is given below by listing preferred embodiments with reference to the accompanying drawings. In the description of the present disclosure, it should be understood that orientation or position relationships indicated by the terms such as “upper”, “lower”, “horizontal”, “vertical”, and “one side” are the orientation or position relationships shown in the accompanying drawings, and are used merely for ease and brevity of illustration and description, rather than indicating or implying that the indicated apparatus or element must have a particular orientation or must be constructed and operated in a particular orientation. Therefore, such terms should not be construed as a limitation to the present disclosure. In addition, the terms “first” and “second” are used merely for the purpose of description, and are not to be construed as indicating or implying relative importance or implying the number of technical features indicated. Therefore, a feature limited by “first” or “second” may explicitly or implicitly include one or more said features. In the description of the present disclosure, “a plurality of” means two or more than two, unless otherwise particularly specified. An embodiment of the present disclosure provides a display screen bracket. A flat television may be mounted to a wall using the display screen bracket. A watching angle of the flat television after the mounting can be adjusted, to satisfy diverse use requirements of clients. As shown inFIGS.1to3, a display screen bracket1includes a first support body11, a second support body12, and a first linkage mechanism13. The first support body11is configured to carry a flat television2. The second support body12is configured to fix the first support body11to a wall or other structures together with the flat television2. The first linkage mechanism13is configured to connect the first support body11and the second support body12into a whole. After the flat television2is mounted using the display screen bracket1, the flat television2is swingable about a first axis21of the flat television. In the present embodiment of the present disclosure, the first axis21is a vertical axis, that is, the flat television2is swingable leftward and rightward. Still referring toFIG.1toFIG.3, a plurality of screw holes are provided on the first support body11. A non-display side of the flat television is fixed to the first support body11using screws. A material and a shape of the first support body11are not particularly limited, and may be selected according to actual needs. The first support body11may be in an axisymmetric shape, for example. A central axis of the first support body11is parallel to the first axis21of the flat television2. The second support body12and the first support body11are disposed opposite to each other. A plurality of screw holes are provided on the second support body12. The second support body12is fixed to the wall or the other structures using screws. A material and a shape of the second support body12are not particularly limited, and may be selected according to actual needs. The first linkage mechanism13includes a first adjustment assembly131, a second adjustment assembly132, and a first link133. The first adjustment assembly131is disposed on the first support body11. The second adjustment assembly132is disposed on the second support body12. The first adjustment assembly131is connected to the second adjustment assembly132using the first link133. In detail, the first adjustment assembly131is disposed on a side of the first support body11that is close to the second support body12. The first adjustment assembly131includes a first guide rail1311and a first guiding member1312. The first guiding member1312is capable of moving along the first guide rail1311. The first guiding member1312may be a first motor, for example. The first guiding member1312is configured to move along the first guide rail1311by means of self-driving. The second adjustment assembly132is disposed on a side of the second support body12that is away from the first support body11. The second adjustment assembly132includes a second guide rail1321and a second guiding member1322. The second guiding member1322is capable of moving along the second guide rail1321. The second guiding member1322may be a second motor, for example. The second guiding member1322is configured to move along the second guide rail1321by means of self-driving. One end of the first link133is rotatably connected to the first guiding member1312, and an other end of the first link133is rotatably connected to the second guiding member1322. The rotatable connection may be implemented as follows, for example. An end portion of the first link133is connected to the first guiding member1312or the second guiding member1322using a rotary shaft. A hollowed-out structure121is provided on the second support body12. The other end of the first link133passes through the hollowed-out structure121to be rotatably connected to the second guiding member1322. When the first guiding member1312and the second guiding member1322are both moved toward a right side along the respective guide rails in a top view, the first support body11may be driven to rotate anticlockwise, thereby causing the flat television2to rotate anticlockwise. When the first guiding member1312and the second guiding member1322are both moved toward a left side along the respective guide rails, the first support body11may be driven to rotate clockwise, thereby driving the flat television2to rotate clockwise. That is to say, by simultaneously moving the first guiding member1312and the second guiding member1322to the right side and the left side in sequence, the flat television2is swung leftward and rightward about the first axis21, thereby adjusting leftward and rightward rotation angles of the flat television2. Further, the first linkage mechanism13further includes a second link134. One end of the second link134is rotatably connected to the second guiding member1322, and an other end of the second link134is rotatably connected to the first support body11. An included angle exists between the first link133and the second link134. The rotatable connection may be implemented as follows, for example. An end portion of the second link134is connected to the second guiding member1322or the first support body11using a rotary shaft. The second link134is disposed for the following purpose. On one hand, coordination and balance of the flat television2during the leftward and rightward swing are enhanced. On the other hand, action of the second link134to the second guiding member1322can offset at least part of action of the first link133to the second guiding member1322, preventing the second guiding member1322from being damaged as a result of concentration of a local stress on the second guiding member1322. Further, the end portion of the first link133that is rotatably connected to the first guiding member1312and the end portion of the second link134that is rotatably connected to the first support body11are respectively located on two sides of the first axis21. Preferably, a top face1331of the first link133and a top face1341of the second link134are located in a same plan. The plane is perpendicular to the side of the first support body11that is close to the second support body12. In this way, the coordination and the balance of the flat television during the leftward and rightward swing can be enhanced. Further, the first linkage mechanism13further includes a locking boss135. The locking boss135is disposed on the side of the first support body11that is close to the second support body12. Preferably, the locking boss135and the first guiding member1312are respectively located on the two sides of the first axis21. The other end of the second link134is rotatably connected to the locking boss135. For example, the other end of the second link134is connected to the locking boss135using a rotary shaft. In addition, the second guiding member1322is disposed between the locking boss135and the first guiding member1312. The first guiding member1312, the second guiding member1322, and the locking boss135may be connected to form a triangle. The first link133and the second link134may be considered as two sides of the triangle. Further, the display screen bracket1further includes a first hanger14and a second hanger15. The first hanger14is disposed on the first support body11, the second hanger15is disposed on the second support body12, and the first hanger14is rotatably connected to the second hanger15. The first hanger14and the second hanger15are configured to connect the first support body11to the second support body12. In this way, not only the connection between the first support body11and the second support body12is firmer, but also the first support body11is swung leftward and rightward more conveniently. In detail, in a top view, a first hanger14is disposed on each of a top and a bottom of the first support body11, and a second hanger15is disposed at each of positions on a top and a bottom of the second support body12that are corresponding to the positions of the first hangers14. The first hanger14and the second hanger15are in an overlapping arrangement. Shaft holes are provided on the first hanger14and the second hanger15at an overlapping position. A rotary shaft extends through the shaft holes to rotatably connect the first hanger14to the second hanger15. In another embodiment of the present disclosure, as shown inFIGS.4to7, the display screen bracket1further includes a second linkage mechanism16. After the flat television2is mounted using the display screen bracket1, the flat television2is swingable about both the first axis21of the flat television and a second axis22of the flat television. The first axis21is perpendicular to the second axis22. That is to say, the first axis21is a vertical axis, and the flat television2is swingable leftward and rightward about the first axis21, so that the leftward and rightward rotation angles of the flat television2are adjustable. The second axis22is a horizontal axis, and the flat television2is swingable upward and downward about the second axis22, so that a pitch angle of the flat television2is adjustable. In detail, still referring toFIGS.4to7, the display screen bracket1includes a first support body11, a second support body12, a first linkage mechanism13, and a second linkage mechanism16. The first support body11is configured to carry the flat television. The second support body12is fixed to a wall or other structures. The first linkage mechanism13is configured to adjust the leftward and rightward rotation angles of the flat television2. The second linkage mechanism16is configured to adjust the pitch angle of the flat television2. The first support body11includes a first sub-support body111and a second sub-support body112. The first sub-support body111and the second sub-support body112are disposed opposite to each other and are rotatably connected. The second sub-support body112is in an axisymmetric shape. A central axis of the second sub-support body112is parallel to the first axis21. In a top view, a first hanger14is disposed on each of a top and a bottom of the second sub-support body112, and a second hanger15is disposed at each of positions on a top and a bottom of the second support body12that are corresponding to the positions of the first hangers14. The first hanger14and the second hanger15are in an overlapping arrangement. Shaft holes are provided on the first hanger14and the second hanger15at an overlapping position. A rotary shaft extends through the shaft holes to rotatably connect the first hanger14to the second hanger15. A third hanger17is disposed on each of two sides of the first sub-support body111, and a fourth hanger18is disposed at each of positions on two sides of the second sub-support body112that are corresponding to the positions of the third hangers17. The third hanger17and the fourth hanger18are in an overlapping arrangement. Shaft holes are provided on the third hanger17and the fourth hanger18at an overlapping position. A rotary shaft extends through the shaft holes to rotatably connect the third hanger17to the fourth hanger18. The first linkage mechanism13includes a first adjustment assembly131, a second adjustment assembly132, a first link133, a second link134, and a locking boss (not shown). The first adjustment assembly131is disposed on a side of the second sub-support body112that is away from the first sub-support body111. The second adjustment assembly132is disposed on a side of the second support body12that is away from the second sub-support body112. The first adjustment assembly131is connected to the second adjustment assembly132using the first link133. The second sub-support body112is connected to the second adjustment assembly132using the second link134. The locking boss is disposed on the side of the second sub-support body112that is away from the first sub-support body111. The locking boss and the first guiding member131are spaced apart from each other and are respectively disposed on the two sides of the first axis21. The first adjustment assembly131includes a first guide rail1311and a first guiding member1312. The first guiding member1312is capable of moving along the first guide rail1311. The first guiding member1312may be a first motor, for example. The first guiding member1312is configured to move along the first guide rail1311by means of self-driving. The second adjustment assembly132includes a second guide rail1321and a second guiding member1322. The second guiding member1322is capable of moving along the second guide rail1321. The second guiding member1322may be a second motor, for example. The second guiding member1322is configured to move along the second guide rail1321by means of self-driving. One end of the first link133is rotatably connected to the first guiding member1312using a rotary shaft. An other end of the first link133is rotatably connected to the second guiding member1322using a rotary shaft. A hollowed-out structure121is provided on the second support body12. The other end of the first link133passes through the hollowed-out structure121to be rotatably connected to the second guiding member1322. One end of the second link134is rotatably connected to the second guiding member1322using a rotary shaft. The other end of the second link134is rotatably connected to the locking boss135using a rotary shaft. The second guiding member1322is disposed between the locking boss and the first guiding member1312. The first guiding member1312, the second guiding member1322, and the locking boss may be connected to form a triangle. The first link133and the second link134may be considered as two sides of the triangle. A top face1331of the first link133and a top face (not marked) of the second link134are located in a same plan. The plane is perpendicular to the side of the second sub-support body112that is close to the second support body12. In this way, the coordination and the balance of the flat television2during the leftward and rightward swing can be enhanced. Still referring toFIGS.4to7, the second linkage mechanism16includes a third motor161and a third link162. The third motor161is disposed on the side of the second sub-support body112that is away from the first sub-support body111. The third motor161is located above the locking boss. The third motor161is drivably connected to one end of the third link162. An other end of the third link162is connected to the first sub-support body111. An end portion of the third link162that is connected to the first sub-support body111reciprocates in a vertical direction under driving of the third motor161to drive the first sub-support body111to swing upward and downward, so as to cause the flat television2to swing about the second axis22of the flat television. In detail, still referring toFIG.4andFIG.5, the second linkage mechanism16further includes an eccentric rotary disc163. The eccentric rotary disc163is disposed about a motor shaft of the third motor161. The eccentric rotary disc163is rotated clockwise or anticlockwise under driving of the third motor161. An eccentric shaft1631is disposed on the eccentric rotary disc163. The eccentric shaft1631is connected to one end of the third link162to drivably connect the third motor161to the end of the third link162. In the present embodiment of the present disclosure, by means of the third link162, a rotation of the eccentric rotary disc163is transformed to swing of the first sub-support body111in a vertical direction, thereby causing the flat television2to swing upward and downward about the second axis22. It should be noted that, the second linkage mechanism16may also have no eccentric rotary disc163. One end of the third link162may be directly connected to the motor shaft of the third motor161. In this case, a limiting groove, such as a Z-shaped limiting groove is required to be provided on the other end of the third link162, so as to cause the other end of the third link162to reciprocate upward and downward in a vertical direction. Still referring toFIGS.4to7, a first locking sheet1111, a second locking sheet1112, and a latch1113are disposed on a side of the first sub-support body111that is close to the second sub-support body112. The first locking sheet1111and the second locking sheet1112are disposed opposite to each other. One end of the latch1113extends through the first locking sheet1111, and an other end of the latch1113extends through the second locking sheet1112. That is to say, the latch1113is mounted and fixed using the first locking sheet1111and the second locking sheet1112. The end portion of the third link162that is connected to the first sub-support body111is disposed about the latch1113, to connect the other end of the third link162to the first sub-support body111. It should be noted that, the first link, the second link, and the third link provided in the above embodiments of the present disclosure may be crank links, for example. The first motor, the second motor, and the third motor may be rotary motors, for example. The second support body may be fixed to a wall or other structures. For example, the second support body may be fixed to a bracket including a telescopic mechanism. A linear distance between the first support body and the second support body is adjusted using a telescopic function of the telescopic mechanism, to adjust a linear distance between the flat television and a watcher. In the foregoing embodiments, the descriptions of the embodiments have respective focuses. For a part that is not described in detail in an embodiment, reference can be made to the detailed description of other embodiments provided above, and the details will not be described herein again. A display screen bracket provided in the embodiments of the present disclosure is described above in detail. Although the principles and implementations of the present invention are described by using specific examples in this specification, the descriptions of the foregoing embodiments are merely used for helping understand the method and the core idea of the present invention. Meanwhile, a person skilled in the art may make modifications to the specific implementations and application range according to the idea of the present invention. In conclusion, the content of this specification is not to be construed as a limitation to the present invention. | 19,708 |
11859759 | Similar reference numerals may have been used in different figures to denote similar components. DESCRIPTION OF EXAMPLE EMBODIMENTS Various examples and aspects of the present application will be described with reference to the details discussed herein. The following description and drawings are illustrative of the present application and are not to be construed as limiting the present application. Numerous details are described to provide a thorough understanding of various embodiments. However, in certain instances, well-known or conventional details are not described in order to provide a concise discussion of the embodiments of the present application. In one aspect, the present application describes a support stand for supporting a magnetic resonance imaging (MRI) scanner while in operation, the MRI scanner including a cylindrical housing having a lateral surface extending parallel to a horizontal bore from a first bore end to a second bore end to encapsulate a main cylindrical magnet, the cylindrical housing defining a longitudinal footprint dimension and a lateral footprint dimension. The support stand includes: a base for positioning the support stand on a floor; a plurality of pillars extending upright from the base, each respective pillar having a first end mounted to the base and an opposing second end; and a vibration isolator mounted at the second end of respective pillars to support the lateral surface of the cylindrical housing, wherein a respective pillar in a pair of pillars is laterally separated from another pillar of that pair on an opposing lateral side of the horizontal bore by a lateral separation distance no greater than the lateral footprint dimension, and wherein a respective pillar in the plurality of pillars is longitudinally separated from another pillar in the plurality of pillars by a longitudinal separation distance no greater than the longitudinal footprint dimension. In another aspect, the present application describes a magnetic resonance imaging (MRI) system including: a MRI scanner having a main cylindrical magnet with a horizontal bore extending parallel to a floor and extending from a first bore end to a second bore end; and a cylindrical housing encapsulating the main cylindrical magnet, the cylindrical housing having a lateral surface extending parallel to the horizontal bore from the first bore end to the second bore end, wherein the cylindrical housing defines a longitudinal footprint dimension and a lateral footprint dimension; and a support stand for supporting the MRI scanner while in operation, the support stand including: a base for positioning the support stand on the floor; a plurality of pillars extending upright from the base, each respective pillar having a first end mounted to the base and an opposing second end; and a vibration isolator mounted at the second end of respective pillars to support the lateral surface of the cylindrical housing, wherein a respective pillar in a pair of pillars is laterally separated from another pillar of that pair on an opposing lateral side of the horizontal bore by a lateral separation distance no greater than the lateral footprint dimension, and wherein a respective pillar in the plurality of pillars is longitudinally separated from another pillar in the plurality of pillars by a longitudinal separation distance no greater than the lateral footprint dimension. Other aspects and features of the present application will be understood by those of ordinary skill in the art from a review of the following description of examples in conjunction with the accompanying figures. In the present application, the terms “comprises” and “comprising” are intended to be inclusive and open ended, and not exclusive. Specifically, when used in the specification and claims, the terms “comprises” and “comprising” and variations thereof mean the specified features, steps, or components are included. These terms are not to be interpreted to exclude the presence of other features, steps, or components. In the present application, the term “exemplary” means “serving as an example, instance, or illustration”, and should not be construed as preferred or advantageous over other configurations disclosed herein. In the present application, the terms “about”, “approximately”, and “substantially” are meant to cover variations that may exist in the upper and lower limits of the ranges of values, such as variations in properties, parameters, and dimensions. In a non-limiting example, the terms “about”, “approximately”, and “substantially” may mean plus or minus 10 percent or less. In the present application, the term “and/or” is intended to cover all possible combinations and sub-combinations of the listed elements, including any one of the listed elements alone, any sub-combination, or all of the elements, and without necessarily excluding additional elements. In the present application, the phrase “at least one of . . . or . . . ” is intended to cover any one or more of the listed elements, including any one of the listed elements alone, any sub-combination, or all of the elements, without necessarily excluding any additional elements, and without necessarily requiring all of the elements. Existing MRI scanners are bulky and heavy and require specialized packaging for transportation, such as framed containers and other shock absorbing materials. The specialized packaging is often discarded after shipment. To install MRI scanners at medical facilities, medical facilities often require modification, such as enlarging entranceway height or width and providing additional structure and padding for supporting the weight of MRI scanners. During operation, MRI scanners generate an appreciable amount of vibration and audible acoustic noise (e.g., knocking sounds) due to rapid and frequent changes in magnetic field orientation. The generated vibrations are transmitted to the environment in which the MRI scanner is installed. Further, environmentally generated vibrations detected at the MRI scanner can impact image capture performance of the MRI scanner. For example, environmentally generated vibrations from nearby closing doors or elevator movement can generate vibrations that can be propagated to the MRI scanner, thereby reducing image resolution or increasing the chance of imaging error. It would be desirable to provide an improved support stand for use during both transport and MRI scanner operation. Further, it would be desirable for the improved support stand to isolate MRI scanners from environmentally generated vibrations and to isolate the environment from the MRI scanner generated vibrations. Such an improved support stand is now provided. Reference is made toFIG.1, which illustrates a perspective, partial cutaway view of a MRI system100, in accordance with an example of the present application. The MRI system100includes a support stand110for supporting a MRI scanner160. FIG.1illustrates a partial cutaway view of selected components of the MRI scanner160. The MRI scanner160includes a main magnet162, a gradient coil164, and a radio frequency (RF) coil (not explicitly identified inFIG.1). The MRI scanner160illustrated inFIG.1may be known as a closed-bore MRI scanner. The MRI scanner160includes a housing172for encapsulating at least the main magnet162, the gradient coil164, and the RF coil. The housing172is generally cylindrical in shape and includes a lateral surface180extending parallel to a patient bore174. The patient bore174is a horizontally-oriented bore. The lateral surface180and the patient bore174may extend from a first bore end176to a second bore end178. During operation, the patient or a portion of the patient under observation may be placed within the patient bore174. While in operation, the main magnet162generates a static magnetic field within the patient bore174, thereby causing protons of organs under observation to align with the direction of the static magnetic field. The gradient coil164generates a magnetic field with a switching frequency that produces a magnetic field with a linear gradient. The linear gradient isolates target protons to achieve resonance to produce a target image. The RF coil generates magnetic pulses for momentarily exciting protons in the static magnetic field, thereby causing momentary rotation of the respective protons away from the direction of the static magnetic field and back to the direction of the static magnetic field. In some examples, the MRI scanner160includes a cryostat170. The cryostat170may include components for maintaining the MRI scanner160within a desired operating temperature range. As described, the housing172encapsulates at least the main magnet162, the gradient coil164, and the RF coil. The housing172is generally cylindrical in shape and may correspond at least to the shape of the main magnet162. InFIG.1, the housing172defines a longitudinal footprint dimension190and a lateral footprint dimension192. As will be illustrated and described in the description herein, when seen from a top view, the housing172may have a generally rectangular footprint defined by the longitudinal footprint dimension190and the lateral footprint dimension192. The longitudinal footprint dimension190is substantially a length of the housing172that extends from the first bore end176to the second bore end178. The lateral footprint dimension192is substantially a diameter of the housing172. The MRI scanner160illustrated inFIG.1is commonly known as a closed-bore MRI scanner; however, other types of MRI scanners, such as open-bore MRI scanners, can be contemplated. The MRI system100also includes the support stand110for supporting the MRI scanner160. The support stand110includes a base112for positioning the MRI system100on a floor within a medical facility. That is, when the MRI scanner160is mounted atop the support stand110, the MRI scanner160can be maneuvered to its desired location within a medical facility using a wheeled mechanism for lifting and moving the base112. The support stand110includes a plurality of pillars, identified individually as120a,120b, and120cinFIG.1. Each of the plurality of pillars extends upright from the base112. Further, each of the plurality of pillars includes a first end mounted to the base112and an opposing second end. As an illustrative example, the third pillar120cincludes a first end122cmounted to the base112and a second end124c. The support stand110also includes a vibration isolator mounted at the second end of respective pillars to support the lateral surface180of the cylindrical housing172. The respective vibration isolators are identified individually as128a,128b, and128cinFIG.1. For example, the third pillar120cincludes the first end122cmounted to the base112and the third vibration isolator128cmounted at the second end124cto support the lateral surface180of the housing172. In some examples, the respective vibration isolators can directly interface with the lateral surface180of the cylindrical housing172. In some other examples, the respective vibration isolators128can interface with standoffs182protruding or extending from the lateral surface180of the housing172. For example, inFIG.1, the standoffs182are illustrated as protruding from the lateral surface180of the housing172in a direction towards the base112. There may be one or more standoffs182extending from the lateral surface180of the housing172, where each respective standoff182is mounted to a respective vibration isolator. It can be appreciated that, in some examples, the standoffs182may not be needed. Reference is now made toFIG.2, which illustrates a perspective view of the support stand110ofFIG.1. The support stand110includes the base112for positioning the support stand110on a floor of a medical facility. The medical facility can be a hospital environment, a private medical clinic, or any other facility requiring a MRI scanner. The base112can be generally rectangular and/or planar in shape; however, any other shape, such as oval, circular, etc. can be contemplated. In some examples, the base112can be welded or cast from non-magnetic and/or non-ferrous and/or non-magnetic material, such as aluminum, and is a combination of beams and planar support structures, as illustrated inFIG.2. In some examples, the base may be constructed of substantially non-ferrous material including at least one of aluminum, SAE 316 stainless steel, fiberglass, plastic, brass, or epoxy. In some examples, the plastic, brass, or epoxy used for constructing the base is reinforced. InFIG.2, the base112is generally rectangular in shape and can include a number of mounting surfaces for mounting each of the plurality of pillars. The plurality of pillars include a first pillar120a, a second pillar120b, a third pillar120c, and a fourth pillar120d. The plurality of pillars extend upright from the base112. In some examples, the plurality of pillars may be constructed of substantially non-ferrous and/or non-magnetic material, including at least one of aluminum, SAE 316 stainless steel or fiberglass. Each respective pillar has a first end and a second end. For example, the first pillar120aincludes a first end122aand a second end124a. Similarly, the second pillar120bincludes a first end122band a second end124b, the third pillar120cincludes a first end122cand a second end124c, and the fourth pillar120dincludes a first end122dand a second end124d. The support stand110illustrated inFIG.2includes four pillars mounted substantially proximal to a corner of the substantially rectangular base to collectively form an equiangular quadrilateral perimeter. However, any number of pillars can be contemplated. For instance, the support stand110can include six pillars where pillars may be mounted substantially proximal to respective lateral edges of the base112. In some other examples, the respective pillars may be mounted to the base at respective positions that may be inward from the respective lateral edges of the base112. During operation, MRI scanners generate appreciable amounts of vibrations that may be detected in the vicinity of the medical facility environment. MRI scanner generated vibrations can be unpleasant in the immediate surroundings and can be in the form of wall or floor vibrations akin to the effects of a minor earthquake. Further, MRI scanners can detect vibrations originating from the medical facility environment. Externally generated vibrations in the medical facility can originate from slamming doors or elevator movement, among other sources within the medical facility. Further, externally generated vibrations can originate from sources outside the medical facility, such as vehicles in a parking garage adjoining the medical facility, underground transit vehicles beneath the medical facility, etc. Externally generated vibrations detected at MRI scanners can impact the ability of the MRI scanner to accurately capture/generate images of a patient. It is desirable to provide an improved support stand to minimize the effect of: (a) MRI scanner generated vibrations on the immediate environment; and (b) externally generated vibrations on the operation of the MRI scanner. The support stand110is the primary mechanical medium between the MRI scanner160and the surrounding environment (e.g., room floor). Thus, it may be desirable to dampen vibrations at the interface between the support stand110and the MRI scanner. The support stand110includes a vibration isolator mounted at the second end of respective pillars to support the lateral surface of a housing of an MRI scanner. For example, the support stand110includes a first vibration isolator128amounted at the second end124aof the first pillar120a. Similarly, a second vibration isolator128bis mounted at the second end124bof the second pillar120b, a third vibration isolator128cis mounted at the second end124cof the third pillar120c, and a fourth vibration isolator128dis mounted at the second end124dof the fourth pillar120d. In some examples, the respective vibration isolators include elastomeric material for minimizing transmission of floor-borne vibration to the MRI scanner160and for minimizing transmission of MRI scanner160generated vibration to the floor and the immediate environment. In some examples, the respective vibration isolators are a hollow elastomeric capsule for encapsulating a gas substance, such as air. In some examples, the respective vibration isolators are air bladders that are adjustably inflatable with a pneumatic air supply source (not illustrated). For instance, the air bladders may include a valve coupled to a pneumatic air supply source via a hose or other conduit, and the pneumatic air supply source can include an air pressure sensor coupled to the respective air bladders and may be configured to detect the volume of air within the air bladders. In response to determining that the volume of air within the air bladders is less than a predetermined threshold, the pneumatic air supply can pump air to the air bladders. The vibration isolators can have a metallic exterior construction with a rubber air bladder contained therein. To optimize vibration dampening and/or stabilizing effect of the support stand110for supporting an MRI scanner, the support stand110can be designed in concert with the MRI scanner160(FIG.1). That is, the support stand110can be designed with the physical characteristics of the MRI scanner160in mind. To maximize the vibration dampening effect or the stabilizing effect of the support stand110on the MRI scanner160, it may be desirable to minimize the distance between a center of gravity of the MRI scanner160and the respective vibration isolators. The center of gravity of the MRI scanner160is a unique point where the weighted relative position of distributed mass sum to zero. That is, the center of gravity is a point representing a mean position of the MRI scanner160as a whole such that when a force is applied to the center of gravity, the MRI scanner160may move in the direction of the applied force without rotating. To minimize the distance between the center of gravity of the MRI scanner160and the respective vibration isolators, an isolation plane255is configured to intersect the center of gravity of the MRI scanner160. The isolation plane255is a reference plane that intersects the respective second ends of the pillars or respective vibration isolators of the support stand110. For example, the first vibration isolator128a, the second vibration isolator128b, the third vibration isolator128c, and the fourth vibration isolator128dmay be in the isolation plane255and the isolation plane255is positioned upwards from the base112. When each of the respective pillars (e.g., first pillar120a, second pillar120b, third pillar120c, and fourth pillar120d) are substantially the same length (e.g., distance from respective first ends to respective second ends), the isolation plane255is parallel to the base112. Thus, to minimize the distance between the center of gravity of the MRI scanner160and the respective vibration isolators, the pillar lengths may be sized such that the isolation plane255is as near to the center of gravity of the MRI scanner160as possible. In some examples, the pillar lengths may be sized such that the isolation plane255intersects the center of gravity of the MRI scanner160. In some examples, each of the first vibration isolator128a, the second vibration isolator128b, the third vibration isolator128c, or the fourth vibration isolator128dcan be individually sized or selected to include characteristics different than another of the vibration isolators. For example, the first vibration isolator128aand the second vibration isolator128bcan be larger in size or can attenuate a different resonant frequency as compared to the third vibration isolator128cand the fourth vibration isolator128d. That is, if the main magnet has a greater weight at a longitudinal end nearest to the first vibration isolator128aand the second vibration isolator128b, the first vibration isolator128aand the second vibration isolator128bcan be selected to be greater in size as compared to the third vibration isolator128cand the fourth vibration isolator128d. In some examples, the vibration isolators are hollow capsules, metallic cylinders, or closed vessels for encapsulating air and the inflation pressure within respective vibration isolators can be selected based on a target resonant or natural frequency. It can be appreciated that when natural frequencies of non-linear vibration isolators approach substantially the same value, dynamic coupling among the vibration isolators can increase. When each respective vibration isolator is configured with a different inflation pressure thereby targeting a different natural vibration frequency, the collection of vibration isolators can provide greater vibration dampening than if the plurality of vibration isolators were configured with substantially the same inflation pressure. When each respective vibration isolator is configured with a slightly different target inflation pressure thereby targeting a different natural vibration frequency, there may be reduced dynamic coupling among the vibration isolators for providing greater vibration dampening than if the plurality of vibration isolators were configured with substantially the same inflation pressure. It can be appreciated that a full body MRI scanner can include a main magnet having a larger diameter and corresponding center of gravity that may be higher from the medical facility floor than a smaller main magnet for a compact MRI scanner (e.g., MRI scanner for legs or arms). Thus, in some examples, the length of respective pillars on a large support stand for a full body MRI scanner may be greater than the length of respective pillars on a medium support stand for a compact MRI scanner having a center of gravity that may be nearer to the medical facility floor. As illustrated, the respective pillars are mounted to and extend upright from the base112to support an associated MRI scanner. Thus, the respective second ends and respective vibration isolators mounted thereon support the MRI scanner from a position upwards from the medical facility floor and can cradle the MRI scanner housing. Further, in some examples, the vibration isolators mounted at the respective second ends can be fixed to the lateral surface180of the housing172such that the support stand110supports the MRI scanner during both transportation and operation. The MRI scanner generated vibrations can be characterized by one or more resonant frequencies or harmonic vibration and thereby cause violent motion. In some examples, the support stand110can further include one or more tuned mass dampers coupled to at least one of the base112or one or more pillars for reducing harmonic vibration. During transportation, it can be desirable to reduce the overall height of the MRI scanner that is supported by the support stand110. In examples where the vibration isolators can be adjustably inflatable with a pneumatic air supply, the MRI scanner that is mounted to the respective pillars may be lowered in height relative to the base112during transport and may be raised in height relative to the base112during MRI scanner operation. In some scenarios, the support stand110additionally includes one or more pads290affixed to a bottom base surface214. For example, the one or more pads290may be rubber pads for attenuating vibrations greater than 60 Hz; however, any other types of pads may be used. InFIG.2, the one or more pads290are positioned at peripheral corners of the base112; however, the one or more pads290may be positioned across a plurality of positions on the bottom base surface214. InFIG.2, a respective pillar in a pair of pillars is laterally separated from another pillar of that pair on an opposing lateral side of the horizontally-oriented patient bore174(FIG.1) by a lateral separation distance no greater than the lateral footprint dimension192(FIG.1). The lateral footprint dimension192can be a diameter of the housing172(FIG.1) and, thus, the respective pillars of the support stand110are within the footprint of the MRI scanner160. For example, the first pillar120aand the second pillar120bmay form a pair of pillars. The first pillar120ais laterally separated from the second pillar120bon an opposing lateral side of the horizontally-oriented patient bore174. Similarly, the third pillar120cand the fourth pillar120dmay form another pair of pillars, and the third pillar120cis laterally separated from the fourth pillar120don an opposing lateral side of the horizontally-oriented patient bore174. Further, inFIG.2, a respective pillar in the plurality of pillars is longitudinally separated from another pillar in the plurality of pillars by a longitudinal separation distance no greater than the longitudinal footprint dimension190(FIG.1). The longitudinal footprint dimension190can be a length of the housing172(FIG.1) and, thus, the respective pillars of the support stand110are within the footprint of the MRI scanner160. For example, the support stand110can be configured such that the first pillar120ais longitudinally separated from the fourth pillar120dby a longitudinal separation distance that is no greater than the longitudinal footprint dimension190(FIG.1). Similarly, the first pillar120amay be longitudinally separated from the second pillar120bby a longitudinal separation distance that is no greater than the longitudinal footprint dimension190because the first pillar120aand the second pillar120bcan have a longitudinal separation distance of substantially zero. Thus, the support stand110includes respective pillars mounted to the base112at positions that are within a footprint of the MRI scanner160(FIG.1). To illustrate, reference is now made toFIG.3A, which illustrates a top view of a MRI scanner footprint330overlaid on the support stand110ofFIGS.1and2, in accordance with an example of the present example. The MRI scanner footprint330is substantially rectangular and is similar in size to the base112of the support stand110. However, in some other examples, the MRI scanner footprint330may be larger in size than the perimeter of the base112. As described, the MRI scanner footprint330is substantially rectangular and includes a longitudinal footprint dimension190and a lateral footprint dimension192.FIG.3Aalso illustrates the orientation of the patient bore174(FIG.1) in hatched lines. In an example, the position at which the respective pillars, such as the first pillar120a, the second pillar120b, the third pillar120c, and the fourth pillar120d, are mounted to the base112is illustrated inFIG.3A. The first pillar120aand the second pillar120bmay be identified as a pair of pillars and the first pillar120ais laterally separated from the second pillar120bon an opposing lateral side of the horizontally-oriented patient bore174by a lateral separation distance196that is no greater than the lateral footprint dimension192. Similarly, the third pillar120cis laterally separated from the fourth pillar120don an opposing lateral side of the horizontally-oriented patient bore174by a lateral separation distance that is no greater than the lateral footprint dimension192. InFIG.3A, the first pillar120ais longitudinally separated from the fourth pillar120dby a longitudinal separation distance198that is no greater than the longitudinal footprint dimension190. Thus, it can be appreciated that the support stand110, including the respective pillars and the base112, can have a support stand footprint area that is less than and within a MRI scanner footprint defined by the longitudinal footprint dimension190and the lateral footprint dimension192. In the described configuration, the support stand110does not increase required floor area of the overall MRI system100(FIG.1). It can be appreciated that although the MRI scanner footprint and the support stand footprint are illustrated to have a substantially rectangular perimeter, in some examples, the MRI scanner footprint can be any other shape and the support stand footprint can be any other shape that may be less than the total area of the MRI scanner footprint and within the MRI scanner footprint perimeter. As MRI scanners are conventionally bulky in size and mass, transporting MRI scanners from production warehouses to medical facilities can be challenging. Because MRI scanners are conventionally placed on padded and/or support reinforced floors (e.g., concrete slabs), specialized equipment, such as cranes or hoists are often used for lifting MRI scanners and placing the MRI scanners into position within medical facilities. Thus, it may be desirable to provide support stands that may be used for supporting MRI scanners both during transport and operation. Reference is now made toFIG.3B, which illustrates a side elevation view of the base112of the support stand illustrated inFIG.3A. Because the support stand can be fixed to the MRI scanner or the housing172of the MRI scanner, it may be desirable to adapt the support stand110to be lifted and maneuvered using a wheeled apparatus. The base112illustrated inFIG.3Bmay be adapted to include features of a shipping pallet or skid. For example, the base112may include one or more base channels318in a bottom base surface214of the base112. That is, the base channels318can be configured to receive a fork of a pallet jack operable to raise the support stand110(FIG.1) and the MRI scanner160(FIG.1) and move the MRI system100(FIG.1) from one location to another location. In some examples, the pallet jack may be a conventional 27″ wide pallet jack commonly found in warehouses and loading docks. Thus, when the MRI scanner160is supported by the support stand110, the MRI scanner160may be transported and positioned at a medical facility without the need for cranes or hoists for placing the MRI scanner160in position on a medical facility floor. Further, the respective vibration isolators (e.g., first vibration isolator128a, second vibration isolator128b, third vibration isolator128c, fourth vibration isolator128dinFIG.2) assist to provide support and shock attenuation during transportation of the MRI scanner, thereby decreasing the risk of damaging MRI scanner components. Reference is now made toFIG.4, which illustrates a perspective view of a MRI system400, in accordance with another example of the present application. The MRI system400includes a support stand410for supporting a MRI scanner460. The MRI scanner460includes a main cylindrical magnet having a horizontal bore474extending parallel to a floor and extending from a first bore end476to a second bore end478. The MRI scanner460also includes a cylindrical housing472for encapsulating the main cylindrical magnet, among other components. Similar to the system ofFIG.1, the cylindrical housing472has a lateral surface480extending parallel to the horizontal bore474from the first bore end476to the second bore end478. Best understood from a top view, the cylindrical housing472defines a longitudinal footprint dimension490and a lateral footprint dimension492. It can be appreciated that the MRI scanner460includes other components, such as computer screens, computer systems, a cryostat, or other components. The support stand410includes a base412for positioning the support stand410on the floor. In some examples, the base412may include one or more pads422affixed to a bottom base surface of the base412for attenuating vibrations originating from the environment floor or for attenuating vibrations originating from the MRI scanner460while in operation. The support stand410includes a plurality of pillars420extending upright from the base412. Each respective pillar420has a first end mounted to the base412and an opposing second end. The support stand410also includes a vibration isolator428mounted at the second end of respective pillars to support the lateral surface480of the cylindrical housing472. Similar to the support stand ofFIG.2, a respective pillar in a pair of pillars is laterally separated from another pillar of that pair on an opposing lateral side of the horizontal bore by a lateral separation distance no greater than the lateral footprint dimension492. Further, a respective pillar in the plurality of pillars420is longitudinally separated from another pillar in the plurality of pillars by a longitudinal separation distance no greater than the longitudinal footprint dimension490. In the example illustrated inFIG.4, the cylindrical housing472may not include any standoffs (e.g., standoffs182ofFIG.1) and the lateral surface480may be supported by the vibration isolators428that are mounted to the respective pillars420. In some examples, the second end of the respective pillars420includes a beveled surface to angle the respective vibration isolator428towards the lateral surface480to support the cylindrical housing. That is, the surface of the second end facing the lateral surface480may not be substantially parallel to the base, but is angled such that the surface of the second end is at an angle relative to the base. The example support stand410illustrated inFIG.4further includes a docking module configured to secure a patient table to the support stand410. For example, the docking module can include an attachment hook440proximal to the first bore end476of the cylindrical housing472for receiving a patient table. It can be appreciated that the attachment hook440can also be included proximal to the second bore end478of the cylindrical housing472. Reference is made toFIG.5, which illustrates a perspective view of a MRI system500, in accordance with another example of the present application. The MRI system500includes a support stand510for supporting a MRI scanner560. The MRI scanner560includes a main cylindrical magnet and includes a cylindrical housing572for encapsulating the main cylindrical magnet, among other components. Similar to the system ofFIG.4, the cylindrical housing572has a lateral surface580extending parallel to a horizontal bore574from a first bore end576to a second bore end578. Similar to the system ofFIG.4, the cylindrical housing572defines a longitudinal footprint dimension and a lateral footprint dimension. It can be appreciated that the MRI scanner560includes other components, such as computer screens, computer systems, a cryostat, or other components. The support stand510includes a base512for positioning the support stand510on the floor. InFIG.5, the support stand510includes a plurality of pillars520extending upright from the base512. Each respective pillar520has a first end mounted to the base512and an opposing second end. The support stand510also includes a vibration isolator528mounted at the second end of respective pillars to support the lateral surface580of the cylindrical housing572. The cylindrical housing572may not include any standoffs and the lateral surface580may be supported by the vibration isolators528that are mounted to the respective pillars520. In the example illustrated inFIG.5, the second end of the respective pillars520includes a beveled surface535to angle the respective vibration isolator528towards the lateral surface580to support the cylindrical housing572. InFIG.5, a first reference axis566(e.g., illustrated as a substantially vertical axis) and a second reference axis568(e.g., illustrated as a substantially horizontal axis, being substantially perpendicular to the first reference axis566) is shown to highlight the beveled surface535at the second end of the respective pillars520. That is, the surface of the second end of the respective pillars520that faces the lateral surface580may not be substantially parallel to the base512, but is angled such that the surface of the second end is at an angle relative to the base512. InFIG.5, the first reference axis566and the second reference axis568is illustrated for a single example pillar520; however, each respective pillar520can similarly include a second end having an angled or beveled surface535relative to the base512for supporting the cylindrical housing572. In some examples described herein, an MRI scanner that is supported by an example support stand may be moved together as a unit. For example, as described herein with reference toFIG.3B, a support stand having a MRI scanner supported thereon may be configured to receive forks of a pallet jack commonly found in warehouses and loading docks for transporting both the support stand and the MRI scanner from one location to another location. In some scenarios, it may be desirable, however, to transport the MRI scanner without the support stand or to raise the MRI scanner above the support stand. Examples features for facilitating the above will be described with reference toFIG.6. Reference is made toFIG.6, which illustrates a perspective view of a MRI system600, in accordance with another example of the present application. The MRI system600includes a support stand610for supporting an MRI scanner660. The MRI scanner660includes a main cylindrical magnet and includes a cylindrical housing672for encapsulating the main cylindrical magnet, among other components. Similar to the system ofFIG.5, the cylindrical housing672has a lateral surface680extending parallel to a horizontal bore from a first bore end to a second bore end. Similar to the system ofFIG.4, the cylindrical housing672defines a longitudinal footprint dimension and a lateral footprint dimension. It can be appreciated that the MRI scanner660includes other components, such as computer screens, computer systems, a cryostat, or other components. As described, the cylindrical housing672has a lateral surface680. The lateral surface680can include standoffs682protruding or extending from the lateral surface680. The cylindrical housing672can include standoffs682on opposing lateral sides of the horizontal bore of the cylindrical housing672(note: in the perspective view ofFIG.6, standoffs682may be seen on one side of cylindrical housing672). In the example ofFIG.6, the standoffs682are illustrated as protruding from the lateral surface680of the housing672in a direction towards the base of the support stand610. The standoffs can be mounted to one or more respective vibration isolators that are affixed to a second end of respective pillars. InFIG.6, the MRI system600includes one or more jacks650. The one or more jacks650are arranged to support the cylindrical housing672. For example, the standoffs682may be mounted on or resting on one or more jacks650, as illustrated inFIG.6. Each jack650may be an elongate structure having a mounting platform654. The standoffs682can rest atop a surface of the mounting platform654of a jack650such that the MRI scanner660is supported by the standoffs682. In some examples, the jack650can be an extendible elongate structure that can be adjusted to extend to the height of the standoffs682relative to the ground. In some examples, each jack650can include a wheel652, such as a caster wheel, such that the MRI scanner660can be transported from one location to another location while being supported by one or more jacks650. In some examples, cylindrical housing672can include one or more housing base channels618. The housing base channels618can be configured to receive a fork of a pallet jack operable to raise the cylindrical housing672of the MRI scanner660and to move the MRI scanner660from one location to another location. In some scenarios, it may be desirable to lift the MRI scanner above the support stand610such that the MRI scanner660can be moved from one location to another location or to swap/repair the support stand610. For example, the MRI scanner660may be elevated above the support stand610such that one or more vibration isolators can be repaired or replaced. Thus, the example standoffs682and housing base channels618are configured to mate or be coupled to one or more jacks650or a warehouse pallet jack for supporting the cylindrical housing672of the MRI scanner660such that the MRI scanner660can be lifted above the support stand610. Reference is made toFIG.7, which illustrates a perspective view of a MRI system700, in accordance with another example of the present application. The MRI system700includes a support stand710for supporting a MRI scanner760. Similar to the MRI scanners illustrated inFIGS.5and6, the MRI scanner760includes a main cylindrical magnet and includes a cylindrical housing772for encapsulating the main cylindrical magnet, among other components. Similar to the system ofFIG.6, the cylindrical housing772has a lateral surface780extending parallel to a horizontal bore from a first bore end to a second bore end. Similar to the system ofFIG.6, the cylindrical housing772defines a longitudinal footprint dimension and a lateral footprint dimension. The MRI scanner760can include other components, such as computer screens, computer systems, a cryostat, or other components. The lateral surface780can include one or more standoffs782protruding or extending from the lateral surface780. The cylindrical housing672can include standoffs782on opposing lateral sides of the horizontal bore of the cylindrical housing772. The standoffs782can be similar to the standoffs682described inFIG.6. The support stand710includes a base712for positioning the support stand710on the floor. InFIG.7, the support stand710includes a pair of pillars720extending upright from the base712. Each of the pair of pillars720includes a first end mounted to the base712and an opposing second end. The support stand710also includes one or more vibration isolators728mounted at the second end of respective pillars to support the lateral surface780via the standoffs782. InFIG.7, each pillar in the pair of pillars720is laterally separated from another pillar of the pair of pillars720on an opposing lateral side of the horizontal bore by a lateral separation distance no greater than the lateral footprint dimension. In some examples, each pillar in the pair of pillars720extends in a longitudinal direction, such as extending substantially from a first bore end to a second bore end of the horizontal bore. In some examples, the each of the pair of pillars720may include a single vibration isolator, such as elastomeric material, that extends in a direction from the first bore end to the second bore end. In some examples, the MRI systems described herein may include one or more mechanical snubbing devices that can limit motion of MRI scanners supported by support stands described herein. That is, the mechanical snubbing devices can be configured to limit motion of an MRI main magnet or cylindrical housing in the event of a seismic event, such as an earthquake. In some examples, the mechanical snubbing devices can be rigidly mounted to the floor of the MRI examination room. In some examples, the mechanical snubbing devices may not be coupled to the MRI main magnet or the cylindrical housing during normal operation. The mechanical snubbing devices can be configured such that movement of the main magnet or cylindrical housing exceeding movement that is anticipated during normal MRI scanner operation or a brief seismic event can bring the mechanical snubbing devices into contact with the cylindrical housing. In the present example, when the main magnet or cylindrical housing movement causes the cylindrical housing to contact the mechanical snubbing devices, the mechanical snubbing devices can provide mechanical resistance to further motion exceeding movement that is anticipated during normal MRI scanner operation or a brief seismic event. In some examples, the above described mechanical snubbing devices can be mounted onto support stands described herein for opposing main magnet or cylindrical housing movement beyond movement that is anticipated during normal MRI scanner operation. To illustrate, reference is made toFIG.8, which illustrates a perspective view of a MRI system800, in accordance with another example of the present application. The MRI system800includes a support stand810for supporting the MRI scanner860. Similar to the MRI scanner illustrated inFIG.7, the MRI scanner860includes a main cylindrical magnet and includes a cylindrical housing872for encapsulating the main cylindrical magnet, among other components. Similar to the system ofFIG.7, the cylindrical housing872defines a longitudinal footprint dimension and a lateral footprint dimension. The MRI scanner860can include other components, such as computer screens, computer systems, a cryostat, or other components. The support stand810includes a base812. InFIG.8, the support stand810includes a plurality of pillars820extending upright from the base812. Each respective pillar820has a first end mounted to the base812and an opposing second end. The support stand810also includes a vibration isolator828mounted at the second end of respective pillars to support a lateral surface of the cylindrical housing872. The MRI system800also includes one or more mechanical snubbing devices816. The mechanical snubbing devices816can be affixed to or adjacent to the support stand810. The one or more mechanical snubbing devices816may not be directly attached to the cylindrical housing872, but may be configured to provide mechanical resistance to movement of the cylindrical housing872that is beyond movement or vibration expected during normal MRI scanner860operation or that is beyond movement expected during common seismic events in the region that the MRI scanner860is located. When the mechanical snubbing devices816are positioned adjacent to the support stand810, the mechanical snubbing devices816can be secured to the floor of the examination room within which the MRI scanner860is located. In some examples, one or more of the mechanical snubbing devices816may be secured to the floor of the examination room and configured to resist movement of the support stand810that is greater than vibration or movement expected during normal MRI scanner860operation. Variations of positioning of the mechanical snubbing devices816relative to the support stand810and to the cylindrical housing872illustrated inFIG.8can be contemplated. Although the support stand examples described herein relate to MRI scanners, it is understood that features of the support stand may be adapted for other medical diagnostic systems that may be susceptible to vibrations or that may generate appreciable vibrations. Certain adaptations and modifications of the described embodiments can be made. Therefore, the above discussed embodiments are considered to be illustrative and not restrictive. | 46,738 |
11859760 | DETAILED DESCRIPTION Embodiments are provided for facilitating the descriptions of the instant disclosure. However, the embodiments are provided as examples for illustrative purpose, but not a limitation to the instant disclosure. In all the figures, the same reference numbers refer to identical or similar elements. FIG.1illustrates a perspective view of a hanging device according to an exemplary embodiment of the instant disclosure.FIG.2illustrates an exploded view of the hanging device of the exemplary embodiment. As shown inFIG.1andFIG.2, the hanging device1comprises a wall fixing plate10, a wall hanging element20, and a spiral spring30. The wall fixing plate10is adapted to be fixed on a wall surface W. For example, in this embodiment, the wall fixing plate10has two lock holes101, so that the wall fixing plate10can be locked on the wall surface W through bolts, but embodiments are not limited thereto. In some embodiments, the wall fixing plate10may be fixed on the wall surface W through other manners (such as attaching or riveting). In some embodiments, the wall surface W may be the surface of the wall, the surface of the ceiling, or the surface of any articles. As shown inFIG.1andFIG.2, in this embodiment, the wall fixing plate10comprises a top portion11, a bottom portion12, a fixing portion13, a first fitting portion14, and an abutting portion16. The fixing portion13and the abutting portion16are between the top portion11and the bottom portion12. In this embodiment, the fixing portion13is a through hole adjacent to the top portion11, and the abutting portion16is adjacent to the bottom portion12. The wall fixing plate10has a via hole15. The via hole15is adjacent to the bottom portion12and is defined through two opposite surfaces of the wall fixing plate10. The abutting portion16may be the hole edge of the via hole15to abut against the spiral spring30. As shown inFIG.2, the two opposite surfaces of the wall fixing plate10are respectively a front surface18and a rear surface19. However, it is understood that, the foregoing embodiments are illustrative examples. In some embodiments, the fixing portion13of the wall fixing plate10may be a slot and not defined through the two opposite surfaces of the wall fixing plate10, and the abutting portion16may be a protruding flange disposed on the surface of the wall fixing plate10. As shown inFIG.1andFIG.2, the wall hanging element20may be any product which has to be hung on. For example, the wall hanging element20may be a surveillance camera, a doorbell, a remote controller, a charger, or the like. The wall hanging element20comprises a housing21and a fixing member29. The housing21has a back surface22. The back surface22has a second fitting portion23and a spring installation region24, and the housing21further has a top end211and a bottom end212. The second fitting portion23, the spring installation region24, and the fixing member29may be disposed on any portion between the top end211and the bottom end212. For example, in this embodiment, the second fitting portion23and the fixing member29are adjacent to the top end211and respectively correspond to the first fitting portion14and the fixing portion13, and the spring installation region24is adjacent to the bottom end212and corresponds to the abutting portion16, but embodiments are not limited thereto. As shown inFIG.2, the fixing member29is disposed in the housing21and shiftably protrudes from the back surface22. Please refer toFIG.5. In this embodiment, the fixing member29comprises an elastic member291and a rod member292. Moreover, in this embodiment, the elastic member291is an elastic arm, but embodiments are not limited thereto; in some embodiments, the elastic member291may be a spring, an elastic piece, or an elastic rubber. One of two ends of the elastic member291is connected to other parts inside the housing21, and the other end of the elastic member291is connected to and pushes against the rod member292to protrude from the back surface22of the housing21. Therefore, when the rod member292is forced by the elastic member291, the rod member292is in a movable and shiftable state so as to protrude from the back surface22or not to protrude from the back surface22. The spring installation region24of the housing21is a region on the back surface22for assembling with the spiral spring30(for example, inFIG.2, the region enclosed by the dot-and-dash line). The spring installation region24has a limiting member25for assembling with the spiral spring30. Moreover, a distance (in this embodiment, the distance in the Y-axis direction) between the fixing member29and the bottom edge of the spring installation region24is greater than a distance (in this embodiment, the distance in the Y-axis direction) between the fixing portion13and the abutting portion16of the wall fixing plate10. Further, as shown inFIG.2, the second fitting portion23on the back surface22of the housing21is provided for being fitted with the first fitting portion14of the wall fixing plate10. For example, the first fitting portion14and the second fitting portion23may be fitted with each other through clearance fit, interference fit, transition fit, or the like. In this embodiment, the first fitting portion14is the edge portion of the top portion11of the wall fixing plate10(in this embodiment, an arc edge), and the second fitting portion23is a buckling flange disposed on the back surface22. Moreover, in this embodiment, the second fitting portion23is an arc flange, and the shape of the arc flange corresponds to the shape of the first fitting portion14, so that the second fitting portion23can be fitted with the first fitting portion14of the wall fixing plate10. FIG.3illustrates an enlarged partial exploded view of the hanging device of the exemplary embodiment.FIG.4illustrates an enlarged partial plan view of the hanging device of the exemplary embodiment. As shown inFIG.2toFIG.4, the spiral spring30is formed by winding a wire, from the inside out, into a spiral structure. In some embodiments, the wire may be flat wire or a plat-shaped wire. The material of the wire may be carbon steel, alloy steel, stainless steel, or other metal alloys, but embodiments are not limited thereto. As shown inFIG.2toFIG.4, the spiral spring30is disposed on the spring installation region24and comprises an inner arc section31, an outer arc section33, and an arc connecting section35. The inner arc section31, the outer arc section33, and the arc connecting section35may be arranged on a same plane. Moreover, a radius of the outer arc section33is greater than a radius of the inner arc section31. For example, the radius of the outer arc section33may be 1.5 to 2.5 times of the radius of the inner arc section31. The arc connecting section35is connected between the inner arc section31and the outer arc section33. Specifically, in this embodiment, the inner arc section31is an initial section of the spiral spring30which has the smallest radius of curvature, and the outer arc section33is a terminal section of the spiral spring30which has the largest radius of curvature. The radius of curvature of the arc connecting section35gradually increases from the inner arc section31to the outer arc section33, so that the spiral spring30forms a continuous spiral line segment (as shown inFIG.4). It is understood that, inFIG.4the dash line on the spiral spring30is provided for indicating the borders among the inner arc section31, the outer arc section33, and the arc connecting section35, but not for limiting the arc length of the inner arc section31, the arc length of the outer arc section33, and the arc length of the arc connecting section35to a certain embodiment. In some embodiments, the inner arc section31of the spiral spring30may be a circular arc, and the central angle of the inner arc section31may be in a range between 45 degrees and 210 degrees. For example, in the embodiment shown inFIG.4, the central angle of the inner arc section31is about 180 degrees, but embodiments are not limited thereto. In some embodiments, the inner arc section31may be configured as a non-circular arc and has an incremental radius of curvature. Similarly, the outer arc section33of the spiral spring30may be a circular arc, and the central angle of the outer arc section33is in a range between 45 degrees and 210 degrees. For example, in the embodiment shown inFIG.4, the central angle of the outer arc section33is about 75 degrees, but embodiments are not limited thereto. In some embodiments, the outer arc section33may be configured as a non-circular arc and has an incremental radius of curvature. As shown inFIG.2toFIG.4, the spiral spring30leans against the limiting member25on the spring installation region24. The limiting member25comprises at least one block protruding from the back surface22and between the arc connecting section35and the inner arc section31, so that the arc connecting section35and the inner arc section31respectively lean against the block, thereby limiting the movement of the spiral spring30. In this embodiment, the limiting member25comprises a first limiting block26and a second limiting block27spacedly arranged along the X-axis direction. The first limiting block26has a first top edge261and a first bottom edge262. The first top edge261is nearer to the top end211of the housing21, as compared with the first bottom edge262(in other words, in this embodiment, a distance between the first top edge261and the top end211of the housing21is less than a distance between the first bottom edge262and the top end211of the housing21). The second limiting block27has a second top edge271and a second bottom edge272. The second top edge271is nearer to the top end211of the housing21, as compared with the second bottom edge272(in other words, in this embodiment, a distance between the second top edge271and the top end211of the housing21is less than a distance between the second bottom edge272and the top end211of the housing21). Moreover, an indentation G is between the first limiting block26and the second limiting block27. In this embodiment, the first limiting block26and the second limiting block27are spaced arranged with each other to form the indentation G. Furthermore, as shown inFIG.4, the arc connecting section35of the spiral spring30leans against the first top edge261and the second top edge271, and the inner arc section31leans against the first bottom edge262. Moreover, an end portion of the inner arc section31has an extension section311, and the inner arc section31is connected between the extension section311and the arc connecting section35. In this embodiment, the extension section311integrally extends and bends from the end portion of the inner arc section31, and the extension section311is inserted into the indentation G. Accordingly, in this embodiment, since the arc connecting section35leans against the first top edge261and the second top edge271as well as the inner arc section31leans against the first bottom edge262, the arc connecting section35is limited from moving downwardly and the inner arc section31is limited from moving upwardly. Hence, the upward and downward movements of the spiral spring30are limited. Moreover, since the extension section311is inserted into the indentation G, the leftward and rightward movements of the spiral spring30are also limited. The outer arc section33of the spiral spring30is not limited, so that the outer arc section33can be forced to move toward the inner arc section31radially. As shown inFIG.4again, the first bottom edge262of the first limiting block26may be an arc edge, and the radius of curvature of the first bottom edge262corresponds to the radius of curvature of the inner arc section31, so that the leaning area between the inner arc section31and the first bottom edge262increases to provide a better limiting performance. The first top edge261of the first limiting block26and the second top edge271of the second limiting block27may be arc edges respectively. The arc connecting section35comprises a first arc section351and a second arc section352, and the radius of curvature of the first arc section351is greater than the radius of curvature of the second arc section352. The first arc section351leans against the first top edge261, and the radius of curvature of the first top edge261corresponds to the radius of curvature of the first arc section351. The second arc section352leans against the second top edge271, and the radius of curvature of the second top edge271corresponds to the radius of curvature of the second arc section352. Therefore, the leaning area between the first arc section351and the first top edge261as well as the leaning area between the second arc section352and the second top edge271can be increased to provide a better limiting performance. FIG.5illustrates a cross-sectional view showing that the wall hanging element is at the fixed position along the line5-5shown inFIG.1.FIG.6illustrates an enlarged partial view showing that the wall hanging element is at the fixed position. As shown inFIG.5andFIG.6, the wall hanging element20can be assembled on the wall fixing plate10and at a fixed position (as the position shown inFIG.5). For example, during assembling the wall hanging element20on the wall fixing plate10, the spiral spring30is inserted into the via hole15of the wall fixing plate10(at this moment, the spiral spring30does not abut against the abutting portion16), so that the second fitting portion23of the housing21is above the first fitting portion14and the fixing member29abuts against the surface of the wall fixing plate10(as shown inFIG.7). Next, the wall hanging element20can be moved to the fixed position based on the gravity force or user operation, so that the fixing member29is buckled with and assembled in the fixing portion13and the second fitting portion23is fitted with the first fitting portion23. Therefore, the wall hanging element20is fixed on the wall fixing plate10and hung on the wall surface. Furthermore, as shown inFIG.5andFIG.6, when the wall hanging element20is moved to the fixed position, the abutting portion16(in this embodiment, the hole edge of the via hole15) pushes the outer arc section33of the spiral spring30to move toward the inner arc section31. Therefore, the spiral spring30is compressed to store the elastic force. In this embodiment, the outer arc section33is nearer to the bottom end212of the housing21, as compared with the inner arc section31; in other words, in this embodiment, the distance between the outer arc section33and the bottom end212of the housing21is less than the distance between the inner arc section31and the bottom end212of the housing21. When the wall hanging element20is moved to the fixed position, the abutting portion16pushes the outer arc section33of the spiral spring30to move toward the top end211of the housing21(that is, in this embodiment, along the Y-axis direction) to come toward the inner arc section31. Therefore, the outer arc section33is compressed toward the inner arc section31to further drive the arc connecting section35and the inner arc section31to have elastic deformation to store the elastic force. Moreover, when the outer arc section33of the spiral spring30is released, the elastic force stored in the spiral spring30can provide a force along the Y-axis direction. Accordingly, in one or some embodiments of the instant disclosure, owing to the snail-like structure of the spiral spring30and the operation of the spiral spring30, the internal stress in the spiral spring30can be distributed over the whole spring when the spiral spring30is compressed. For example, as shown inFIG.6, when the spiral spring30is compressed, several sections of the spiral spring30(such as the sections filled with dots shown inFIG.6) together suffer the internal stress, thereby increasing the yield strength of the spiral spring30. Therefore, the spiral spring30can sustain the weight of the wall hanging element20to prevent from the breaking of the spiral spring30due to fatigue, thus increasing the service life of the spiral spring30. FIG.7illustrates a cross-sectional view showing that the wall hanging element is at the released position.FIG.8illustrates an enlarged partial plan view showing that the wall hanging element is at the released position. As shown inFIG.7andFIG.8, when the wall hanging element20is to be detached off, the user can operate the fixing member29to be detached from the fixing portion13. For example, the user can operate the fixing member29to be detached from the fixing portion13by hands or by hand tools. Then, the elastic force stored in the spiral spring30thus drive the wall hanging element20to move toward the top portion11of the wall fixing plate10to a released position (as indicated inFIG.7) along the Y-axis direction (as the arrow A shown inFIG.7). Specifically, in this embodiment, when the wall hanging element20is moved from the fixed position to the released position, the second fitting portion23of the wall hanging element20can be moved upwardly to detach from the first fitting portion14of the wall fixing plate10. Hence, at this moment, the wall hanging element20is not fixed and can be detached from the wall fixing plate10easily. Moreover, according to one or some embodiments of the instant disclosure, after the spiral spring30is released, the actuation movement of the spiral spring30is long, thus providing a higher elastic force. Therefore, even in a narrow space (for example, in the space of the via hole15, where the thickness of the via hole15is approximately the thickness of the wall fixing plate10), the elastic force generated by the spiral spring30and the actuation movement of the spiral spring30can be ensured enough to drive the wall hanging element20to move from the fixed position to the released position. As shown inFIG.2, in this embodiment, the back surface22of the housing21further comprises two side flanges221. The two side flanges221are spacedly arranged and connected to the second fitting portion23. The wall fixing plate10has two side portions17, the two side portions17are connected between the top portion11and the bottom portion12. During moving the wall hanging element20between the fixed position and the released position, the wall fixing plate10can be disposed between the two side flanges221, and the two side portions17are close to or in contact with the two side flanges221. Therefore, during the movement, the wall fixing plate10can be guided and limited by the two side flanges221to prevent the deflection or wobbling. As shown inFIG.4, the limiting member25further comprises a third limiting block28. The second limiting block27is between the first limiting block26and the third limiting block28, and a portion of the arc connecting section35is between the second limiting block27and the third limiting block28. In this embodiment, the second arc section352of the arc connecting section35is connected between the first arc section351and the inner arc section31, and a portion of the second arc section352is between the second limiting block27and the third limiting block28. Accordingly, as shown inFIG.4andFIG.6, during the process that the spiral spring30is released and compressed, the arc connecting section35can be limited between the second limiting block27and the third limiting block28, thus preventing the unexpected movements of the spiral spring30. As shown inFIG.3toFIG.5, the spring installation region24on the back surface22of the housing21further comprises a stopping plate40and a limiting post41, so that the spiral spring30can be limited in the spring installation region24. In this embodiment, the limiting post41is connected between the stopping plate40and the housing21. In this embodiment, one of two ends of the limiting post41is fixed on the housing21through attaching, locking, engaging or the like, and the other end of the limiting post41is integrally connected to the stopping plate40, so that the stopping plate40is kept spaced from the back surface22of the housing21by a spacing. The inner arc section31surrounds the limiting post41, and the stopping plate40covers the spiral spring30to limit the axial movement of the spiral spring30, thus preventing the spiral spring30from leaving the spring installation region24easily. Further, as shown inFIG.5, when the wall hanging element20is at the fixed position, a portion of the wall fixing plate10is further inserted into the spacing between the stopping plate40and the back surface22. Therefore, after the wall hanging element20is assembled with the wall fixing plate10, the wall hanging element20can be stably fixed and is not wobbled easily. Moreover, as shown inFIG.7, when the wall hanging element20is at the released position, the stopping plate40corresponds to the via hole15of the wall fixing plate10. Therefore, the spiral spring30, the stopping plate40, and the limiting post41can be detached from the wall fixing plate10through the via hole15. As shown inFIG.4andFIG.8, the spiral spring30has a longitudinal center line L passing through a center of circle C of the inner arc section31. The outer arc section33has a terminal portion331and a connection end332. The connection end332is connected to the arc connecting section35. The terminal portion331extends away from the connection end332, and the terminal portion331of the outer arc section33is adjacent to the longitudinal center line L. The term “adjacent to”, in this embodiment, may indicate that, the angle θ between the connection line of the terminal portion331and the center of circle C and the longitudinal center line L is in a range between 0 degree and 45 degrees or between 15 degrees and 30 degrees. Moreover, in this embodiment, the connection end332and the terminal portion331of the outer arc section33are respectively at two opposite sides of the longitudinal center line L. Therefore, when the wall hanging element20is at the fixed position, the abutting portion16can be ensured to abut against the outer arc section33of the spiral spring30to move toward the inner arc section31. However, it is understood that, the foregoing embodiment are provided as illustrative purposes; in some embodiments, the connection end332and the terminal portion331of the outer arc section33may be at the same side of the longitudinal center line L. In another embodiment, alternatively, the terminal portion331of the outer arc section33may be on the longitudinal center line L. Based on the above, in the hanging device according to one or some embodiments of the instant disclosure, the wall hanging element can be quickly assembled on the wall fixing plate through the fixing member and the second fitting portion. Furthermore, after the fixing member is detached from the wall fixing plate, the elastic force stored in the spiral spring drives the wall hanging element to move with respect to the wall fixing plate, so that the wall hanging element can be detached from the wall fixing plate easily and conveniently. Moreover, when the spiral spring is compressed, the inner stress applied to the spiral spring can be distributed over the entire spring properly, thereby increasing the yield strength and the service life of the spiral spring. Furthermore, owing to the snail-like structure of the spiral spring, after the spiral spring is released, the spiral spring can have a longer actuation movement to provide a greater elastic force. Hence, even in a narrow space, the elastic force generated by the spiral spring and the actuation movement of the spiral spring can be ensured enough to drive the wall hanging element to move from the fixed position to the released position. While the instant disclosure has been described by the way of example and in terms of the preferred embodiments, it is to be understood that the invention need not be limited to the disclosed embodiments. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures. | 24,193 |
11859761 | DETAILED DESCRIPTION The following relates to platforms that support micro motion optics. Particularly, platforms are desirable that support fine movements of optics devices, such as telescopes, cameras, and other devices. Fine motion may be desirable to enable high magnification of such devices. Even small movements caused by environmental forces, such as wind, vibration, or other forces, may move a device enough to make it difficult to focus on a relatively nearby small object or an object that is a long distance away. However small the movement, a lost view may make it difficult to relocate with the lens. The optics platform described herein allows for small incremental motion to yield fine optics adjustments. This includes sweeping adjustments provided by semi-circular horizontal and vertical movement. Such movement is especially useful for high magnification or precise focusing of devices such as telescopes, spotting scopes, cameras, or other optics devices. The optics platform described herein allows for ease in centering an image and following an object using fine adjustment capabilities. An example optics platform includes a base plate with a swing arm pivotally attached to the base plate. The attachment allows the swing arm to articulate in a semi-circular motion around a vertical axis of the base plate. A pivot arm is pivotally attached to the swing arm to articulate in a semi-circular motion around a horizontal axis of the swing arm. The movement of the swing arm and the pivot arm may be performed simultaneously or independently of each other. In an example, a first harness is used to constrain the semi-circular movement of the swing arm to a horizontal plane relative to the base plate. In an example, the first harness comprises an interlocking end member on the swing arm and base plate. The interlocking end member is to interlock the swing arm with the base plate. In an example, the interlocking end member includes a notch on the swing arm and a lip on the base plate. In an example, a second harness is used to constrain semi-circular movement of the pivot arm to a vertical plane relative to the swing arm. In an example, the second harness comprises an interlocking end member to interlock the pivot arm with the swing arm. In an example, the interlocking end member includes sidewalls of the swing arm and the elongate member of the pivot arm. In other examples, the first and second harness include other types of structure, including barrel nuts and other structure that restricts movement between the base plate, swing arm, and pivot arm. In an example a first biasing member is to counter a force on the swing arm in the horizontal plane relative to the base plate. A second biasing member is to counter a force on the pivot arm in the vertical plane relative to the swing arm. In an example, the first and second biasing members include springs. The spring of the first biasing member is configured to provide a counter tension against the swing arm movement. The spring of the second biasing member is configured to provide a counter tension against the pivot arm movement. In an example, the force on the swing arm is provided by a windage knob that is threaded through a sidewall of the base plate. In an example, the force on the pivot arm is provided by an elevation knob that is threaded through the swing arm. In an example, the pivot arm further includes a top plate that is to support an external device. In an example, the base plate includes a ball mount attachment on a bottom side of the base plate. The ball mount attachment is to attach to a standard tripod. In an example, the base plate comprises a base spring hole and a base pivot hole within the base spring hole. A base pin within the base pivot hole pivotally attaches the swing arm to the base plate. A base spring within the base spring hole is configured to apply a spring counter tension against a force applied to articulate the swing arm around the base pin and base plate. The counter tension on the swing arm enables a precisely controlled movement of the swing arm. In an example, the base plate includes a pie-shaped, wedge-shaped, or otherwise triangular base. A base pivot hole is located at or near an apex of the pie-shaped base. A swing pivot hole is located on an underside of the swing arm. The base pivot hole and the swing pivot hole are in alignment. The base pin being inserted within the base pivot hole and the swing pivot hole pivotally attaches the base plate and the swing arm. In another example, the base plate includes a pie-shaped base. A windage knob is located at or near a corner end of the pie-shaped base. A windage knob is screwed through the base plate to contact a side of the swing arm and provide a force that facilitates the semi-circular motion of the swing arm, the semi-circular motion being parallel to a planar surface of the base plate. In an example, the swing arm includes an elongate member having a swing pivot hole at or near one end that aligns with a base pivot hole of the base plate for providing a vertical axis on which the swing arm articulates relative to the base plate. In an example, the swing arm includes an offset member that extends perpendicularly outward from the elongate member. A notch on the offset member slidably engages around an end of the base plate. The notch is to hold the swing arm slidably engaged while the swing arm articulates about the base plate. In an example, the pivot arm includes an arm extension that pivotally attaches to the swing arm. A top plate at the end of the pivot arm is to support at least one external device. In an example, the attachment is accomplished with a pivot attachment on a bottom side of the arm extension. A force exerted at or near an end of the arm extension causes the pivot arm to articulate around the pivot attachment. In an example, the pivot arm includes a biasing member to provide a counter force to the force applied at or near an end of the arm extension of the pivot arm. The force and counter force enable a fine-tuned, precise movement and position of the pivot arm relative to the swing arm. In an example, the biasing member includes a pivot spring held between a pivot spring hole on the pivot arm and a swing spring hole on the swing arm. The pivot spring is configured to provide the counter force to the force applied at or near the end of the arm extension of the pivot arm. In an example, an optics platform includes a base plate that includes a generally flat pie-shaped base member with at least one sidewall on a side of the base plate. The optics platform further includes a swing arm that is pivotally attached to the base plate to articulate in a semi-circular motion around a vertical axis of the base plate. A pivot arm is pivotally attached to the swing arm to articulate in a semi-circular motion around a horizontal axis of the swing arm. A top plate is attached to the pivot arm and is to support at least one external device. In an example, a first harness is to constrain movement of the swing arm to be in a horizontal plane relative to the base plate. The first harness includes a windage knob on a sidewall at or near a corner end of the base plate. A horizontal force on the swing arm is provided by a windage knob that is threaded in and out of the sidewall of the base plate. A base spring hole is located at or near an apex of the pie-shaped base of the base plate. The base spring hole is to contain a base spring that provides counter tension to the horizontal force applied by the windage knob. A base pivot hole within the base plate includes a base pin therethrough which pivotally attaches the base plate and the swing arm. The base pin provides a vertical axis for the swing arm to articulate relative to the base plate. The swing arm includes a notch that slidably engages around an end of the base plate and thereby isolates the swing arm from vertical movement. A second harness includes a pivot attachment on a bottom side of the pivot arm to pivotally attach the pivot arm to the swing arm. A force on the pivot arm is provided by an elevation knob that is threaded in and out of the bottom of the swing arm. A pivot spring hole is located on the pivot arm and a swing spring hole is located on the swing arm. A pivot spring is contained between the pivot spring hole and the swing spring hole. The pivot spring is to provide counter tension to the force applied by the elevation knob on the pivot arm. Turning toFIG.1, an example optics platform100is shown according to an example of the principles described herein. The optics platform100includes a base plate102with a swing arm126and pivot arm146attached thereon. In summary, the swing arm126is interlocked with the base plate102for fine incremental motion of the swing arm126relative to the base plate102. The surface of the base plate102is generally flat and allows semi-circular motion of the swing arm126relative to the flat surface of the base plate102, which surface will be referenced as a horizontal plane. The optics platform100includes structure underneath the base plate102, as discussed below, that allows for quick attachment or release of the optics platform100from a mount, such as a camera stand or tripod. In the example shown inFIG.1, the structure underneath the base plate102is a ball mount attachment198. In motion, the pivot arm146and the swing arm126articulate together in a semi-circular path around a vertical axis and along the surface of the base plate102. The pivot arm146articulates in a semi-circular path relative to the swing arm126around a horizontal axis. Movements of the pivot arm146and swing arm126are indicated by arrows inFIG.1. The two movements may be asynchronous, or otherwise operate independently of each other, or they may move synchronously. In other words, the pivot arm146and the swing arm126may move together or the pivot arm146may move independently of the swing arm126. The two movements are both relative to the base plate102. The pairing of the base plate102and the swing arm126is responsible for horizontal semi-circular motion of a device (such as a telescope, spotting scope, camera, or other optic) that is attached to the optics platform100. The pairing of the swing arm126and pivot arm146is responsible for a vertical, semi-circular motion of the device. The swing arm126movement and the pivot arm146movement are controlled manually with independent controls for each movement. In other examples, the movements are controlled by a single structure. A close-up view of the slidable connection between the base plate102and the swing arm126is illustrated inFIG.2. The swing arm126articulates or slides along the base plate102. A notch132on the swing arm126slidably engages a lip of the base plate102, restricting undesirable vertical movement of the swing arm126relative to the base plate102. The notch132follows the semi-circular shape of the lip of the base plate102as it slides around the base plate102. In this manner, movement of the swing arm126is parallel to the top and bottom surface of the lip for a precise, non-wobbling semi-circular path. While other optics platforms may function only in an X, Y, and Z axis, the added semi-circular motion described herein, with multiple articulations and counter tension, provide the user with increased functionality and precision. The interlocking relationship between the swing arm126and the base plate102, and the swing arm126and the pivot arm146, provides control and stability for precise vertical and horizontal positioning along a swinging planar movement. Turning toFIG.3, the swing arm126is shown separate from the base plate102and pivot arm146. The swing arm126includes an elongate member with a swing pivot hole142at or near one end and an offset member at an opposite end. The offset member extends perpendicularly outward and has a notch132which is a t-slot or hook-like opening that slidably engages around the lip, or outer edge, of the base plate102to hold the swing arm126slidably engaged and prevent vertical movement while the swing arm126articulates about the base plate102. A slot122is located on the underside of the swing arm126. The slot122includes an elongated cavity lengthwise along the underside of the swing arm126. The slot122turns toward the side of the swing arm126at an end closest to the spring hole and pivot hole142so that it extends to an outer side of the swing arm126. In this manner, an end of the pivot spring158-1, -2(FIG.7) can be inserted through the opening at the side of the swing arm126and then slide within the slot122to engage the swing arm126. In this manner, the end of the pivot spring158-1, -2(FIG.7) is joined between the swing arm126and the base plate102. Instead of a notch or slot, further examples include other restrictive structure that control movement along a horizontal path. Also on the underside of the swing arm126is an elevation hole124in which a control (e.g., elevation knob134, seeFIG.8) may be inserted to control movement of the pivot arm146(seeFIG.5). FIG.4aillustrates an example base plate102as viewed from the top. The base plate102includes a generally flat member that includes a windage hole116, base spring hole106, base pivot hole112, and pie-shaped recess110. The base plate102is generally wedge-shaped or pie-shaped and the pie-shaped recess110follows the angles and curvature of the pie shape of the base plate102. Within the pie-shaped recess110, the swing arm126(seeFIG.3) articulates as it swings back and forth from side to side. The swing arm126pivots from side to side as defined by sidewalls of the pie-shaped recess110. FIG.4billustrates a base spring108that is nested within the base spring hole106. One end of the base spring108moves side to side in the pie-shaped recess110against movement of the swing arm126. The base spring108provides counter tension against force applied to the swing arm126(seeFIG.3). At or near an apex of the pie-shaped recess110is the corresponding base spring hole106to the pivot spring hole142on the swing arm126(seeFIG.3). The base spring hole106includes a circular recess within the flat member. Within the base spring hole106and centrally aligned with the base spring hole106is a base pivot hole112, which is a hole that extends therethrough the base plate102. The swing pivot hole142of the swing arm126(seeFIG.3) is to align with the base pivot hole112of the base plate102in order for the swing arm126to articulate around with respect to the base plate102. Turning toFIG.5, an example pivot arm146is shown separate from the base plate102and swing arm126. The pivot arm146includes an arm extension148and a top plate152. The arm extension148includes an elongate member that extends outward and bends or curves around itself. The arm extension148shown inFIG.5curves completely around itself to form a U-shape with two end portions extending in a parallel direction. One end portion will be referred to as the bottom end portion. The other end portion will be referred to as the top end portion. The top end portion does not extend as far as the bottom end portion. In other examples, the top end portion extends at least as far as the bottom end portion or beyond the bottom end portion. In further examples, the curvature is not enough for the top end portion to completely curve around to be parallel with the bottom end portion. The top plate152is a flat elongated member to support at least one external device, such as a camera or scope, etc. The space between the top end portion and top end plate152to the bottom end portion of the arm extension148is advantageous for dampening vibrations on an optics device. Vibrations may be caused by contact with the bottom end portion of the arm extension148, the swing arm126, and the base plate102. The optics device is also isolated from experiencing the effects of vibrations or counter tension of biasing members, oscillations from a mount, movements associated with the elevation knob, etc. On the bottom of the bottom end portion are pivot spring holes160-1, -2for spring attachment to the base plate102. The pivot spring holes160-1, -2are cavities or recesses adjacent to the pivot pin hole162. The pivot arm146receives at least one biasing member in at least one of the pivot spring holes160-1, -2, that provides counter tension to the revolving motion. At least one pivot spring158-1, -2(seeFIG.8) is positioned between respective pivot spring holes160-1, -2and swing spring holes144-1, -2(seeFIG.6) within the swing arm126(seeFIG.6). The pivot spring158-1, -2provides the counter tension to the force applied at an end of the bottom end portion of the pivot arm146. The use of one pivot spring or multiple pivot springs and the location of the pivot spring or pivot springs allows a different spring tension to be utilized. For different weights of the optical devices on the optics platforms, different spring tensions may be desired. For example, a weight balance desired for a spotting scope may be different than the weight balance desired for a camera and thus a spring tension can be configured accordingly. In the example shown inFIG.5, the pivot arm146includes a pivot attachment170on a bottom side of the pivot arm146. The pivot arm146is pivotally attached to the swing arm126by a pivot pin150(seeFIG.8) such that a force exerted at or near the end of the bottom end portion, as indicated by the arrow, causes the pivot arm146to articulate around the horizontal axis through the pivot pin150in the swinging circular motion. The articulation angles the top plate152upward and downward relative to the base plate102(seeFIGS.4aand4b). An external device attached to the top plate152may therefore be tilted upward and downward depending on the direction of rotation of the elevation knob134(seeFIG.8) or other force. The pivot arm146is contained within a cavity on top of the swing arm126housing to swing upward and downward relative to the pivot attachment170. In a top perspective view of the swing arm126as shown inFIG.6, the top of the swing arm126is removed to show a cavity136, or interior space, within which the pivot arm146is slidably placed against sidewalls of the swing arm126. The sidewalls define the interior space and prevent undesirable horizontal movement of the pivot arm146as the pivot arm146is revolved around the horizontal axis of the pivot pin150(seeFIG.8) in a swinging motion. The pivot spring hole142can be seen within the cavity136. Also, the elevation hole124that is threaded for the elevation knob134(seeFIG.8) may be seen within the cavity136.FIG.6also depicts the swing spring holes144-1, -2that receive the pivot springs158-1, -2(FIG.7) as described above. A side cutout view of the optic device is shown inFIG.7. The pivot pin hole162runs perpendicular to the length of the arm attachment148at the pivot attachment170. The pivot pin150is inserted within the pivot pin hole162and attaches at ends to interior sidewalls of swing arm126. The pivot arm146pivots, or in other words, swings upward and downward around the horizontal axis as defined by the pivot pin150relative to the swing arm126. An elevation hole124extends vertically upward through the swing arm126starting at an end of the offset member. The elevation hole124is threaded for the elevation knob134(seeFIG.8) to be screwed into and thereby exert force on the pivot arm146. Turning toFIG.8, a side cutout view of the optics platform100illustrates the pivot arm146attached to the swing arm126attached to the base plate102via a base pin138that extends between the base pivot hole112(seeFIG.4a) and the swing pivot hole142(seeFIG.3). The base pin138provides a vertical axis around which the swing arm126articulates relative to the base plate102. The combination of fixation from the base pin138and the notch132on the swing arm126provides for horizontal semi-circular motion of the swing arm126relative to the base plate102. A base spring108is contained within the base spring hole106(seeFIG.4a). The base spring108is sandwiched between the base spring hole106and a corresponding swing pivot hole142(seeFIG.3) on the swing arm126. The base spring108is under tension between the base spring hole106and the swing pivot hole142(seeFIG.3) and thereby exerts a spring tension between the swing arm126and the base plate102as the swing arm126pivots or articulates in a swinging motion around the base pivot hole112. The elevation knob134is rotated to apply an upward force on the pivot arm146. At least one pivot spring158-1, -2provides counter tension as the pivot arm146articulates around the pivot pin150. The pivot pin150is located in the pivot pin hole162. InFIG.9, a front cutout view of the optics platform100shows the windage knob118connected to the side of the base plate102. The windage knob118includes a threaded elongate member that is inserted within the windage hole116of the base plate102. The windage knob118includes a knob or handle or other structure for manual application. Rotation of the windage knob118causes force to be exerted on the swing arm126at the point of contact which causes the swing arm126to move. The windage knob118is screwed in and out of the side of the base plate102to provide horizontal back and forth swing motion of the swing arm126that is precisely controlled. In an example, the swing arm126can return to an initial position against the side of the base plate102by unscrewing the windage knob118in a counterclockwise direction, under spring pressure that provides controlled movement. Movement away from the initial position against the side of the base plate102is performed by screwing the windage knob118in a clockwise direction under spring pressure. Counter tension against the forces of the windage knob118provide precision of movement of the windage knob118. Also shown inFIG.9is an elevation knob134that is screwed underneath a bottom side of the swing arm126. The elevation knob134includes a threaded elongate member that is inserted with the elevation hole124(labeled inFIG.7). The elevation knob134includes a knob or handle or other structure for manual application. Rotation of the elevation knob134causes force to be exerted on the pivot arm146at the point of contact which causes the pivot arm146to move. The elevation knob134is screwed in and out of the swing arm126to articulate the pivot arm146about the horizontal axis of the swing arm126. In an example, the pivot arm146can return to an initial position within the swing arm126by unscrewing the elevation knob134in a counterclockwise direction, under spring pressure to provide controlled movement. Movement away from the initial position against the swing arm126is performed by screwing the elevation knob134in a clockwise direction under spring pressure. Counter tension against the forces of the elevation knob134provide precision of movement of the elevation knob134. Turning toFIG.10, an example attachment structure for the optics platform100in the form of a ball mount attachment198is shown. The ball mount attachment198is located underneath the base plate102and includes an attachment with curved arms that engage around a standard tripod and allow a secure mount of a device to a tripod. In an example, the first or second harness includes structure that includes a barrel nut that restrict movement. Turning toFIG.11, an example optics platform100includes barrel nuts174-1, -2, -3, -4that are used to tighten respective threaded portions of the windage knob118and the elevation knob134. Particularly, barrel nut174-1is screwed into the swing arm146to provide tightness around threaded portion of elevation knob134. Barrel nut174-2is screwed into the base plate102to provide tightness around threaded portion of windage knob118. Barrel nut174-3is screwed into the base plate102to provide tightness around threaded portion of windage knob118. Barrel nut174-4is screwed into the base plate102to provide tightness around threaded portion of windage knob118. The barrel nuts174-1, -2, -3, -4allow linear movement of the swing arm126on the threaded, fixed windage knob118and elevation knob134. The barrel nuts174-1, -2, -3, -4move via threads on the windage knob118and elevation knob134. The round barrel nut rotation of barrel nuts174-1, -2, -3, -4accommodates the angle changes as the swing-arm moves move along a straight threaded knob. Minor elliptical cuts not shown in the diagram make this linear motion possible. Note that barrel nuts may be located in other locations to provide tightness and securement to threaded portions of the various control features. FIG.12illustrates an exploded view of the various components including base plate102, swing arm126, pivot arm146, windage knob118, elevation knob134, top plate152, pivot spring158, base spring108, base pin138, barrel nuts174-1, -2, -3, -4. A stay pin178pins the base pin138to the base plate102. It prevents the base pin138from slipping out during rotation of the swing arm126. In an example, the first or second harness includes structure such as at least one threaded bolt, worm gear, linear accelerating device, or other type of structure. In an example, two clamping arms interface with the swing arm126via a pin that is affixed through the pivot hole of the base plate102to control movement of the swing arm126. In another example, the first or second harness is placed in the body of the swing arm126at the pivot hole to control movement of the pivot arm146. In both scenarios, the first and second harness may allow forward and reverse motion through the threaded pivot hole. Thus, the movement of the swing arm and pivot arm may be controlled via a springless adjust system. The springs are types of biasing members that counter the forces on the pivot arm146and the swing arm126. In an example, the biasing members may include additional structures than the examples already disclosed. The biasing members for the pivot arm146and the swing arm126may be the same or different. At least one biasing member may include a spring or spring-like member. The biasing member is to resist the force applied at or near a second end of the arm extension148as the arm extension148pivots. The biasing member provides resistance of pivot arm146movement which enables a user to fine tune a position of the pivot arm146relative to the swing arm126. The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein. | 27,046 |
11859762 | DETAILED DESCRIPTION OF THE INVENTION Certain terminology is used in the following description for convenience only and is not limiting. The words “lower”, “upper”, “upward”, “down” and “downward” designate directions in the drawings to which reference is made. The words “inner”, “inwardly” and “outer”, “outwardly” refer to directions toward and away from, respectively, a designated centerline or a geometric center of an element being described, the particular meaning being readily apparent from the context of the description. Further, as used herein, the words “connected” and “coupled” are each intended to include direct connections between two members without any other members interposed therebetween and indirect connections between members in which one or more other members are interposed therebetween. The terminology includes the words specifically mentioned above, derivatives thereof, and words of similar import. Referring now to the drawings in detail, wherein like numbers are used to indicate like elements throughout, there is shown inFIGS.1-18a lubricant pump10for driving lubricant from a container1to at least one lubricant distributor2for delivering lubricant to one or more lubrication points6, such as for example, bearings, gear faces, etc. The container1has upper and lower ends1a,1band an interior storage cavity CSfor retaining a quantity of lubricant and the lubricant distributor2preferably includes one or more injectors3. The pump10basically comprises a housing12mountable to the upper end la of the container1, a movable valve element14disposed within the housing12, an elongated pumping element16and a pump actuator18. The housing12has a vertically-extending, central bore20, a lubricant outlet passage22extending between the central bore20and an outlet port24fluidly connectable with the lubricant distributor2, and a vent chamber26having an inlet28and an outlet30. A vent inlet passage32extends between the central bore20and the vent chamber inlet28and a vent outlet passage34extends between the vent chamber outlet30and a vent outlet port36fluidly connectable with the container cavity CS. Further, the valve element14is disposed within the vent chamber26and is displaceable along an axis AVbetween first and second positions P1, P2, respectively, as indicated inFIGS.6,7,16and17. In the first position P1, the valve element14obstructs at least one of the chamber inlet28and the chamber outlet30, preferably the inlet28, as shown inFIGS.6and16. In the second position P2of the valve element14, the chamber inlet28is fluidly connected with the chamber outlet30to provide an internal flow path from the central bore20to the vent outlet port36, as depicted inFIGS.7and17. As such, lubricant within the housing12can be vented back into the container1to relieve or release lubricant pressure within the housing12, and thereby within the distributor2, to enable the injector(s)3to reset. Furthermore, the elongated pumping element16is vertically-extending and has upper and lower ends16a,16b, the lower end16bbeing disposeable within the container cavity CSand preferably within a quantity of lubricant disposed within the cavity CS, as best shown inFIG.2The pumping element16is disposed within the central bore20such that an annular flow channel21is defined between the pumping element16and the central bore20, the outlet passage22and the vent inlet passage32each being fluidly connected with the flow channel21so as to receive lubricant within the channel21, as discussed below. Also, the pump actuator18is connected with or disposed within the housing12and is configured to reciprocally linearly displace the pumping element16along a vertical axis AP, and thereby within the quantity of lubricant. As such, the pumping element16drives lubricant from the container cavity CSand into the flow channel21, and thereafter through the outlet passage22and outlet port24and into a delivery line5of the distributor2, or alternatively through the vent inlet passage32to recirculate back to the container cavity CS, as described below. Preferably, the pump housing12includes a monobloc40providing the central bore20, the outlet passage22, the vent chamber26, the vent inlet passage32, and the vent outlet passage34. As used herein, the term “monobloc” is intended to mean that the housing portion40is formed as a single piece or component, as opposed to an assembly of two or more pieces/components, for example formed as a casting, forging, etc. with appropriate machining to form the central bore20and the various passages and ports. More specifically, the monobloc40has upper and lower ends40a,40band at least one and preferably a plurality of side surfaces42. The lower end40bis connectable with the container1, preferably mountable onto a lid or cover4on the upper end1aof the container1, and the upper end40ais configured to support an upper housing portion44for containing and supporting the pump actuator18, as described below. Further, the central bore20extends between and through the monobloc upper and lower ends40a,40b, the outlet port24extends through one side surface42and the vent outlet port36extends through the monobloc lower end40b. However, although the preferably including the monobloc40providing the lubricant outlet passage22and the internal vent chamber26and vent passages32,34, the housing12may alternatively be provided by an assembly of two or more components (structure not shown). Further, the lubricant pump10preferably further comprises a valve actuator50configured to bias the valve element14toward the first position P1, such that lubricant is prevented from venting from the housing12and instead flows out the lubricant outlet passage22to the delivery line5. As such, the housing12preferably further includes an actuator chamber52, which is spaced axially from and connected with the vent chamber26and sized to receive the valve actuator50. Specifically, the actuator chamber52is preferably provided by a circular cylindrical body54attached to or integral with the monobloc40and having a circular cylindrical interior bore55connected with the vent chamber26and defining the chamber52. Referring now toFIGS.2and3, although the present invention is primarily concerned with the structure of the housing12and the internal vent structure thereof, such that a detailed description of the pump actuator components are beyond the scope of the present disclosure, certain structural features are necessary to provide context to the details of the novel pump10. The pumping element16preferably includes a displaceable ram assembly60disposed within a fixed sleeve assembly61. The ram assembly60is generally elongated, extends through the housing central bore20, and has an upper end60aconnected with the pump actuator18and a lower end60bdisposed within the container cavity CS. The sleeve assembly61has an upper end61aconnected with the housing12and a lower end61bdisposed within the container1and is sized diametrically larger than the pumping element16. As such, an annular sleeve channel62is defined between the ram assembly60and the sleeve61, which is fluidly connected with the flow channel21within the housing12. As the ram assembly60reciprocates vertically along the pumping axis AP, the lower end60bof the ram assembly60forces lubricant into the annular sleeve channel62and pressurizes the lubricant, such that the lubricant is displaced upwardly into the housing channel21and thereafter to the lubricant outlet passage22(or to the vent inlet passage32). To reciprocate the ram assembly60of the pumping element16, the pump actuator18preferably includes a motor63and a rotational-to-linear mechanism64, preferably a scotch yoke65, as best shown inFIG.2. The mechanism64is connected with the upper end60aof the ram assembly60and converts rotation of the motor output shaft63a, through a gear train66, to linear displacement of the ram assembly60along the pumping axis AP. The motor63is an electric motor in certain pump constructions shown inFIGS.1-12, or is a fluid motor (i.e., hydraulic or pneumatic) in other pump constructions shown inFIGS.13-17, each pump construction being described below. Although the basic structure is preferably generally as described above, the pumping element16and the pump actuator18may be constructed in any appropriate manner. Referring now toFIGS.4-12, for constructions in which the pump actuator18includes an electric motor63, the valve actuator50is preferably a solenoid70electrically connected with the motor63and includes a linearly displaceable armature or output shaft72attached to the valve element14. The solenoid70is configured to displace the valve element14toward the first position P1, by extension of the solenoid shaft72with respect to the solenoid body74, when the motor63drives the pump actuator18, such that the valve element14obstructs the chamber inlet28or/and the chamber outlet30. Thus, while the electric motor63is driving the pumping element16, the valve element14prevents venting of the lubricant, such that substantially all of the lubricant entering the flow channel21passes through the lubricant outlet passage22and thereafter to the lubricant distributor(s)2. However, when the motor63stops driving the pump actuator18, the solenoid70is disconnected from electric power, causing the solenoid shaft72to retract and displace the valve element14to the second position P2. As such, lubricant within the housing12is vented through the vent inlet passage32, the vent chamber26, the vent outlet passage34and back into the container1. Referring toFIGS.5-12, with the solenoid valve actuator70, the vent chamber26is preferably defined by an inner cylindrical surface27and a radial end surface29, with the chamber inlet28and the chamber outlet30being spaced axially apart and each extending through the cylindrical surface27. Also, the lubricant pump10preferably further comprises a tubular sleeve76disposed within the vent chamber26for receiving a preferred valve element14. The valve element14preferably includes a cylindrical body78having an outer circumferential surface79and an annular channel80extending radially inwardly from the outer surface79so as to define first and second outer surface sections79a,79b, as indicated inFIG.12. At least one of the first and second outer surface sections79a,79bobstruct at least one of the vent chamber inlet28and the vent chamber outlet30, respectively, when the cylindrical body78is located at the valve first position P1. Further, the channel80fluidly connects the chamber inlet28and the chamber outlet30when the valve body78is disposed in the valve element second position P2. Further, the sleeve76has opposing first and second axial ends76a,76b, an outer circumferential surface81A disposed within and against the chamber side surface27and an opposing inner circumferential surface81B defining a central bore82sized to receive the valve cylindrical body78. The sleeve76further has first and second ports84,86extending radially between the outer and inner surfaces81A,81B and being spaced axially apart. The first port84is located to fluidly connect the chamber inlet28with the sleeve bore82and the second port86is located to fluidly connect the chamber outlet30with the bore82. Preferably, the inner circumferential surface81B of the sleeve76is formed having a surface roughness (Ra) of less than twelve microns (12μ), with the surface sections79a,79bof the valve body78being similarly formed or finished, such as by grinding, polishing, etc. As such, friction between the valve body78and the sleeve76is substantially minimized, thereby reducing the pulling force required of the solenoid70to displace the valve element14to the first position P1. As a result, the required size of the solenoid70may be correspondingly minimized. Referring now toFIGS.5-11, the housing12preferably further includes a slotted opening88and the sleeve76has at least one projection90disposable within the slotted opening88to align the first port84with the chamber inlet28and the second port86with the chamber outlet30. That is, the projection(s)90are located on the sleeve76relative to the ports84,86and relative to the slotted opening88such that engagement of the projection(s)90in slotted opening88properly orients the ports84,86with the chamber openings28,30. Preferably, the slotted opening88extends vertically in the chamber radial end surface29and the sleeve76includes two projections90extending axially from the sleeve first axial end76a. However, the opening88and projections90may be otherwise located and formed, for example, an axially-extending slotted opening (not shown) in the chamber inner surface and a single axial projection (not shown) extending radially-outwardly from the sleeve outer surface81A. Furthermore, the sleeve76is preferably sized such that the sleeve outer circumferential surface81A engages the chamber inner circumferential surface27with a location fit, such that the sleeve76is readily removable from the chamber26for reasons discussed below. Therefore, to maintain the sleeve76disposed within the vent chamber26, the lubricant pump10preferably further comprises a retainer92releasably engaged with the sleeve76, preferably against the sleeve second axial end76b. The retainer92is preferably formed as a threaded fastener94extending into a radial surface31about the chamber outer end and having a head95disposable against the second axial end76bof the sleeve76. However, the retainer92may alternatively be formed in any other appropriate manner to releasably retain the sleeve76within the vent chamber26. Referring now toFIGS.13-17, for constructions of the pump10in which the pump actuator18includes a fluid motor63, the valve actuator50preferably includes a piston100connected with the valve element14and disposed within the actuator chamber52. The chamber52provides a piston chamber102fluidly connected with a pressurized fluid supply for the motor63, i.e., hydraulic fluid or compressed air, or directly with the motor63, in either case through a fluid supply hose68(FIG.17), as described below. With this structure, pressurized working fluid is directed into the piston chamber102when the fluid motor63is operating, such that the piston100biases the valve element14toward the first position P1, and thus preventing lubricant flow through the vent chamber26. More specifically, the vent chamber26is preferably defined by a cylindrical inner surface27having inner and outer axial ends27a,27b(FIG.15), respectively, and a radial end surface29at the surface inner end27a. The chamber inlet28extends through the vent chamber end surface29and the chamber outlet30is spaced axially from the inlet28and extends through the cylindrical surface27. The piston chamber102is preferably defined by a cylindrical inner surface103having inner and outer axial ends103a,103b, which is spaced axially and radially outwardly from the vent inner surface27, and an inner end surface104extending radially between the inner end103aof the piston chamber102and the outer axial end27aof the vent inner surface27. As such, the piston chamber102is essentially formed as a counterbore of the vent chamber26. Further, the piston chamber102is enclosed by an endcap105attached to the cylindrical body54and having a central port105aconfigured to receive an end of the fluid supply hose68, such that the hose68provides fluid for operating the piston100, as depicted inFIG.17. Further, as indicated inFIG.13, the valve element14includes a circular cylindrical body106having a first diameter D1and the piston includes a circular cylindrical body108connected with the body106and having a second diameter D2substantially greater than the first diameter D1. The valve element body106has a radial end surface107exposable to fluid in the vent chamber26and the piston body108has a radial end surface109exposable to fluid within the piston chamber102. Preferably, the valve body106and the piston body108are integrally formed as one-piece construction, but may alternatively be formed as two or more connected pieces. With the above structure, when pressure in the vent chamber26and the piston chamber102is generally equal, the valve element14will remain located or disposed at the valve first position P1due to the substantially greater surface area of the piston end surface109in comparison with the surface area of the valve end surface107. However, when the fluid motor63ceases operating, the pressure within the piston chamber102decreases while the pressure in the vent chamber26remains at the maximum fluid pressure generated by the pumping element16. At some point, the pressure within the piston chamber102decreases until fluid pressure on the valve element end surface107exceeds fluid pressure on the piston end surface109by a predetermined magnitude. At this point, the valve element14is biased toward the second position P2, such that the vent chamber inlet28is fluidly connected with the vent chamber outlet30. Thereafter, fluid within the lubricant channel21passes through the vent inlet passage32, the vent chamber26, the vent outlet passage34and back into the container cavity CS. Referring toFIG.18, with either construction, the vent chamber26is preferably configured to receive a plug110to prevent flow between the vent chamber inlet28and the vent chamber outlet30, as depicted for the first pump construction. Thereby, the pump10will not vent to the container1and can be used in applications in which it is desired to pump all of the lubricant from the container1or from another type of container, as opposed to supplying lubricant to a delivery system2that requires periodic resetting of delivery devices (e.g., lubricant injectors3) and thus also venting. The pump10of the present invention has a number of advantages over known lubricant pumps used for delivering grease. Known grease pumps typically include a separate vent valve that is attached to the pump outlet and normally passes grease through to the distributor and injectors, and otherwise directs grease back to the reservoir through a separate hose. The present pump10eliminates the requirement for the external valve and the hose for directing lubricant/grease back to the reservoir. By having the valve element14enclosed within the housing12, the valve element14is protected from dirt and moisture and the potential for impact damage as would be the case with an externally mounted valve. Further, the valve element14may be readily removed from the vent chamber16and replaced with the plug110to convert the pump10for non-venting applications. Representative, non-limiting examples of the present invention were described above in detail with reference to the attached drawings. This detailed description is merely intended to teach a person of skill in the art further details for practicing preferred aspects of the present teachings and is not intended to limit the scope of the invention. Moreover, combinations of features and steps disclosed in the above detailed description may not be necessary to practice the invention in the broadest sense, and are instead taught merely to particularly describe representative examples of the invention. Furthermore, various features of the above-described representative examples, as well as the various independent and dependent claims below, may be combined in ways that are not specifically and explicitly enumerated in order to provide additional useful embodiments of the present teachings. All features disclosed in the description and/or the claims are intended to be disclosed separately and independently from each other for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter, independent of the compositions of the features in the embodiments and/or the claims. In addition, all value ranges or indications of groups of entities are intended to disclose every possible intermediate value or intermediate entity for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter. The invention is not restricted to the above-described embodiments, and may be varied within the scope of the following claims. | 20,219 |
11859763 | DESCRIPTION OF THE EMBODIMENTS The following describes a pouch container, a grease gun, and a connecting member according to an embodiment of the invention with reference to the accompanying drawings. The pouch container (container) according to the embodiment is filled with a lubricant composition (grease) injected into, for example, an eccentric oscillating-type planetary gear reducer. The lubricant composition (grease) according to the embodiment is defined as follows.1. A lubricant composition for an eccentric oscillating-type planetary gear reducer includes the following components (a) to (c):(a) a base oil containing a synthetic oil,(b) hydrocarbon wax, and(c) a calcium salt of at least one type selected from the group consisting of calcium salt of petroleum sulfonic acid, calcium salt of alkylaromatic sulfonic acid, calcium salt of oxidized wax, overbased calcium salt of petroleum sulfonic acid, overbased calcium salt of alkylaromatic sulfonic acid, and overbased calcium salt of oxidized wax.2. The lubricant composition for a reducer described in the above item 1, wherein the hydrocarbon wax (b) is at least one selected from the group consisting of a polyethylene wax and a polypropylene wax.3. The lubricant composition for a reducer described in the above item 1 or 2, wherein the hydrocarbon wax (b) is contained in an amount of 0.1 to 20 mass % of the total mass of the composition.4. The lubricant composition for a reducer described in any one of the above items 1 to 3, wherein the synthetic oil in the base oil (a) is a synthetic hydrocarbon oil.5. The lubricant composition for a reducer described in any one of the above items 1 to 4, wherein the base oil (a) has a kinematic viscosity of 20 to 300 mm2/s at 40° C.6. The lubricant composition for a reducer described in any one of the above items 1 to 5, wherein the calcium salt (c) includes the calcium salt of alkyl aromatic sulfonic acid and the overbasic calcium salt of alkyl aromatic sulfonic acid. The base oil (a) used in the embodiments includes a synthetic oil as an essential component. However another base oil component such as a mineral oil may also be contained in the base oil. Any synthetic oils generally used in conventional lubricant compositions, for example, a synthetic hydrocarbon oil, an ester oil, phenyl ether, polyglycol and the like are usable as the synthetic oil. One kind of synthetic oil may be used alone, or two or more kinds of synthetic oils may be used in combination. Among others, a synthetic hydrocarbon oil is preferably used as the synthetic oil. Specifically, one or more types of α-olefins that are mixed and polymerized can be used as the synthetic hydrocarbon oil. Examples of the α-olefin include α-olefins produced using ingredients such as ethylene, propylene, butene, and the derivatives thereof. Preferably, α-olefins having 6 to 18 carbon atoms (e.g., 1-decene, 1-dodecene and the like) can be used. Most preferably, poly α-olefin (PAO), which is an oligomer of 1-decene or 1-dodecene, is used as the synthetic hydrocarbon oil. The base oil may preferably contains a synthetic hydrocarbon oil (for example, PAO), and more preferably, a combination of the synthetic hydrocarbon oil (for example, PAO) and a mineral oil may be used as the base oil. The proportion of the synthetic oil (for example, the synthetic hydrocarbon oil such as PAO) in the base oil may preferably be in the range of 10 to 100%, and more preferably 10 to 50 mass % (for example, 10 to 20 mass %). When the proportion of the synthetic oil is lower than 10 mass %, the input torque may increase at low temperatures. The proportion of the base oil in the lubricant composition is preferably 50 to 99 mass %, more preferably 70 to 95 mass %. The base oil used in the embodiment may have a kinematic viscosity at 40° C. of 20 to 300 mm2/s, preferably 30 to 220 mm2/s (for example, 40 to 200 mm2/s), and more preferably 50 to 150 mm2/s (for example, 60 to 100 mm2/s). When the kinematic viscosity of the base oil is lower than 20 mm2/s, the product life may be short under high temperatures. Whereas when the kinematic viscosity is higher than 300 mm2/s, some failure may occur at low temperatures at the start of the operation. Note that the kinematic viscosity of the base oil at 40° C. is determined in accordance with Japanese Industrial Standards JIS K 2283. <Hydrocarbon Wax> The hydrocarbon wax (b) used in the embodiment is not particularly limited, but may comprise at least one chemical compound selected from the group consisting of polyolefin wax (such as a polyethylene wax, an oxidized polyethylene wax, a polypropylene wax, an ethylene-propylene copolymer wax and the like), montan wax, and amide wax. In particular, the polyolefin wax is preferred among the above specific examples. The weight-average molecular weight of the polyolefin wax is not particularly limited but may be in the range of about 1,000 to 20,000. The melting viscosity of the polyolefin wax is not particularly limited but may be in the range of 25,000 to 30,000 mPa-s at 140° C., or in the range of 9,000 to 10,000 mPa-s at 170° C. The density of the polyolefin wax is not particularly limited either. Any of a high-density polyolefin wax (with a density of 0.96 g/cm3or more, for example), a medium-density polyolefin wax (with a density of ranging from 0.94 to 0.95 g/cm3, for example) and a low-density polyolefin wax (with a density of 0.93 g/cm3or less, for example) can be used. The high-density polyolefin wax is characterized by high melting point, high softening point, high crystallinity, and high degree of hardness; while the low-density polyolefin wax is characterized by low melting point, low softening point, and soft. In terms of heat resistance, the polyolefin wax preferably has a dropping point of 100° C. or higher, more preferably 110° C. or higher. In terms of solubility in the base oil, the dropping point of the polyolefin wax is preferably 150° C. or lower, more preferably 135° C. or lower. The acid value of the polyolefin wax is preferably in the range of 0 to 10 mgKOH/g, and more preferably 0 to 5 mgKOH/g. When the acid value is within the above-mentioned range, oxidative deterioration of the lubricant composition by acid components can be reduced. Among various polyolefin waxes, at least one selected from the group consisting of polyethylene wax, polypropylene wax, and ethylene-propylene copolymer wax is preferable, and at least one selected from the group consisting of polyethylene wax and polypropylene wax is more preferable. Specific examples of commercially available polyethylene wax include Licowax PE520, Licowax PE190 and Licowax PE130 manufactured by Clariant Japan K.K.; and specific examples of commercially available polypropylene wax include Licosen PP 7502, Licosen PP 3602 and Ceridust 6050M manufactured by Clariant Japan K.K., and Hi-WAX NP105 and Hi-WAX NP500 manufactured by Mitsui Chemicals, Inc. The most preferable hydrocarbon wax is polypropylene wax. The proportion of the hydrocarbon wax in the lubricant composition may be in the range of 0.1 to 20 mass %, preferably 0.1 to 10 mass %, more preferably 0.5 to 7 mass %, and most preferably 1 to 5 mass %. <Calcium Salt> The calcium salt (c) used in the embodiment is at least one selected from the group consisting of calcium salt of petroleum sulfonic acid, calcium salt of alkylaromatic sulfonic acid, calcium salt of oxidized wax, overbased calcium salt of petroleum sulfonic acid, overbased calcium salt of alkylaromatic sulfonic acid, and overbased calcium salt of oxidized wax. The term “overbasic calcium salt of X” herein means a calcium salt of X having a base number of 200 mgKOH/g or more when determined in accordance with JIS K 2501. When simply expressed as “calcium salt of X,” the calcium salt of X does not indicate an overbasic salt, but a neutral or basic calcium salt, that is, a calcium salt of X having a basic number of less than 200 mgKOH/g determined in accordance with JIS K 2501. Particularly, at least one selected from the group consisting of calcium salt of alkyl aromatic sulfonic acid and overbasic calcium salt of alkyl aromatic sulfonic acid is preferably used as the calcium salt. It is more preferable to a combination of calcium salt of alkyl aromatic sulfonic acid and overbasic calcium salt of alkyl aromatic sulfonic acid. In the above-mentioned combination, the proportion of the overbasic calcium salt of alkyl aromatic sulfonic acid may be in the range of 50 to 99 mass %, preferably 60 to 90 mass %, and more preferably 65 to 80 mass %. Usage of the combination can further improve the durability at high temperatures. The proportion of the calcium salt in the lubricant composition may preferably be 0.1 to 20 mass %, more preferably 0.5 to 10 mass % (for example, 1 to 5 mass %). When the proportion of the calcium salt in the lubricant composition is less than 0.1 mass %, the product life may be short under high temperatures. Whereas when the proportion of the calcium salt is more than 20 mass %, the effect commensurate with the added amount cannot be obtained. <Thickener> The lubricant composition in the embodiment may further includes a thickener (d). Any kind of thickener can be used. For example, soap-based thickeners such as lithium soaps and lithium complex soaps, urea-based thickeners such as diurea, inorganic thickeners such as organoclay and silica, organic thickeners such as PTFE, and the like are usable as the thickener. In particular, the lithium soap type thickeners and the urea type thickeners are preferable, and the former is more preferred. The proportion of the thickener in the lubricant composition is preferably 0 to 20 mass % (for example, 1 to 15 mass %), and more preferably 0.5 to 10 mass % (for example, 0.5 to 3 mass %). When the proportion of the thickener in the lubricant composition is less than 0.5 mass %, a sufficient thickening effect cannot be obtained. Whereas when the proportion of the thickener exceeds 20 mass %, the resultant lubricant composition may become too hard to penetrate into a portion to be lubricated, resulting in insufficient lubrication. When the lubricant composition includes a thickener, the worked penetration of the composition is preferably in the range of 300 to 450 (for example, 350 to 410), and more preferably 395 to 425. The worked penetration herein used means a cone penetration measured immediately after the plunger of a given test apparatus is stroked 60 times while the sample is maintained in the apparatus, as defined in JIS K 2220. The lubricant composition of the embodiment may further includes other optional additives when necessary. The optional additives include a rust inhibitor or detergent-dispersant other than the calcium salt (c), an extreme pressure agent, an antioxidant, a metal corrosion inhibitor, an oiliness improver, an antiwear agent, a solid lubricant and the like. In particular, the extreme pressure agent (e) is preferably used. <Extreme Pressure Agent> The extreme pressure agent (e) that can be optionally used in the embodiment is not particularly limited. For example, at least one selected from the group consisting of thiophosphates and thiocarbamates can be used as the extreme pressure agent. The thiophosphates include dithiophosphates, such as a zinc salt or molybdenum salt of dithiophosphoric acid (for example, dialkyldithiophosphoric acid). The thiocarbamates include dithiocarbamates, such as a zinc salt or molybdenum salt of dithiocathamic acid (for example, dialkyldithiocarbamic acid). The preferable extreme pressure agent is at least one selected from the group consisting of molybdenum dithiocarbamate and zinc dithiophosphate. Use of molybdenum dithiocarbamate (in particular, molybdenum dialkyldithiocarbatnate) in combination with zinc dithiophosphate (in particular, zinc dialkyldithiophosphate is more preferable. In the above-mentioned combination, the proportion of the molybdenum dithiocarbamate may preferably be 50 to 99 mass %, and more preferably 55 to 90 mass %. The fraction of the extreme pressure agent in the lubricant composition may be 0 to 1.5 mass %, and more preferably 0.5 to 1 mass %. When the fraction of the extreme pressure agent in the lubricant composition exceeds 1.5 mass %, precipitation of the additive may cause vibration or other problems of the speed reducer more frequently. As one preferable embodiment, provided is a lubricant composition that can be used for an eccentrically oscillating speed reducer of planetary gear type. The lubricant composition includes the following components (a) to (e):(a) a base oil comprising a synthetic hydrocarbon oil;(b) at least one selected from the group consisting of polyethylene wax and polypropylene wax;(c) at least one calcium salt selected from the group consisting of a calcium salt of alkyl aromatic sulfonic acid and an overbasic calcium salt of alkyl aromatic sulfonic acid;(d) a lithium-soap based thickener, and(e) at least one selected from the group consisting of molybdenum dithiocarbamate and zinc dithiophosphate. The lubricant composition of the invention can be used for an eccentrically oscillating speed reducer of planetary gear type. Especially, in light of the advantages of excellent durability under high temperatures and minimum variation of the output torque, the lubricant composition is preferably used for an eccentrically oscillating speed reducer of planetary gear type used in joints of robots. One of the typical eccentrically oscillating speed reducers of planetary gear type has a first-stage speed reduction mechanism and a second-stage speed reduction mechanism. The first-stage speed reduction mechanism is designed to reduce the rotational speed of a motor and transmit the reduced speed to the second-stage speed reduction mechanism. The second-stage speed reduction mechanism includes an inner gear, an outer gear meshing with the inner gear, a crankshaft engaged with the outer gear to allow the outer gear to set up an eccentrically oscillating motion with respect to the inner gear, and a support which supports the crankshaft rotatably, with the output being taken out from the inner gear or the support. A pouch container according to the embodiment will now be described with reference to the drawings. FIG.1is a perspective view of the pouch container according to the embodiment, andFIG.2is a schematic enlarged sectional view of a region near a spout base body of the pouch container according to the embodiment. The pouch container is indicated by reference numeral1in the drawings. The pouch container (container)1in the embodiment is filled with a lubricant composition (grease) injected into, for example, an eccentric oscillating-type planetary gear reducer. The pouch container (container)1according to the embodiment can be used as a lubricant feeder. As shown inFIG.1, the pouch container1in the embodiment has a ship bottom shape (boat shape). A film1chaving an irregular hexagon is arranged at one ends of two substantially rectangular films (film material)1aand1b, and the entire circumference of the film1cis fused to the films1aand1b. Further, both side edges of the films1aand1bare fused to each other, and after filling the content, the other ends of the films1aand1bare fused to seal the container. In this way, the pouch container1in the embodiment is formed. As shown inFIG.2, in the embodiment, the films1a,1band1cforming the pouch (storage member) of the pouch container1have a gas barrier property. An aluminum foil1dforming the pouch (storage member) of the pouch container1serves as a gas barrier layer and a water vapor barrier layer. A stretched polyamide resin layer1eis laminated as a base film on one surface of the aluminum foil1d, and a low density polyethylene film layer if or an unstretched polypropylene film layer is laminated on the other surface of the aluminum foil1d. The stretched polyamide resin layer1e, which is the base film, is fused such that it is situated on the outermost surface of the pouch container1. As shown inFIG.1, the film1cof the pouch container1becomes substantially flat when the pouch container1is filled with the content. The spout1gis attached and fixed to a flat portion of the film1c. As shown inFIG.2, the spout1gis formed of a spout base body1h. The spout base body1hincludes a cylindrical portion1jand a flange portion1kformed on an end of the cylindrical portion1j. The flange portion1kis attached and fixed to the film1cof the pouch container1with a hot melt layer1m. A male thread in is formed on an outer peripheral surface of the cylindrical portion1jof the spout base body1h. A cap2may be provided for the spout1g. The cap2has a bottomed cylindrical body with an opening formed on its butt side, and a tip end of the cylindrical body is sealed when unused. The cap is opened when the content is pushed out as required. Further, on an inner peripheral surface of the butt portion of the cap2, a female thread to be engaged with the male thread in is formed. An open facilitating portion1pmay be formed in a portion of the film1cof the pouch situated on the inner side of the spout base body1h. The open facilitating portion1phas a structure in which only the stretched polyamide resin layer1e, which is the outermost base film of the pouch container1, is omitted. To make a hole in the pouch container1, the tip of a suitable stick or the like is inserted inside the spout base body1hfrom the opening of the cylindrical portion1jto pierce the open facilitating portion1p. At this time, since the stretched polyamide resin layer1e, which is a high-strength base film, is not provided in the open facilitating portion1p, it is possible to easily pierce and make a hole in the pouch even by using a stick with a round tip or the like. Furthermore, features described below can also be adopted as necessary. For example, (1) a structure in which a circular cut is made by a cutting blade in the stretched polyamide resin layer1ewhich is the base film; (2) a large number of small pores are formed in the outermost stretched polyamide resin layer1ewhich is also the base film; and/or (3) a structure in which an X-shaped cut is made in the entire film1c, and the formed cut is covered with aluminum foil or paper. Alternatively, the pouch container1may be composed of a single-layer film of a stretched polyamide resin or the like. In this case, a thinned portion may be formed in the single-layer film to provide the open facilitating portion. Further, the cut made by a cutting blade may have a X shape or the like instead of the circular shape as mentioned above. In the case where the pouch is formed of a single layer film, an X-shaped cut may be made therein and the cut may be covered with aluminum foil or paper. In the case where the pouch container is made of a multi-layer film, the kinds of films to be laminated, the laminated structure and the like are not limited to the above described combination. For example, (1) a laminated structure without aluminum foil, (2) a laminated structure in which a polyamide resin layer is also disposed on the inner surface of the aluminum foil in addition to the above-mentioned laminated structure, and the like may also be adopted. As for the above-mentioned (1) laminated structure having no aluminum foil, a pierce facilitating portion (open facilitating portion) may be formed by forming notches or cuts only in the base film or forming a large number of small pores similarly to the above-mentioned laminated structure. In addition, to form the open facilitating portion in the structure (2) in which the polyamide resin layer is also provided on the inner side of the aluminum foil, the outermost stretched polyamide resin layer1ewhich is the base film, the aluminum foil1d, and the aluminum foil may be omitted in the region where the open facilitating portion is provided. Besides, to form the open facilitating portion in the structure (2) in which the polyamide resin layer is also provided on the inner side of the aluminum foil, a notch is formed only in the outermost stretched polyamide resin layer1e. Alternatively, in the structure (2) in which the polyamide resin layer is also provided on the inner side of the aluminum foil, the open facilitating portion may be formed by forming a notch or cut in the base film or by forming a large number of small pores similarly to the above-mentioned laminated structure. When adopting the open facilitating portion by a large number of small pores, the large number of small pores may be formed only in the outermost stretched polyamide resin layer1e. As the material for the base film, in addition to the stretched polyamide resin, known materials such as stretched polypropylene and polyethylene that are used for the same kind of pouch can be adopted. In the above pouch container1, the constituent films1a,1band1chave the same film structure, and the open facilitating portion1pis formed at the portion of the film1cto which the spout1gis attached inside the spout1g. The film1cmay have a structure where the film1smore easily pierced than the films1aand1b. Specifically, to form the above-described pouch, the first film1aand the second film1bare overlapped with each other, and the third film1cis arranged at one end portions of the first film1a. The entire circumference of the third film1cis bonded or fused to the first film1aor the second film1b. Subsequently both side edges of the first film1aand the second film1bare bonded or fused to each other, and the other ends of the films1aand1bare bonded or fused after the pouch is filled with the content. In the pouch container1such as a pouch having a ship bottom shape (boat shape) formed in the above described way, when the spout1gis attached to the third film1cforming one end portion of the pouch container1, the structure of the third film1cmay have the structure easier to be pierced as compared with the first and second films1aand1b. For example, the first and second films1aand1bmay be composed of a polyamide resin layer (15 μm; thickness, hereinafter the same))/aluminum foil (9 μm)/a polyamide resin layer (25 μm)/a low density polyethylene resin layer (70 μm) stated from the outer surface side of the pouch container1(outermost surface of the pouch container1). The third film1cmay be composed of a polyamide resin layer (15 μm)/aluminum foil (9 μm)/a low density polyethylene layer (30 μm) stated from the outer surface side of the pouch container1(outermost surface of the pouch container1). In this way, the strength of the pouch container1is ensured since the strength of the first film1aand the second film1bforming the body of the pouch is enhanced. Whereas the third film1cthat forms the end portion of the pouch container1and to which the spout1gis attached is configured such that it is easily pierced with a stick or the like. The third film1chas a lower strength than the first and second films1aand1b. However, when the third film1cis inserted into an extruder and sealant or the like is pushed out from the container through the spout1gas described above, the third film1ccontacts the inner end surface of the extruder and the pushing force is received by the inner end surface of the extruder. Therefore the third film1cis not damaged during extrusion. The joint strength between the first film1aand the second film1bcan be ensured by increasing the thickness of a sealant layer in the first and second films1aand1b. The pouch container1in the embodiment may be formed in any shape as long as the content can be completely extruded therefrom using an extruder or the like. Specifically, as for the shape of the pouch container1according to the embodiment, a tubular pouch, a bag-like pouch, a ship bottom shaped pouch (boat shaped pouch) or a standing pouch is preferable in terms of handling and workability of the container. A grease gun and a connecting member according to the embodiment will now be described with reference to the drawings. FIG.3is an exploded perspective view of a grease gun according to the embodiment.FIG.4is a schematic enlarged sectional view of a tip portion of the grease gun according to the embodiment. In the drawings, the grease gun is indicated by reference numeral10. The grease gun10in the embodiment serves as a lubricant feeder, and is used, when injecting the lubricant composition (grease) into, for example, an eccentric oscillating-type planetary gear reducer. As shown inFIG.3, the grease gun10in the embodiment includes a cylinder (cylindrical member)11which is a main body of the grease gun and whose both ends are opened. The grease gun10in the embodiment further includes a lid12having a through hole12aformed therein, a connecting member20that is to be attached to the spout1gof the pouch container1inside the lid12, and a piston14disposed slidably inside the cylinder11, and a trigger mechanism (pusher)13that supports and moves the piston14relative to the cylinder11. The cylinder11has a substantially cylindrical shape and accommodates the pouch container1containing a lubricant composition (grease) therein. The piston14is able to push the pouch container1inside the cylinder11, and a rod that is moved by a trigger mechanism (push member)13in the axial direction is connected to the piston. Alternatively, a guide movable relative to the rod of the piston14may be fitted to the piston14. As shown inFIGS.3and4, a threaded portion12bis formed on the inner side of the lid12that contacts with an outer peripheral surface of the end portion of the cylinder11, thereby the lid12can be fastened to the cylinder11. A threaded portion11bcorresponding to the threaded portion12bof the lid12is formed on the outer peripheral surface of the end portion of the cylinder11. The trigger mechanism (push member)13has a trigger13afor moving the piston14. The trigger mechanism (push member)13also serves as the support member13band closes the other end of the cylinder11. The push member is manually operated with the trigger. Alternatively the push member may be operated hydraulically, electrically or pneumatically as long as it can press the pouch container1. FIG.5is a sectional view of a connecting member according to the embodiment.FIG.6is a cross-sectional view along the line VI-VI inFIG.5. The connecting member20has a tip portion21inserted in the through hole12aof the lid12, and a flange portion22that is placed inside the lid12and abuts on a circumferential edge of the through hole12a. The connecting member20is configured to be detachable from the cylinder11. A through hole23is formed in the connecting member20along an axis line extending from a tip portion21to the flange portion22. The through hole23is formed coaxially with the tip portion21and the flange portion22. The tip portion21is formed in a columnar shape. When the connecting member20is set in the cylinder11, the tip portion21passes the through hole12aof the lid12and partly projects from the lid12. An end of the tip portion21opposite to the end protruding from the lid12is connected to the inside of the cylinder11. The flange portion22is formed by enlarging the outer circumference of the end portion of the tip portion21connected to the inside of the cylinder11. The outer diameter of the flange portion22is substantially the same as the inner diameter of the cylinder11or slightly smaller than the inner diameter of the cylinder11. The through hole23is a hole formed in the tip portion21and penetrates the tip portion in the direction from the end portion of the tip portion21protruding from the lid12(the end portion of the tip portion21) toward the inside of the cylinder11. The opening of the through hole23has a diameter that allows the cylindrical portion1jof the spout1gof the pouch container1to be inserted therethrough and attached. A threaded portion23ais formed on the inner peripheral surface of the portion of the through hole23that opens toward the inside of the cylinder11. The threaded portion23acorresponds to the male thread in formed on the outer peripheral surface of the cylindrical portion1jof the spout1gof the pouch container1. That is, the pitch, the nominal diameter, the root diameter, the effective diameter, the angle of the screw thread, etc. are set such that the threaded portion23aand the male screw in are engaged to each other to seal the spout1gand the through hole23. It should be noted thatFIG.4also shows the spout1gso that the correspondence between the threaded portion23aand the male screw in can be seen. Any fastening structures other than threads may be used. The opening of the through hole23situated at the end of the tip portion21has a diameter that allows an end portion33of a grease gun hose (connecting tube)30to be inserted and attached, which will be later described. In the through hole23, a threaded portion23bis formed on the inner peripheral surface of the opening at the end of the tip portion21. The threaded portion23bcorresponds to a male screw33nformed on the grease gun hose30. That is, the pitch, the nominal diameter, the root diameter, the effective diameter, the angle of the screw thread, etc. are set such that the threaded portion23band the male screw33nare engaged to each other to seal the grease gun hose30and the through hole23. Either one of the threaded portion23aand the threaded portion23bmay be a reversed thread. In this embodiment, the threaded portion23amay be a left-hand thread. In this way, when the male thread33nof the end portion33of the grease gun hose30and the male thread in of the spout1gof the pouch container1are fastened and connected to the connecting member20, it is possible to prevent the threaded portion from coming off from the other threaded portion. Alternatively, both the threaded portion23aand the threaded portion23bmay not be reversed threads. The connecting member20in which the through hole23is formed is a member different from the cylindrical portion1jof the spout1gof the pouch container1. The through hole23has the opening connected to the inside of the cylinder11and the opening provided at the end of the tip portion21. The connecting member20in which the through hole23is formed connects the cylindrical portion1jof the spout1gof the pouch container1and the end portion33of the grease gun hose30. Thus, the portion forming the opening connected to the inside of the cylinder11and the portion forming the opening provided at the end of the tip portion21have different diameters from each other. The portion forming the opening connected to the inside of the cylinder11is connected to the cylindrical portion1jof the spout1gof the pouch container1. The portion forming the opening provided at the end of the tip portion21is connected to the end portion33of the grease gun hose30. Accordingly the diameter of the through hole23changes in the axial direction of the connecting member20. Specifically, a stepped portion23cis formed that reduces the diameter from the opening connected to the inside of the cylinder11to the opening provided at the end of the tip portion21. Alternatively it is also possible to form a diameter-reduced portion whose inner surface is inclined along the axial direction without forming the step portion23c. A surface22cof the flange portion22that faces the outside of the tip portion21in the axial direction (facing the end of the tip portion21) contacts a surface12c. The surface12cof the through hole12ain the lid12faces the inside of the cylinder11. In this manner, the surface22cof the flange portion22contacts the surface12cof the lid body12. The connecting member20can be set in the lid body12by inserting the tip portion21through the through hole12a. A stepped portion21dis provided on the outer peripheral surface of the tip portion21. The outer edge of the tip portion21is smaller in diameter than the outer edge of the surface22c. In the step portion21d, a flat portion21eis formed at a position abutting the through hole12aof the lid12. Two flat portions21eare provided symmetrically with respect to the axis of the connecting member20. The flat portion21eis disposed in parallel with the axis of the connecting member20. The two flat portions21eare formed to be parallel to each other. The flat portion21eis formed such that a part of the tip portion21corresponding to the flat portion21eis reduced in diameter relative to a tip end part of the tip portion21situated closer to the tip end than the flat portion21e. The length of the flat portion21ein the direction along the axis of the connecting member20is set such that the flat portion21ecan be held by a jig. On the inner circumferential surface of the through hole12aof the lid12, a flat portion12ecorresponding to the flat portion21eis provided. Two flat portions12eare formed at the symmetrical positions with respect to the axis of the through hole12a. The flat portions12eare provided parallel to the axis of the through hole12a. The two flat portions12eare disposed parallel to each other. The flat portion12eis formed such that the corresponding portion of the flat portion12eis reduced in diameter relative to the inner circumference of the through hole12a. FIG.7schematically illustrates the grease gun being used according to the embodiment. When the grease gun10in the embodiment is used, the grease gun hose30is used as shown inFIG.7. A lubricant composition (grease) is filled through the grease gun hose30. Thus, the grease gun hose30has an end portion31that is to be connected to an inlet of an eccentric oscillating-type planetary gear speed reducer RV and an end portion33that is to be connected to the spout1gof the pouch container1via the connecting member20. The end portion31has a shape connectible to the inlet of the reducer RV to supply the lubricant composition (grease) to the reducer RV, for example, the end portion31can be a grease nipple or the like. The shape of the end portion31is not particularly limited as long as it corresponds to the inlet of the speed reducer RV. A male thread33nis formed on the end portion33. The male screw33ncorresponds to the threaded portion23bformed on the inner circumferential surface of the opening of the through hole23at the end of the tip portion21that protrudes from the lid12. The grease gun hose30is formed such that its inner diameter and length have predetermined dimensions. Specifically, the dimensions of the grease gun hose are determined depending on parameters of the grease gun10such as a pumping pressure such that the condition of the grease to be injected into the reducer RV satisfies a predetermined condition. In particular, the relational expression of the pumpability is expressed as follows. η=KPπD4/(Lν/t) η: Apparent viscosity (depending on the worked penetration of the grease, the kinematic viscosity of the base oil, and the proportion of the base oil) P: Pumping pressure D: Pipe inner diameter L: Pipe length ν/t: Flow rate K: constant When using the grease gun10, the lid12is removed from the cylinder11. The spout1gof the pouch container1serving as a cartridge is connected to the inner opening of the through hole23in the connecting member20. At this time, the male thread in and the threaded portion23aare engaged to fasten and seal. At this time, the tip portion21of the connecting member20may be inserted in the through hole12aof the lid12, or the connecting member20may be separated from the lid12. Subsequently, the connecting member20to which the spout1gof the pouch container1has been connected is brought into a state in which the tip portion21penetrates the lid12in the through hole12a. Alternatively the connecting member may be in advance in the state in which the tip portion21penetrates the lid12in the through hole12a. Subsequently, the spout1gof the pouch container1is inserted into the cylinder11such that the spout1gfaces the threaded portion23aof the connection member20which penetrates the lid12. Then, the male thread1non the outer peripheral surface of the cylindrical portion1jof the spout1gand the threaded portion23aare fastened. The pouch container1serves as the cartridge. The lid12is attached to the tip of the cylinder11by engaging the threaded portion11bof the cylinder11with the threaded portion12bof the lid12to seal the inside of the cylinder11. At this time, the surface22cof the flange portion22and the surface12cof the lid12contact each other, and the tip portion21is passed through in the through hole12a. In this way, the connection member20is set in a predetermined position of the lid body12. In this state, the pouch container1is opened by opening the open facilitating portion1pof the spout1g. At the same time, the end portion33of the grease gun hose30is connected to the opening of the through hole23of the connecting member20that partly projects from the lid12. At this time, the threaded portion23band the male thread33nare fastened to each other. In this way, the grease gun hose30and the through hole23are sealed. Further, the end portion31of the grease gun hose30is connected to the inlet of the eccentric oscillating-type planetary gear reducer RV. In this state, by operating the trigger mechanism (push member)13, the piston14is moved to approach the lid12. The piston14presses the bottom of the pouch container1to push out the lubricant composition (grease) filled in the pouch container on predetermined conditions. The lubricant composition (grease) flowing through the grease gun hose30is injected into the speed reducer RV from the inlet at a predetermined flow rate and pressure. The above steps may be performed in a different order from the order described above. With the grease gun10according to the embodiment, it is possible to replace the grease filled in the speed reducer RV without leak of the lubricant composition (grease) from the connecting member20and by pressing out the grease from the grease gun10at a predetermined flow rate and pressure. With the grease gun10according to the embodiment, it is possible to improve the product life of the speed reducer RV at high temperatures and prevent an increase in input torque at low temperatures. Further, with the grease gun10according to the embodiment, it is possible to prevent seeping of the lubricant composition that can increase the starting efficiency of the speed reducer RV, and it is possible to divide the lubricant composition into small packages. Therefore, by using the pouch container1that can easily and inexpensively store the lubricant composition (grease) for a long period of time, the grease gun10according to the embodiment is able to easily perform injection of the grease into the speed reducer RV. When the grease filled in the speed reducer RV is replaced, the grease gun10can be easily connected to the speed reducer RV without transferring the grease to another container. Consequently it is possible to prevent leakage of the lubricant composition (grease) from the connecting member. As discussed above, with the grease gun10according to the embodiment, the process of the connecting work and the injection work can be simplified, and the work time of replacing the grease in the speed reducer can be reduced. The conditions of pumping the lubricant composition (grease) in this embodiment are as follows: the grip force for the trigger13aof the grease gun10is 50 gfk, the lever ratio is 1:12, and the inner diameter is 53 mm; the pumping pressure with the grease gun hose is30: 3 MPa or less; the inner diameter of the grease gun hose30is 2.5-20 mm; the length of the grease gun hose30is 1000 mm or less; the delivery flow rate is 1 to 7 cm3/s; the worked penetration of the grease is 300-450; the kinematic viscosity of the grease base oil is 20 to 150 mm2/s (40° C.); and the proportion of the base oil in the grease: 50 to 99% by weight. | 39,906 |
11859764 | DETAILED DESCRIPTION Reference will now be made in detail to specific implementations. Examples of these implementations are illustrated in the accompanying drawings. It should be noted that these examples are described for illustrative purposes and are not intended to limit the scope of this disclosure. Rather, alternatives, modifications, and equivalents of the described implementations are included within the scope of this disclosure as defined by the appended claims. In addition, specific details may be provided in order to promote a thorough understanding of the described implementations. Some implementations within the scope of this disclosure may be practiced without some or all of these details. Further, well known features may not have been described in detail for the sake of clarity. The present disclosure describes various devices, systems, and techniques relating to steam trap monitoring, including battery-less steam trap monitors that run on power harvested from their environments, systems for acquiring steam trap monitor data for the traps in a facility or across multiple facilities, and techniques for processing steam trap monitor data to reliably determine the status of individual steam traps and potentially other system parameters. It should be noted that the described examples may be used in various combinations. It should also be noted that at least some of the examples described herein may be implemented independently of the others. For example, the techniques described herein for processing steam trap monitor data may be employed to process data captured using any of a wide variety of monitors including, but not limited to, the monitors described herein. Similarly, the steam trap monitors described herein may be used with any of a wide variety of monitoring systems and data processing techniques including, but not limited to, the systems and techniques described herein. FIG.1depicts a steam trap monitoring system100in which multiple steam traps102(potentially hundreds or even thousands) are deployed throughout a facility that employs a steam system. The details of the steam system are not shown for reasons of clarity. In addition, the steam traps inFIG.1are depicted as conventional inverted-bucket-type steam traps. However, it should be noted that this is merely one example of the types of steam traps that may be monitored as described herein. That is, the systems, monitors, and techniques described herein may be used with any of the four basic types of steam traps, e.g., mechanical traps, temperature traps, thermodynamic traps, and Venturi nozzle traps. Each steam trap102has an associated steam trap monitor (STM)104mounted on or near the steam trap. STMs104generate various types of sensor data relating to the associated steam trap102and its adjacent piping. STMs104transmit the sensor data to control nodes106that, in turn, transmit the sensor data to an STM data service108via network110. As will be appreciated, the number of STMs104and control nodes106will vary depending on the facility. STM service108may conform to any of a wide variety of architectures such as, for example, a services platform deployed at one or more co-locations, each implemented with one or more servers112. STM service108may also be partially or entirely implemented using cloud-based computing resources. Network110represents any subset or combination of a wide variety of network environments including, for example, TCP/UDP over IP-based networks, unicast/multicast/broadcast networks, telecommunications networks, wireless networks, satellite networks, cable networks, public networks, private networks, wide area networks, local area networks, the Internet, the World Wide Web, intranets, extranets, and so on. At least some of the examples described herein contemplate implementations based on computing models that enable ubiquitous, convenient, on-demand network access to a pool of computing resources (e.g., cloud-based networks, servers, storage, applications, and services). As will be understood, such computing resources may be integrated with and/or under the control of the same entity controlling STM data service108. Alternatively, such resources may be independent of service108, e.g., on a platform under control of a separate provider of computing resources with which service108connects to consume computing resources as needed, e.g., a cloud-computing platform or service. It should also be noted that, despite any references to particular computing paradigms and software tools herein, the computer program instructions on which various implementations are based may correspond to any of a wide variety of programming languages, software tools and data formats, may be stored in any type of non-transitory computer-readable storage media or memory device(s), and may be executed according to a variety of computing models including, for example, a client/server model, a peer-to-peer model, on a stand-alone computing device, or according to a distributed computing model in which various functionalities may be effected or employed at different locations. STMs104may communicate with control nodes106using any of a wide variety of wired and wireless protocols and technologies. According to some implementations, control nodes106and STMs104communicate using a proprietary low-power communication protocol known as Evernet™ provided by Everactive, Inc., of Santa Clara, California Examples of such protocols and associated circuitry suitable for use with such implementations are described in U.S. Pat. Nos. 9,020,456 and 9,413,403, and U.S. Patent Publications No. 2014/0269563 and No. 2016/0037486, the entire disclosure of each of which is incorporated herein by reference for all purposes. However, it should be noted that implementations are contemplated in which other modes of communication between the STMs and the rest of the system are employed. Control nodes106may be implemented using any of a variety of suitable industrial Internet gateways, and may connect to STM service108using any of a variety of wired and wireless protocols, e.g., various versions of Ethernet, various cellular (e.g., 3G, LTE, 5G, etc.), various wi-fi (802.11b/g/n, etc.), etc. In some cases, otherwise conventional gateways are augmented to include components that implement the Evernet™ protocol. Each STM104generates sensor data representing one or more temperatures associated with the steam trap with which it is associated, and possibly other sensed data associated with the trap. The one or more temperatures include steam temperature and/or condensate temperature. Steam temperature is captured using a temperature sensor (e.g., a thermistor) connected to the piping of the system side of the trap (which might be live steam or a load). Condensate temperature is captured using a temperature sensor (e.g., a thermistor) connected to the piping through which condensate and non-condensable gases are expelled. The STMs may also be configured to capture and generate sensor data representing ambient temperature and/or humidity of the environment in which the STM is deployed. Each STM104may also be configured to generate sensor data representing a variety of other parameters generated by a variety of sensor types and/or sources. For example, an STM might monitor light levels, humidity, vibrational or other types of mechanical energy, acoustic energy, ultrasonic energy, etc. According to a particular implementation, in response to a wakeup message from its control node106or a local wakeup timer, each STM104transitions from a low-power mode, takes readings on each of its sensors, and transmits digitized versions of the readings to its control node106in a packet in which each sensor and its reading are paired (e.g., as a label-value pair). The packet also includes information (e.g., in a header) that identifies the specific STM with a unique identifier and the timestamp of the readings in the packet. The wakeup messages may be periodically transmitted from each control node to its associated STMs. Each control node106stores the packets received from its STMs104in its local database, and periodically or opportunistically uploads the stored information to STM data service108(e.g., to a cloud-based service when the control node is connected to the Internet). Thus, if there is an outage, the control node is able to cache the sensor data until the connection is restored. The processing of the sensor data is done by STM data service108, e.g., using logic114. STM data service108also stores historical data for steam trap monitoring system100(e.g., in data store116). Steam trap data and other system data generated by STM data service108and stored in data store116may be accessed on demand (e.g., in a dashboard on computing device118) by responsible personnel associated with the facility or facilities in which the steam trap monitoring system is deployed. Steam temperature and condensate temperature are useful for determining the state of a steam trap because a steam trap is designed to collect condensate that forms in the steam system at or near where the trap is deployed. A steam trap is usually installed at low points in the steam distribution system. Every so often, the steam trap expels collected condensate into a drain line. When a steam trap fails, it often fails to a condition which results in steam going straight through the trap into the drain line. In a simple example, the steam side of a steam trap is typically expected to be at or near the temperature of live steam (e.g., well over 100 degrees C.). By contrast, because of the presence of condensate, the condensate side of the trap is typically expected to be at a lower temperature than the steam side of the trap. If a steam trap fails open, this may be detected based on a higher than expected temperature at the condensate side of the trap relative to the steam temperature. However, because of the different types of steam traps, the different applications in which they are installed, the diversity of failure modes, and the inherent noisiness of the temperature data, determining the state of the trap using a simple comparison of the two temperatures may not be particularly reliable. As will be discussed below, the present disclosure enables a variety of techniques by which these and potentially other parameters may be processed to determine more reliably the state of an individual steam trap. In addition, a variety of system parameters beyond the state of the individual steam trap may be detected or determined by monitoring these temperatures and/or other parameters. For example, a dip in steam temperature might be caused by a drop in pressure at the boiler or a pressure reducing valve (PRV). Such a determination might be made based on a set of data points from one STM and/or data sets from multiple STMs distributed around the system. Data from multiple STMs may also be used to make finer-grained assessments such as, for example, distinguishing between a pressure problem with the boiler or the pressure reducing valve (PRV). More generally, implementations are contemplated in which various subsets of STM data (both captured data and derived data) may be used to define a normal baseline operation (and potentially some range around normal) for any of a wide variety of system behaviors or components. Such definitions of normal may then be used to detect deviations from the expected range. This might initially involve the identification of a general fault condition, but also could be refined over time to identify specific states and/or failure modes as represented by corresponding data signatures. Such signatures might be represented using data generated by one or multiple STMs, at a given point in time, or over a particular time range. According to some implementations, STMs are employed that operate using power harvested from the environments in which they are deployed.FIG.2is a block diagram of an example of such an STM200. In the depicted implementation, STM200is powered using energy harvested from its environment with a photovoltaic (PV) device202that captures energy from the ambient light in the vicinity of STM200, and a thermoelectric generator (TEG)204that captures thermal energy from, for example, the pipes of the steam distribution system. As will be discussed, implementations are contemplated in which the STM's power management unit may be configured such that the STM can use power from the PV device in a “solar only” mode (as indicated by the dashed line from PV device202to VIN), the TEG in a “TEG only” mode, or a combination of both in a “solar assist” mode (as indicated by the solid line from PV device202to VCAP). Suitable switching circuitry for configuring these connections will be known to those of skill in the art and so is not depicted for clarity. STM200includes a power management unit (PMU)206that controls the delivery of power to controller208and data transmitter210via load switch212. VIN is the harvesting input to PMU206, and VCAP, and three voltage rails (not shown for clarity) are the generated outputs. PMU206charges energy storage device214(e.g., a super-capacitor) with VCAP via charging circuit216using energy harvested from either or both of PV device202and TEG204(depending on the harvesting mode). Load switch212and charging circuit216control when power is provided to the rest of STM200and allow STM200to be functional while energy storage device214is charging. STM200receives a wakeup message (e.g., with wakeup receiver218) from a system control node with which it is associated. Receipt of the wakeup message triggers control of load switch212by PMU206to provide power to controller208for capturing readings associated with the steam trap being monitored by STM200, and to transmitter210for transmitting sensor data to the control node. PMU206also communicates with controller208via digital I/O channel220. This can be used by the controller to monitor the status of the PMU206, and to update its configuration or calibration settings. Once awakened and powered up, controller208captures readings using one or more sets of sensors associated with STM200. As depicted, these might include one or more temperature sensors222(e.g., thermistors connected to the piping adjacent the trap). Sensors to detect or measure other parameters or types of readings (e.g., ambient temperature and/or light, acoustic, ultrasonic, humidity, vibrational/mechanical energy, etc.) are also contemplated. As discussed above, controller208packetizes the digitized sensor data and transmits the packet(s) to the associated sensor node via data transmitter210. According to a particular implementation, PMU206includes a boost DC-DC converter that employs maximum power point tracking to boost the relatively low voltage VIN received from one of the harvesting sources (e.g., PV device202or TEG204depending on the mode) to a higher voltage VCAP at its output that is used to charge the energy storage device (e.g.,214). Once VCAP is sufficiently high, a buck/boost, a single-input-multiple-output (SIMO) DC-DC converter turns on and takes VCAP and brings it up or down (depending on the level of charge of energy storage device214), generating three voltage rails; +2.5, +1.2, and +0.6 volts respectively. These voltage rails are for use in powering the other electronics of STM200(e.g., controller208and transmitter210). In the “solar assist” harvesting mode, PV device202may be attached directly to VCAP through diode224(to prevent leakage) as represented by the solid line connection inFIG.2. In this mode, and assuming its output is sufficient to forward bias diode224, PV device202may provide a charging assist to TEG204with the energy of the two harvesting sources naturally combining in energy storage device214without requiring complicated control electronics. According to a particular implementation, in the “solar assist” mode, PV device202is used to raise VCAP such that the biasing to the boost converter turns on. This allows the boost to harvest from lower input voltages (e.g., allowing harvesting from lower temperature deltas on TEG204). In another implementation, PV device202may connect to VIN of PMU206as shown by the dashed line inFIG.2. This allows for lower levels of light, or lower voltage PV cells to be boosted to recharge the energy storage element. More generally, implementations are enabled by the present disclosure in which energy may be harvested from multiple different energy sources and used in any combination to power such an STM. Other potential sources for harvesting include vibration energy (e.g., using a piezoelectric-based device) and RF energy. As will be appreciated, these are AC energy sources and so would require AC-DC converters. And if the resulting DC voltages from any of these are not sufficiently high, they could be boosted using a boost converter. The processing of STM sensor data by an STM algorithm and its component analysis algorithms according to a particular class of implementations will now be described with reference toFIGS.3-6. As mentioned above, these processing techniques may be used in conjunction with STMs enabled by the present disclosure, but also may be used with any of a wide variety of STM types. As illustrated inFIG.3, the inputs to the STM algorithm include time series data, e.g., vectors, for the STM representing steam temperature (Tsteam), condensate temperature (Tcond), (optionally) ambient temperate (Tamb), and time stamps for the corresponding values of the time series data (Time). Vector extraction (302) generates vector features from these input vectors for a number of different vector types. According to some implementations, each vector may include feature values for the STM over its entire history, and each time the STM algorithm and its various analysis components runs, this entire history of the STM may be processed. This approach may be useful in that, to determine the state of the steam trap at any given point in time, its behavior over its lifetime may be relevant and so can be taken into account. That is, the historical behavior of the STM is often useful in understanding and/or informing its current behavior. It should be noted, however, that implementations are contemplated in which only a subset of an STM's sensor data for a given time range might be processed. For example, if an STM has generated 10 years of sensor data, and there are time constraints on how quickly the state of the STM must be determined, an STM algorithm might be constrained to using sensor data from only the most recent year to speed up the processing time. In addition, repair or calibration of an STM might be introduced into its data set as a “ground truth” event that can serve to inform subsequent event detections and confidence scores and/or define the range of sensor data to be used. According to some implementations, the vectors generated as a result of vector extraction302include a dt vector the values of which represent the time difference between consecutive samples in the time series data (e.g., as derived from the Time input vector). As will be discussed, this information is useful in determining the rate of change of any of the time series data and may be used, for example, in determining the timing of steam on and steam off events. As will also be discussed, the dt vector may also be used in detecting steam modulation, and detecting events representing significant changes in status of the steam trap. Vector extraction302also results in generation of vectors referred to herein as Ts Envelope (max and min) and Tc Envelope (max and min) that represent temperature envelopes for the steam temperature and the condensate temperature, respectively. Each envelope is represented by two vectors including temperature values that are time-aligned to the original temperature values of the corresponding temperature vector, e.g., the values of the Ts Envelope (max and min) vectors are time-aligned to the values of the Ts vector. One of the envelope's vectors represents the maximum values of the corresponding temperature, while the other represents the minimum values. These representations adapt slowly to changes in the underlying temperate and are useful for detecting when these temperatures change in unexpected ways. Vector extraction302may also result in generation of vectors for both steam temperature and condensate temperature referred to herein as Delta-T (steam and cond). The values of these Delta-T vectors represent the difference between consecutive temperature samples. This information may be useful, for example, in distinguishing between different trap states and/or failure modes. Vector extraction302might also result in generation of vectors referred to herein as Ts Variance Energy and Tc Variance Energy. These are generated by feeding Ts and Tc, respectively, through a DC blocking filter to generate a measure of the energy in each of the signals. These vectors are representations of the stability of the corresponding temperatures (i.e., the steam and condensate temperatures) when they are stable, and can be thought of as a kind of noise floor. Implementations are contemplated in which either the raw magnitude or the log of the raw magnitude of the temperature values are used. Again, this information may be useful in distinguishing between different trap states and/or failure modes. Vector extraction302might also result in generation of a vector referred to herein as Steam Off Decay Rate which represents the rate at which a trap cools off when steam is shut off in the system, e.g., the decay constant from the edge following a “steam off” event. The vector can be derived by low-pass filtering the Ts or Tc temperature data, with abnormal states or conditions being detected by observing the standard deviation and looking for outliers. At least some of these vectors are passed through multiple filters (304) to provide different perspectives on the behavior of the vector. Most vectors receive some degree of low-pass filtering (short- or long-term averaging). The filtered vectors (from which digital signatures may be derived) are then analyzed using one or more analysis components (306) to generate various outputs, each of which has an associated confidence value. Some examples of such analyses components are discussed below. The outputs from the analysis components may then be processed by another layer of logic to identify a possible state of the steam trap and/or the steam system (308). The identified state of a trap might be specific (e.g., normal, failed open, failed closed, etc.). Alternatively, the identified state might just be that something is not normal and a flag could be set that a specific steam trap should be manually checked. According to some implementations, one of the analysis components306uses steam temperature data to determine whether live steam is flowing at the steam trap. This steam on/off detection analysis is based on the assumption that determination of the state of the steam trap can be accomplished with a higher degree of reliability if it is known whether or not the steam is on at the trap. Whether or not steam is flowing to the trap (also referred to as the “system state”) is determined by processing the steam temperature data using multiple determination methods as illustrated in the diagram ofFIG.4. Each method (402-1through402-n) generates a state output estimate vector along with a confidence vector. The outputs from the different determination methods are then selected and/or combined (404) to derive an overall system state estimate vector and an associated confidence vector. According to a particular implementation, the result of the method with the highest confidence is used to determine the overall system state. Alternatively, implementations are contemplated in which some combination of the outputs and confidence levels of the different methods is used. One method suitable for use in steam on/off detection establishes fixed thresholds for the conditions “steam on” and “steam off” and uses hysteresis between the thresholds. The “steam on” threshold might be about 90 degrees C., while the “steam off” threshold might be about 60 degrees C. However, it should be understood that different thresholds might be used to better reflect the type of steam trap and the application in which it is installed. It should also be understood that the hysteresis thresholds do not necessarily need to the same as the on and off thresholds. For example, the hysteresis threshold down to which a steam on event might be maintained could be 70 degrees C., while the hysteresis threshold up to which an steam off event might be maintained could be 80 degrees C. A confidence value may be calculated such that when the steam temperature is outside the thresholds, there is a reasonable level of confidence (e.g., >50%) that the system state is known. On the other hand, if the steam temperature is between the thresholds, knowledge of the system state is significantly less certain. Parameters that may be tuned for this method to suit a particular application or steam trap type include the “steam on” and “steam off” thresholds, and the confidence level at the thresholds. Another method suitable for use in steam on/off detection adapts to the steam trap being monitored by generating “floating” thresholds. This is achieved by tracking the envelope of the steam temperature based on the observed extremes. According to this method, steam is considered (1) “on” if the observed steam temperature exceeds the median value by some programmable value; (2) “off” if the observed temperature is below the median value by some programmable value; and (3) unchanged from the previous state if the temperature falls near the median (i.e., hysteresis). In a first pass of a particular implementation, multi-segmented logic is applied to the observed steam temperature as it relates to the existing extremum. This logic operates as follows. If the observed temperature exceeds the current extremum, update the extremum through a low-pass filter. If the observed temperature is near an extremum (e.g., within a programmable value), and the observed temperature is stable (e.g., its derivative is below a programmable value), then update the extrema using a second low-pass filter. If the observed temperature is between the extremum and far from an extremum (e.g., outside of some programmable value), update the opposite extrema using a third low-pass filter. If none of these conditions are met, then the new extremum value matches their previous value. The confidence vector generated by this method may take into account various parameters such as, for example, the temperature delta between the tracking extremum, the distance between the observed temperature and the tracked median, and/or the proximity of the tracking extremum to ambient temperature, among others. Further stability may also be provided through the use of an additional low pass filter on the median values. Another method suitable for use in steam on/off detection involves the accumulation of ground truth events for particular steam traps (e.g., repair or recalibration) to inform the thresholds to which observed samples of time series data are compared. This approach involves the use of Boolean vectors representing each steam trap that include features representing, for example, the steam trap type and the specific application in which the steam trap is installed. The Boolean vectors are used to determine how closely the ground truth events for a particular steam trap should match those of another. For example, a temperature envelope for a given steam trap can be predicted based on analysis of the ground truth events for steam traps with which the given stream trap is closely correlated. Because of the use of hysteresis, the point in time at which a “steam off” event is reported will likely be delayed relative to the point in time at which the event actually occurred. So in some cases it may be important that the determination of such events not rely solely on the crossing of a threshold. That is, it may be undesirable to evaluate the state of a steam trap when live steam is not present. And because the reporting of “steam off” event is likely delayed from the point in time at which the steam actually turned off, the data immediately preceding the report is considered unreliable for this purpose. Therefore, according to a specific implementation, the time of the actual “steam off” event is determined. This is done by stepping back through the steam temperature data from the point in time at which the state change is reported to identify the point in time at which the steam temperature began to drop. According to some implementations, states and confidence values for multiple STMs may be used to determine a system state, e.g., whether steam is on or off, with higher confidence. And these may be combined and/or weighted based on correlations among the traps, e.g., the steam trap types and the applications in which each is installed. The data for each STM might have associated metadata that represent various characteristics of the trap with which it is associated such as, for example, the steam trap type being monitored and the application in which the steam trap is installed, e.g., drip, coil, process, heat exchanger, etc. Such metadata may be taken into account in the processing of the outputs and confidence scores of the STM algorithm as well as any of its analysis components. According to some implementations, one or more of the analysis components306of the STM algorithm ofFIG.3uses the steam on/off state, steam and condensate temperature data, envelope tracking data, and trap and/or system metadata to determine one or more states of a particular steam trap. This analysis component identifies steam trap states based on corresponding changes in a distribution of the steam and condensate temperature data over time. A particular steam trap state (e.g., failed open) is identified based on the direction and magnitude of the change. Assuming live steam is flowing at the steam trap (e.g., the “steam on” system state has been detected as described above) and as depicted inFIG.5, the center of a “steam on” data cluster is determined by converting the steam and condensate temperature data and the temperature envelope tracking data Ts Envelope (max) and Tc Envelope (max) from Cartesian to polar coordinates (506and512). Changes in the steam and condensate temperature data relative to a central point defined by the envelope tracking data and having a magnitude greater than a specified level (e.g., 1 to 3 standard deviations) (514and516), and a direction bounded by a specified range of angles (518) are flagged. Flagged events are reported with associated confidence scores (520). The specified range of angles that define the direction of movement of the trap temperature data and/or the specified magnitude of the change may vary considerably depending on the trap type and the trap application, with different ranges of angles potentially representing different trap states or failure modes. In many cases, steam traps are installed in applications in which the trap experiences considerable variation in the behavior of the live steam at the steam side of the trap under normal operating conditions. These normal operating conditions can look very different from the normal operating conditions for traps that experience more consistent live steam behavior. For example, for a trap that cycles on and off rapidly, the steam and/or condensate temperatures typically do not reach the same extremes as for a trap that is on or off for longer periods of time. This is to be expected, as the thermal mass of the system takes a long time to get to full temperature, effectively acting as a low-pass filter. In another example, a trap might be installed on the opposite side of a load from the steam distribution system at a point at which condensate is expected to form during normal operation, e.g., a system with a heat exchanger having a trap below the exchanger. In such an application, the steam side of the trap would be expected to have a considerable amount of condensate under normal conditions, bringing the expected steam temperature down significantly as compared to a trap connected directly to the steam distribution system. For example, in such applications, the steam temperature for the “steam on” condition is lower than a trap on the steam supply. In addition, the temperature of the load might be regulated using a valve on top of the heat exchanger that cycles on and off to control the amount of steam going to the exchanger. This causes the trap temperatures to rise and fall according to a regular pattern with consistent frequency content. These variations in the conditions experienced by steam traps in such applications are known collectively by the term “modulated steam.” As will be appreciated, it may be important to determine whether a particular trap is experiencing modulated steam as part of determining the state of the trap. Therefore, according to some implementations, one or more of the analysis components306of the STM algorithm ofFIG.3uses the steam temperature data for a steam trap to detect whether that trap is deployed in a modulated steam application. Such analysis components are configured to detect regular or even semi-regular cycling in the steam temperature. According to one class of implementations, the steam temperature data are converted to the frequency domain (e.g., using a Fast Fourier Transform or FFT) to determine the frequency and/or magnitude of any cycles in the temperature data. Such an approach may be desirable in cases where the magnitudes of the frequency components are important. On the other hand, this approach might not be particularly well suited if there is not a high degree of confidence that the sampling rate for the temperature data will be consistent. According to another class of implementations, an autocorrelation algorithm may be used to determine the overall period of any repeating cycle in the steam temperature data. The use of an autocorrelation algorithm is also particularly well suited to implementations which seek only to determine whether or not cycling is occurring as opposed to determining the constituent frequency components of the cycling. A particular implementation of a modulation detection analysis using an autocorrelation algorithm will now be described with reference toFIG.6. However, it should be noted that the present disclosure both contemplates and enables implementations in which frequency conversion (e.g., using an FFT) is employed, either as an alternative or in combination with an autocorrelation function. Regardless of the technique used to detect temperature cycling, the steam temperature data (Ts) are preconditioned prior to analysis; in this specific implementation, using a band pass filter602. Such preconditioning may be useful, for example, in cases in which the steam temperature data have a large DC offset. Use of a DC blocking filter with a relatively steep roll off prevents overflow of the autocorrelation algorithm (or masking of the low frequency components of the FFT output). Such filtering may also be useful for implementations in which high frequency changes from sample to sample are considered to be noise. An autocorrelation algorithm (606) is run on the steam temperature data using a regular number of samples. The autocorrelation algorithm may, but is not required to, account for missing samples or variations in sample timing. A variety of post-processing techniques may be applied to the raw autocorrelation output prior to its interpretation. For example, central peak removal involves “de-mirroring” of the raw autocorrelation output followed by removal of the central peak. For a cyclic signal, the output of an autocorrelation algorithm is mirrored about the central (zero delay) point. This means that half of the output vector can be discarded without incurring any loss of information. In one approach, the first half of the vector is discarded as this results in a vector arranged in order of increasing delay (starting at zero). As is well known, there will always be a peak at the zero delay point, and it will always be the highest level of the autocorrelation output. This is because at zero delay, there is a 100% correlation of the signal, and no other alignment can result in better than 100% correlation. However, because we are trying to identify a cyclic delay, this peak (which represents zero delay) is irrelevant, so it is advantageous to remove it. The peak can be removed by analyzing the first derivative of the autocorrelation output to isolate the central peak from any adjacent peaks. Since the central peak is guaranteed to be the highest peak, the first derivative to either side of the peak is guaranteed to be negative. Moving along the autocorrelation output, the first derivative will turn positive at the foot of the next peak, however slightly. Thus, simple logical analysis allows us to determine the limits of the central peak. The peak is then removed by setting all values in the central section of the data to be equal to the first value outside that section. If the peak occupies the entire block, the correlation for the entire block is set to zero. The absolute magnitude of the various peaks in the autocorrelation output may not be particularly important as it is a function of the magnitude of the input signal. And since no amount of delay can produce a higher correlation than the 100% correlation found at the central peak, it may be advantageous to represent all other outputs as relative to the central point. This gives a correlation factor that is irrespective of signal level. Thus, the autocorrelation output may be normalized to the central (zero delay) point. This gives a meaningful representation of how well the signal repeats itself at various delay amount. In addition to the application of the autocorrelation algorithm (706), a representation of the energy of each block of temperature data is determined (716). If the autocorrelation output has been normalized, it may no longer include sufficient information for determining whether it represents actual cycling of the trap (e.g., several degrees of temperature swing) or only a slight undulation in the temperature readings (e.g., spanning only one or two degrees). Determining the energy level of the original input block can be used to resolve this ambiguity. The autocorrelation vector and the energy measurement vector are fed through thresholding and qualification logic718to qualify them as representative of modulated steam. All threshold outputs are combined using a logical AND statement. In some cases, a simple thresholding of the inputs may be done. It will be understood by those skilled in the art that changes in the form and details of the implementations described herein may be made without departing from the scope of this disclosure. In addition, although various advantages, aspects, and objects have been described with reference to various implementations, the scope of this disclosure should not be limited by reference to such advantages, aspects, and objects. Rather, the scope of this disclosure should be determined with reference to the appended claims. | 39,627 |
11859765 | DETAILED DESCRIPTION Referring toFIGS.1and2, a first example storage tank100for liquid hydrogen comprises first102and second106concentric hollow spherical shells which are mutually spaced apart defining an inter-sphere cavity104. The first and second shells102,106have a common centre120and are each constructed of a laminate comprising carbon-fibre reinforced polymer composite material. The first shell102forms a first vessel having an internal space122for storing liquid hydrogen. The second shell106forms a second vessel which surrounds the first vessel. Referring specifically toFIG.2, which shows a portion100A of the cross-section of the storage tank100ofFIG.1, the first102and second106shells are mechanically coupled by a plurality of pins103, each of which passes through at least some of the layers of the first shell102and at least some of the layers of the second shell106. The pins103are uniformly distributed over 4π steradians with respect to the centre120of the storage tank100, although variants of the tank100such pins may have some other spatial and/or areal distribution. The pins103are thermally insulating and are manufactured from carbon fibre composite, inorganic fibre composite or cured reinforced glass fibre. As indicated inFIG.2, the pins103extend radially with respect to the centre120of the storage tank100and are therefore normal to the first and second shells104,106, however in variants of the storage tank100such pins may meet the shells at an angle or other than 90°. A conduit130passes through the first and second shells102,106allowing filling and emptying of the storage tank100, however the conduit130otherwise has no load-bearing function. The inter-sphere cavity104between the first102and second106shells may be evacuated or filled with an insulating material such as foam, aerogel or vermiculite (hydrous phyllosilicate mineral). The pins103extend through at least some of the layers of the first shell102and some of the layers of the second shell106.FIG.3shows a cross section of a portion of the second shell106:FIG.4shows a cross section of a portion of the first shell102. A pin103may have an outer radial portion such as103A which extends through all layers of the second shell106, or alternatively an outer radial portion such as1038which extends through only through a subset of radially inner layers of the second shell106. A pin103may have an inner radial portion such as103C which extends through all layers of the first shell102or alternatively an inner radial portion such as103D which extends through a subset of outer layers of the first shell102. The storage tank100may be constructed using a simpler manufacturing process involving less tooling and fewer process steps than is the case for known tanks for storing liquid hydrogen. The storage tank100has also has a lower mass and reduced thermal losses compared to tanks of the prior art. The plurality of pins103allow for the shells104,106to be thinner, and hence lighter, than similar shells in tanks of the prior art. The storage tank100may be manufactured as follows, in a first step, an internal spherical mandrel tool is prepared, the mandrel tool being collapsible and extractable through an opening in the storage tank100after manufacturing operations have been completed. The surface of the mandrel tool provides sufficient rigidity and stability for subsequent winding, pinning and curing operations described below. In a second stage, the mandrel tool is placed on a suitable automated filament winding machine or automated fibre placement machine and rotated about an axis whilst fibre reinforced polymer tape is wound onto the surface of the mandrel tool under tension and to a prescribed and programmed laminate design which will ultimately produce the first shell102. The resulting tape winding is consolidated to the required thickness during winding, or in a subsequent vacuum ‘debulking’ operation. In a third step, the tape winding is covered by a “wash-out” core comprising a low-density foam or similar material to define the inter-sphere cavity104of the storage tank100. This material is sacrificial and is removed after moulding is completed. In a fourth step, tape making up material of the second shell106is wound over the ‘wash out’ core to a required thickness and laminate design using the same filament winding or automated fibre placement equipment as is used in the second step. In a fifth step, the tape windings for the first and second shells102,106are ‘pinned’ with the pins103that pierce through the tape winding for the second shell106and the ‘wash-out’ core and into the tape winding for the first shell102. The pins103are distributed over a solid angle of approximately 4π steradians with respect to the centre of the spherical mandrel tool and at angles to the two tape windings and with an areal density and length to meet functional requirements of the storage tank100. The pins103may extend to an inner mould line (IML)121against the spherical mandrel tool (as indicated by the radially inner portion103C of a pin103shown inFIG.4), in which case they pass through the entire thickness of the tape winding for the first shell102, or alternatively the pins103may stop short of the IML121(as indicated by the radially inner portion103D of a pin103inFIG.4). The manufacturing of the pins103, and their insertion, are performed by methods set out in granted patents U.S. Ser. No. 10/307,973 and U.S. Pat. No. 8,893,367, the entire contents of both of which are hereby incorporated by reference. In a sixth step, the tape windings and wash-out core are consolidated and cured by application of heat and pressure in order to cross-link matrix resin of the tape windings to achieve properties desired of the laminate shells102,106. The mandrel is then extracted. In a seventh step, the wash-out core defining the inter-sphere cavity104is removed, leaving only the pins103within the inter-sphere cavity104. The wash-out core is removed using a method appropriate to the material of the core material, e.g. use of water as a solvent in the case of sugar-based core, use of organic solvent or caustic soda for a polymer-based core, or use of organic solvent (or heat) in the case of a wax core. Finally, in an eighth step, the inter-sphere space104is either evacuated or filled with particulate insulating material. Referring toFIGS.5and6, a second example storage tank is indicated generally by200,200A. The storage tank200comprises first202, second206and third210concentric spherical shells of carbon fibre reinforced polymer composite laminate material having a common centre220and defining first, second and third vessels respectively and first and second inter-sphere spaces204,208. The first shell202defines a volume222for storing liquid hydrogen. A conduit230passes through the first, second and third shells allowing the tank to be filled and emptied, but otherwise does not have any mechanical or structural function. A conduit231passes through the second and third shells206,210allowing venting of hydrogen which passes through the first shell202into the first inter-sphere space204. The first and second shells202,206are mechanically coupled by a plurality of thermally conducting pins203, each of which passes through at least some layers of the second shell206and at least some layers of the first shell202. Referring toFIGS.7and8, a pin203may have an outer radial portion such as203A which passes through all layers of the second shell206or alternatively an outer radial portion such as203B which passes through only an inner subset of layers of the second shell206. A pin203may have an inner radial portion such as203C which passes through all layers of the first shell202and up to the inner mould line (IML)221of the first shell202or alternatively a pin203may have an inner radial portion such as203D which passes through only an outer subset of layers of the first shell. In these cases, the pins203are thermally insulating and are manufactured from carbon fibre composite, inorganic fibre composite or cured reinforced glass fibre. A pin203may have an inner radial portion such as203E which passes through all layers of the first shell202and into the interior222of the first shell. In this case the pin203is thermally conducting, allowing heat to pass from the first inter-sphere space204into the interior222of the tank200and hence providing for active boil-off of liquid hydrogen stored in the volume222of the storage tank200. In this case the outer radial portion of a pin203may either pass through all layers of the second shell206, or only a subset of inner layers of the second shell206, as indicated by203A,203B inFIG.7. Referring toFIGS.9and10, pins207mechanically couple the second and third shells206,210and extend radially with respect to the centre220of the tank200. The pins207are thermally insulating and are manufactured from carbon fibre composite, inorganic fibre composite or cured reinforced glass fibre. A pin207extends through a least some of the layers of the second shell206and through at least some of the layers of the third shell210. A pin207may have an outer radial portion such as207A which passes through all layers of the third shell210or alternatively an outer radial portion such as207B which passes only through an inner subset of layers of the third shell210. A pin207may have an inner portion such as207C which passes through all layers of the second shell206, or alternatively an inner radial portion such as207D which passes only through a subset of outer layers of the second shell206. The areal densities of the pins203,207and/or their number densities per unit solid angle may be constant or may vary in azimuth and elevation. The storage tank200is manufactured by first carrying out the first to fifth steps described above in relation to the storage tank100ofFIGS.1and2. The following steps are then carried out: Step6A: Another core comprising either a wash-out core or insulating foam covers the tape winding for the second shell206to define the volume of the second inter-sphere cavity208. This material is either sacrificial and removed after moulding is completed or forms insulation for the finished tank200. Step7A: A tape winding for the third shell210is wound over the wash-out core or insulating foam layer defining the second inter-sphere cavity208to the required thickness and laminate design using the same filament winding or automated fibre placement equipment used to apply the tape windings for the first and second shells202,206. This tape winding includes provision for any features to stiffen or mount the finished storage tank200. Step8A: The tape winding for the third shell210is pinned from its outer surface through and into the tape winding for the second shell206using thermally insulating pins207and in a pattern and areal density to structurally support the first and second shells202,206. Step9: Pressure and heat are applied by any one of a number of means in order to consolidate and cross-link matrix resin within the tape windings to achieve the desired laminate properties. The mandrel tooling is then extracted. Step10: The wash-out core defining the first inter-sphere cavity204, and, where present, the wash-out core defining the second inter-sphere cavity208, is removed as described above in relation to manufacture of the storage tank100. Step11: The second inter-sphere space is either evacuated or filled with insulating material. Apparatus may be used in conjunction with the tank200to recover hydrogen which diffuses from the interior volume222of the first vessel into the first inter-sphere space204. The apparatus may also provide for the temperature and/or pressure of hydrogen within the first inter-sphere space204to be regulated. The manufacture of the first100and second200example storage tanks may be carried out using automated equipment familiar to those skilled in the art. | 11,954 |
11859766 | DETAILED DESCRIPTION The present invention is a fusible plug suitable for a high pressure gas cylinder. The fusible plug of the present invention is attached to a high pressure gas cylinder and acts to quickly release gas in the high pressure gas cylinder to the outside when the high pressure gas cylinder is exposed to an abnormally high temperature and normally acts not to release the gas in the high pressure gas cylinder to the outside. The fusible plug includes a communication hole drilled so as to cause the high pressure gas cylinder to communicate with the outside. The communication hole is filled with the low melting point alloy and the communication hole is closed by the low melting point alloy normally solidified and composited in a state of the porous material is impregnated with the low melting point alloy. On the other hand, when the temperature becomes abnormally high, the low melting point alloy melts and is eluted from the porous body to the outside, so that the communication hole is opened and the contents (gas) in the container can be quickly released to the outside. The fusible plug of the present invention is made of a material similar to that of a normal fusible plug made of brass, stainless steel, or the like and is manufactured by a normal method such as cutting so as to have a desired shape and dimension. In a fusible plug1of the present invention, after a porous material3is press-fitted so as to occupy a part of a communication hole2in the length direction, all or a part of the porous material3is impregnated with a low melting point alloy4to solidify and composite the low melting point alloy4. This state is schematically illustrated inFIGS.1A to1H. The fusible plug1is connected to a high pressure gas cylinder10with a screw part or the like and a predetermined high pressure is applied to the low melting point alloy. The communication hole may have a stepped cross section so that the filled low melting point alloy or the like does not jump out to the outside with pressure from a high pressure side. That is, in the fusible plug1of the present invention, all or a part of the porous material3press-fitted into the communication hole2is impregnated with the low melting point alloy4to composite the low melting point alloy4. As a result, even when the fusible plug1is attached to the high pressure gas cylinder and the high pressure from the gas inside the container is applied to the low melting point alloy in the communication hole, the low melting point alloy is not displaced and the gas inside the container does not normally leak to the outside. The low melting point alloy impregnating all or a part of the porous material3and composited is reinforced by the porous material and retains high strength as a whole compared with the strength of only the low melting point alloy. As schematically shown inFIGS.1A and1B, the low melting point alloy4is sometimes filled in the communication hole2other than the porous material3. However, as shown inFIGS.1C to1H, in the present invention, it is preferable from an economic viewpoint that the low melting point alloy4filled in the communication hole2other than the porous material3is reduced as much as possible. If the low melting point alloy can retain desired strength and sealability, a part of the porous material may be impregnated with the low melting point alloy to composite the low melting point alloy. As the low melting point alloy to be filled in the communication hole of the fusible plug, an alloy matching a desired melting point only has to be selected. The low melting point alloy does not need to be limited in particular. The low melting point alloy is an alloy including two or more kinds of metal selected from Bi, Sn, In, Ag, Zn, and the like, and is preferably an alloy such as a bismuth Bi/indium In-based alloy, a bismuth Bi/indium In/tin Sn-based alloy, or a bismuth Bi/indium In/silver Ag-based alloy from the viewpoint of easily obtaining a low melting point. In the present invention, since the fusible plug is attached to the high pressure gas cylinder, from the viewpoint of safety and stability of functional characteristics, an alloy having a melting point of 110±5.5° C. is preferable as the low melting point alloy in use. Examples of such a low melting point alloy include a 67 mass % Bi-33 mass % In alloy. In the present invention, the porous material to be press-fitted into the communication hole of the fusible plug is preferably a porous metal sintered body from the viewpoint of easily securing desired strength. As the porous metal sintered body, a porous metal sintered body having pores with an area ratio of 30% or more and preferably 50% or less and having pores with a diameter exceeding 5 μm among the pores with an area ratio of 80% or more with respect to all the pores can be exemplified. When the pores of the porous metal sintered body are less than 30% in terms of area ratio, the pores of the porous sintered body are not impregnated with the molten metal of the low melting point alloy when impregnated with the low melting point alloy, and the low melting point alloy cannot be reinforced. Further, when exposed to an abnormally high temperature, the low melting point alloy melts and is released to the outside, and even if the communication hole becomes “open”, the gas in the container cannot be quickly released to the outside. On the other hand, when the pores exceeds 50% in terms of area ratio, it is likely that the number of pores is too large, the strength is reduced, the low melting point alloy is deformed under high pressure, and strength reinforcement of a desired low melting point alloy becomes insufficient. Therefore, the porosity of the porous metal sintered body is preferably set to 30% or more and 50% or less. In addition, when the area ratio of pores having a diameter exceeding 5 μm among the pores is less than 80% with respect to all the pores, the amount of fine pores increases, and the pores of the sintered body are less easily impregnated with the molten metal of the low melting point alloy, so that it becomes difficult to secure desired strength. For this reason, the porous metal sintered body is preferably a porous metal sintered body having a porosity of 30% or more, preferably 50% or less in terms of area ratio as described above and having 80% or more of pores having a diameter exceeding 5 μm among the pores with respect to the total pore area. As such a porous metal sintered body, a porous austenitic stainless steel sintered body is preferable. Since the fusible plug of the present invention is used in an indoor and outdoor high pressure gas environment, the porous metal sintered body is preferably a porous austenitic stainless steel sintered body excellent in corrosion resistance. Since the porous austenitic stainless steel sintered body is also excellent in hydrogen embrittlement resistance, the porous austenitic stainless steel sintered body is also suitable for use in a high pressure hydrogen gas environment. Examples of the austenitic stainless steel include SUS 201, SUS 202, SUS 301, SUS 302, SUS 303, SUS 303 Se, SUS 304, SUS 304 L, SUS 304 N1, SUS 304 N2, SUS 304 LN, SUS 305, SUS 309 S, SUS 310 S, SUS 316, SUS 316 L, SUS 316 N, SUS 316 LN, SUS 316 J1, SUS 316 J1L, SUS 317, SUS 317 L, SUS 317 J1, SUS 321, SUS 347, and SUH 660. The porous metal sintered body is preferably a porous metal sintered body having transverse rupture strength of 50 MPa or more when being subjected to determination of transverse rupture strength conforming to the provisions of the Japan Powder Metallurgy Association Standard JPMA M09-1992 (corresponding ISO standard ISO 3325) to calculate the transverse rupture strength. When the transverse rupture strength of the porous metal sintered body is less than 50 MPa, sufficient strength of a fusible plug for a high pressure gas cylinder cannot be secured even when the low melting point alloy is composited in a state in which the porous material is impregnated with the low melting point alloy. Therefore, the transverse rupture strength of the porous metal sintered body is preferably set to 50 MPa or more. The transverse rupture strength is more preferably 100 MPa or more. In addition, in the fusible plug of the present invention, the compressive yield strength of a region formed by compositing the low melting point alloy in a state in which the porous metal sintered body is impregnated with the low melting point alloy in the communication hole is preferably 1.5 times or more the compressive yield strength of only the low melting point alloy. In the fusible plug of the present invention, the porous metal sintered body is attached to at least a part of the communication hole in the length direction. However, when the compressive yield strength of the region formed by compositing the low melting point alloy in a state in which the porous metal sintered body is impregnated with the low melting point alloy is less than 1.5 times the compressive yield strength of only the low melting point alloy, strength reinforcement of a desired low melting point alloy cannot be performed and a fusible plug having desired pressure resistance cannot be obtained as a fusible plug for a high pressure gas cylinder. The compressive yield strength is more preferably 2.0 times or more. The term “having desired pressure resistance” as used herein refers to a state in which leakage of contents is not observed against predetermined high pressure applied to the fusible plug in a state in which the fusible plug is connected to the high pressure gas cylinder. The fusible plug of the present invention having the above configuration has pressure resistance of 87.5 MPa or more. Next, a preferred method for manufacturing the porous metal sintered body is explained. After alloy powder, graphite powder, and lubricant powder used as raw materials are mixed to obtain mixed powder, the mixed powder is charged into a mold and pressure-molded to obtain a green compact, and the green compact is sintered to obtain a porous metal sintered body. As the raw material powder, the alloy powder to be used is preferably alloy powder adjusted to have a particle size distribution that passes through a 30 mesh sieve (hereinafter, also referred to as 30 mesh under or −30 mesh) and does not pass through a 350 mesh sieve (hereinafter, also referred to as 350 mesh over or +350 mesh). When −350 mesh particles are present, an amount of presence of fine pores having a diameter of less than 5 μm increases, the molten metal of the low melting point alloy less easily infiltrates into the pores of the sintered body, and it becomes difficult to secure desired strength. In addition, the alloy powder to be used is preferably austenitic stainless steel powder having the above-described particle size distribution from the viewpoint of oxidation resistance and corrosion resistance when being press-fitted into the fusible plug. Examples of preferable austenitic stainless steel include SUS 201, SUS 202, SUS 301, SUS 302, SUS 303, SUS 303 Se, SUS 304, SUS 304 L, SUS 304 N1, SUS 304 N2, SUS 304 LN, SUS 305, SUS 309 S, SUS 310 S, SUS 316, SUS 316 L, SUS 316 N, SUS 316 LN, SUS 316 J1, SUS 316 J1L, SUS 317, SUS 317 L, SUS 317 J1, SUS 321, SUS 347, and SUH 660. Examples of a lubricant to be used include zinc stearate. The method for molding the green compact is not particularly limited. However, it is preferable to use a molding press or the like. The green compact molded into a predetermined shape is sintered to be a porous sintered body having a predetermined shape. Sintering conditions are preferably adjusted so as to have the porosity described above and so as to have transverse rupture strength of 50 MPa or more as calculated by a determination of transverse rupture strength conforming to the provisions of JPMA M09-1992. The porous material (porous metal sintered body) obtained in this way is press-fitted into the communication hole of the fusible plug. It is preferable that the porous material is press-fitted so that a part of the communication hole in the length direction occupies the entire cross section. The press-fitting length of the porous material only has to be determined according to an environment to which the porous material is exposed. The press-fitting length does not need to be particularly limited. The press-fitting length only has to be length at which as the low melting point alloy can be reinforced to such an extent that the low melting point alloy is not displaced according to high pressure to which the low melting point alloy is exposed. For example, a porous material (porous metal sintered body) having transverse rupture strength of 50 MPa or more under an environment of high pressure of 87.5 MPa is preferable to be press-fit by about 3 mm to 15 mm in the longitudinal direction of the communication hole. Subsequently, after the porous material (porous metal sintered body) is press-fitted into a part in the longitudinal direction of the communication hole of the fusible plug, the communication hole is further filled with a low melting point alloy in a molten state, and all or a part of the porous material (porous metal sintered body) is impregnated with the low melting point alloy to solidify and composite the low melting point alloy. As a result, the low melting point alloy filled in the communication hole is reinforced by the porous material (porous metal sintered body), and the low melting point alloy as a whole maintains a strength 1.5 times or more higher than the compressive yield strength of only the low melting point alloy. The present invention is further explained below with reference to Examples. Example The fusible plug1made of brass including the communication hole2drilled therein was manufactured. The communication hole2had a step as shown inFIGS.1A to1H. Then, the porous metal sintered body3was press-fitted from the high pressure gas cylinder10side (diameter: 9 mmφ side) of the communication hole2. The length of the press-fitted porous metal sintered body was set to 9 mm. Subsequently, a low melting point alloy (67 mass % Bi-33 mass % In alloy: melting point 110° C.) was filled in a molten state in the communication hole into which the porous metal sintered body was press-fitted. The press-fitted porous metal sintered body was impregnated with the low melting point alloy to obtain a fusible plug in a state in which the low melting point alloy was solidified and composited. In addition, a fusible plug filled with the low melting point alloy so as to fill the entire communication hole without press-fitting the porous metal sintered body was used as a conventional example. As shown inFIGS.1A to1H, the high pressure gas cylinder10was connected to one side of the obtained fusible plug1via a screw part, high pressure (87.5 MPa) was applied to the low melting point alloy in the communication hole at an environmental temperature of 85° C., and the pressure resistance of the fusible plug was evaluated. The press-fitted porous metal sintered body was manufactured by the following method. A lubricant powder was blended in a component-based alloy powder (steel powder) shown in Table 1, mixed, and kneaded to obtain mixed powder. The blended alloy powder (steel powder) was classified in advance to obtain SUS 316 steel powder in which a particle size distribution shown in Table 1 was adjusted. Subsequently, the obtained mixed powder was charged into a mold and pressure-molded by a molding press to obtain a green compact having a predetermined size (size: approximately 9 mmφ). TABLE 1Particle size distribution of steelpowder (% by mass)SteelCompo-−30−36−42−60−100Powdernent-+30to +36to +42to +60to +100to +350No.basedmeshmeshmeshmeshmeshmeshASUS316104535631BSUS316371549242 Subsequently, the green compact was sintered at a sintering temperature of 1100 to 1350° C. to obtain a porous metal sintered body (porous austenitic stainless steel sintered body). The total porosity of the obtained porous metal sintered body was calculated by density measurement. The density was measured by the Archimedes method. In addition, a ratio of fine pores to all pores was calculated by imaging the structure of the cross section of the sintered body in a pressing direction with an optical microscope, calculating a total area of the fine pores having a diameter of 5 μm or less and an area of all the pores with an image analysis, and calculating (the total area of the fine pores having the diameter of 5 μm or less)/(the area of all the pores). The measurement was performed at three points on the circumference. A test piece of transverse rupture strength (width: 10 mm, thickness: 6 mm, length: 40 mm) conforming to the provisions of JPMA M09-1992 was collected from a sintered body manufactured by the same manufacturing method as that of the porous metal sintered body described above, a determination of transverse rupture strength was performed, and transverse rupture strength was calculated. The transverse rupture strength is shown in Table 2. A roller having a diameter of 5 mm was used in the test. A center-to-center distance (distance between supporting points) of a supporting roller was set to 20 mm. The transverse rupture strength was calculated using the following equation. Transverse rupture strength=(3×F×L)/(2×b×h2) where, F is a load (N) at the time when the test piece is broken,L is a distance between supporting points (mm),b is a width of the test piece (mm), andh is a thickness of the test piece (mm). As in the example of the present invention explained above, a compression test piece (test piece size: 0 mm×8 mm) was collected from each of a region obtained by impregnating the porous metal sintered body with the low melting point alloy from the inside of the communication hole into which the porous metal sintered body was press-fitted and in which the low melting point alloy is further filled and solidifying and compositing the low melting point alloy and a region formed by only the low melting point alloy without impregnating the porous metal sintered body, and a compression test was carried out to determine the compressive yield strength. In the compression test, as shown inFIG.2, a compression test piece was allowed to stand on a fixed base and was compressed at a displacement rate of 1 mm/sec via a compression driving jig, and compressive stress at the time of yield was obtained as a “compressive yield strength”. From the obtained results, a ratio of the compressive yield strength (compressive yield strength of a region obtained by compositing the low melting point alloy)/(compressive yield strength of a region of only the low melting point alloy) was calculated. The obtained results are shown in Table 2. TABLE 2Compressive yieldstrength ratio of lowmelting point alloyimpregnated compositedregion(Compressive yieldstrength of low meltingMixedSintered bodypoint alloy impregnatedPorouspowder5 μm orTransversecomposited region)/metalAlloyless finerupture(compressive yieldsinteredpowder*Porositypore ratiostrengthstrength of lowbody No.Type(area %)(%)(MPa)melting point alloy)Remarks1A553.0191.3Comparativeexample2523.3271.4Comparativeexample3494.1551.8Conformingexample4454.31022.4Conformingexample5405.01763.0Conformingexample6345.52283.6Conformingexample7305.92524.0Conformingexample8246.3312Cannot be compositedComparativeexample9206.5361Cannot be compositedComparativeexample10B563.5281.4Comparativeexample11484.11212.4Conformingexample12454.41963.2Conformingexample13394.82804.2Conformingexample14335.23765.3Conformingexample15285.4451Cannot be compositedComparativeexample*See Table 1 As described above, among the porous metal sintered bodies press-fitted into the communication hole, the porous metal sintered body conforming to the scope of the present invention is a porous material having transverse rupture strength of 50 MPa or more and further having high compressive yield strength of 1.5 times or more as compared with the case of using only the low melting point alloy by impregnating the porous metal sintered body with the low melting point alloy and compositing the low melting point alloy. Evaluation results of pressure resistance as a fusible plug are shown in Table 3. In all of the present invention examples (the fusible plug), even when being exposed to an environmental temperature of 85° C., there was no displacement and no breakage of the low melting point alloy, and therefore, no release of contents was observed. When the fusible plug was heated to approximately 120° C., the low melting point metal was melted, and release of the contents was observed. As described above, the fusible plug of the present invention can be considered a fusible plug having pressure resistance of 87.5 MPa or more under an environment with an environmental temperature of up to 85° C. On the other hand, in the comparative examples outside the scope of the present invention, breakage or gas leaks occurred. In the conventional example in which the porous metal sintered body was not press-fitted into the communication hole, displacement of the low melting point alloy was observed not only when the environmental temperature was 85° C. but also when the environmental temperature was room temperature. TABLE 3Press-fittedporousFusiblesintered bodyPressurePlug No.No.*resistance**Remarks11xComparative example22xComparative example33∘Present inventive example44∘Present inventive example55∘Present inventive example66∘Present inventive example77∘Present inventive example88—***Comparative example99—***Comparative example1010xComparative example1111∘Present inventive example1212∘Present inventive example1313∘Present inventive example1414∘Present inventive example1515—***Comparative example16—xConventional example*See Table 2.**Conditions: environmental temperature: 85° C., pressure: 87.5 MPa∘ No breakage or gas leaksx There is damage or gas leaks.***Not carried out | 22,035 |
11859767 | DETAILED DESCRIPTION Reference will now be made to the present system, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. One exemplary embodiment of a system, and in particular a solar powered connected monitoring system, is illustrated inFIG.1and is designated by reference number101. A method for monitoring an amount of a commodity in a remote storage container via the system is disclosed. The method comprises (i) measuring via a sensor the amount of the commodity in the remote storage container and outputting an analog or digital signal, wherein if the signal outputted by the sensor is an analog signal, the method further comprises converting the analog signal to a digital signal. The method further comprises (ii) packaging the digital signal into a data file. In addition, the method comprises (iii) publishing via a wireless connection the data file to a message query telemetry transport (MQTT) broker for access by a user. The method additionally comprises (iv) receiving confirmation that the MQTT broker received the data file. The method also comprises (v) accessing by the user information from the data file. Finally, the method comprises (vi) repeating steps (i) to (v) after a predetermined time. Exemplary embodiments and aspects of the system and method are described below with reference to the Figures. Illustrated inFIG.2is a core system201joined to the sensor205with an electrical cable203such that the sensor205is in communication with the core system201via the cable203. The cable203is used to transmit an analog or digital signal from the sensor205to the core system205. The core system201may be referred to as a device and is part of the system101. Illustrated inFIG.3is the exploded view of the core system or device201. In the embodiment ofFIG.3, the core system or device201comprises a lower housing301, an energy storage module303, a cellular antenna305, a power management module307, an upper housing309, buttons311, light313, a processor315, a printed circuit board317, an analog to digital converter319, a memory and internal clock321, a solar cell323, and a Bluetooth Low Energy (BLE) antenna325. Illustrated inFIG.3is the upper housing309of the core system or device201, which upper housing309encapsulates components of the core system201including, but not limited to, buttons311and lights313and presents a human-machine interface. The lights313on the upper housing309provide visual feedback for the user including, but not limited to, system power indication, successful connection indication, fault indication, and low energy management module indication. The buttons311on the upper housing309provide a means for the user to conduct system functions including, but not limited to, powering up, restarting, resetting, calibrating, or powering down the core system201. The upper housing309also encapsulates the solar cell323. The solar cell converts energy from the sun into electricity. The electricity generated is stored in the energy storage module303. As understood in the art, the solar cell may alternatively be a separate part of the system101and not integral with the core system201. Said differently, the system may include a solar panel comprising the solar cell separate from the core system201, which solar cell is in electrical communication with the core system201. Further still, the system101may be powered via alternative power sources, e.g. a battery, a public utility, a generator, etc. Illustrated inFIG.3is the lower housing301of the core system201. The lower housing301encapsulates the energy storage module303. The energy storage module303may be a battery, super-capacitor, or combination of both. The bottom of the lower housing301is typically the portion of the system101and/or core system201that mounts to the storage container being monitored. The core system201may be magnetically affixed to the storage container or held in place with fasteners or an adhesive. In another embodiment, the system101is not physically attached to the storage container but is adjacent the storage container. Illustrated inFIG.3is the power management module307which converts and manages the energy stored in the energy management module303to provide energy to the system101, including electronics, during system processes and use. The power management module307is also responsible for storing the energy generated by the solar cell, when utilized, into the energy storage module303. The power management module307reads the energy level of the energy storage module303from the sensor205and transmits this information to the processor315. Illustrated inFIG.4is a diagram of how the internal components of the system101interact with each other in an exemplary embodiment. When the system101exits sleep mode, and performs the MQTT publish cycle, the analog signal from the sensor205(if not generated as a digital signal by the sensor205) is converted to a digital signal via an analog to digital converter319. If the signal generated by the sensor205is a digital signal, there is no need to utilize the analog to digital converter319or convert the analog signal into a digital signal. However, it's typical that the signal generated by the sensor205is an analog signal. This converted sensor signal is then processed by the processor and packaged into a data file, such as a JSON file. System information, such as scheduled MQTT publish cycles, error or fault codes, and the energy storage sensor reading303, are also packaged into the data file. Once the data file is created, it is stored in the memory of the system321and then transmitted to the cellular network via the cellular antenna305. As illustrated inFIG.4, the sensor205can comprise a single sensor, or a combination of sensors, including, but not limited to, a pressure sensor, temperature sensor, hall sensor, ultrasonic sensor, and light sensor. As readily understood in the art, the sensor205can be selected based on the particular fluid or commodity to be monitored via the system. For example, the sensor can measure fluid pressure (either a liquid or vapor pressure), a fluid level, etc. Illustrated inFIG.5is a flow chart diagram of the MQTT publish cycle program of the system101. This program is stored in the memory of the system321and is compiled by the processor of the system315. As illustrated inFIG.5, the first process of the program is to connect the system to the cellular network503. Once the system is connected, the system clock is calibrated to match current Universal Time (UTC)505. Once the time clock is calibrated, the MQTT publishing cycle schedule of the system is configured and set507in the system memory581. The system then connects to the MQTT broker509, initiating the first MQTT publish cycle. If the connection is successful511, the system reads the converted digital inputs from the sensor513and compiles the sensor and system data into a JSON file515. The JSON file is stored to the system's internal memory583, and then published to the MQTT broker519via the cellular network. Once the JSON file is published to the MQTT broker, the system enters an MQTT broker subscription time window, where it waits until it receives confirmation from the broker that its published JSON file has been received, and that the system is cleared to enter sleep mode521. During this process521, the system may also be directed to start a software update, recalibrate the system time clock, or to reconfigure its MQTT sleep and publish cycle schedule, instead of, or prior to, entering sleep mode. Once the published JSON file is confirmed521, the system calculates and stores the energy generation data523between the previous and current publish cycle into the memory585as a timeseries. Subsequently, the system stores the energy consumption data525between the previous and current publish cycle into the memory587as a timeseries. After storing energy consumption data525, system enters sleep mode527, the system's clock counts down the time until it reaches the next scheduled MQTT publish cycle581. Once the scheduled time is reached, the system wakes up and starts a new MQTT publish cycle529 The first process in the MQTT publish cycle involves the system connecting to the cellular network531, followed by connecting to the MQTT broker509. If the connection is successful, the system moves on to the next process. However, if the connection is unsuccessful, the system attempts to re-connect with the cellular network and MQTT broker. The system also has a predetermined number of connection attempts allowed during one MQTT publish cycle. If the number of attempts exceeds the maximum number of predetermined connection attempts533, the system skips the rest of the MQTT publish cycle and enters sleep mode527until the next scheduled publish cycle. The MQTT publish cycle described inFIG.5continues indefinitely until the user stops the process using the buttons311, or the system receives a message, via the MQTT broker705, that it must stop the MQTT publishing cycle of the system. Illustrated inFIG.6is the flow chart diagram of the program that is responsible for optimizing the publishing cycle schedule of the system101. The program is running in parallel to the MQTT publish cycle program. The program calculates the average energy usage603over a pre-determined time period. It calculates the average energy usage using the data in the energy consumed timeseries database587stored in the system's memory321. The program then calculates the average energy generated605by the solar cell323over a pre-determined time period. It calculates the average energy generated using the data stored in the energy generated timeseries database585. Once the average energy consumption and generation is determined, the program calculates the optimal publishing cycle schedule over a set time period using a combination of mathematical equations and machine learning methods607. Once the optimal publishing schedule has been determined, the program updates the publish cycle schedule document581stored in the system's memory321. Illustrated inFIG.7is a schematic and diagrammatic view of the solar powered connected monitoring system101where cellular communication703, MQTT Broker705, master controller709, database707, and web application711is employed. The 500-gallon residential propane container701is illustrated as an example of a container that is monitored by the system101. The information measured at the storage container by the system101is transmitted via cellular network to the cellular tower703. From there, the information is published to a specific topic in the MQTT broker705. Once data is published to a specific topic in the MQTT broker705, subscribed systems, such as the master controller709and database707, are capable of viewing and storing the published data. The MQTT broker allows multiple systems101to publish data to unique or general topics. The database707is subscribed to the topics in the MQTT broker and stores all of the published JSON files. The information stored is then accessed by a web application711where it can be visually displayed on a phone, tablet, or computer for access by the user. Illustrated inFIG.8is the system101installed on a 500-gallon residential propane container801. In the embodiment ofFIG.8, the sensor205of the system101replaces the fluid level gauge of the container. The terms “comprising” or “comprise” are used herein in their broadest sense to mean and encompass the notions of “including,” “include,” “consist(ing) essentially of,” and “consist(ing) of. The use of “for example,” “e.g.,” “such as,” and “including” to list illustrative examples does not limit to only the listed examples. Thus, “for example” or “such as” means “for example, but not limited to” or “such as, but not limited to” and encompasses other similar or equivalent examples. The term “about” as used herein serves to reasonably encompass or describe minor variations in numerical values measured by instrumental analysis or as a result of sample handling. Such minor variations may be in the order of ±0-25, ±0-10, ±0-5, or ±0-2.5, % of the numerical values. Further, the term “about” applies to both numerical values when associated with a range of values. Moreover, the term “about” may apply to numerical values even when not explicitly stated. Generally, as used herein a hyphen “-” or dash “—” in a range of values is “to” or “through”; a “>” is “above” or “greater-than”; a “≥” is “at least” or “greater-than or equal to”; a “<” is “below” or “less-than”; and a “≤” is “at most” or “less-than or equal to.” On an individual basis, each of the aforementioned applications for patent, patents, and/or patent application publications, is expressly incorporated herein by reference in its entirety in one or more non-limiting embodiments. It is to be understood that the appended claims are not limited to express and particular compounds, compositions, or methods described in the detailed description, which may vary between particular embodiments which fall within the scope of the appended claims. With respect to any Markush groups relied upon herein for describing particular features or aspects of various embodiments, different, special, and/or unexpected results may be obtained from each member of the respective Markush group independent from all other Markush members. Each member of a Markush group may be relied upon individually and or in combination and provides adequate support for specific embodiments within the scope of the appended claims. Further, any ranges and subranges relied upon in describing various embodiments of the present invention independently and collectively fall within the scope of the appended claims, and are understood to describe and contemplate all ranges including whole and/or fractional values therein, even if such values are not expressly written herein. One of skill in the art readily recognizes that the enumerated ranges and subranges sufficiently describe and enable various embodiments of the present invention, and such ranges and subranges may be further delineated into relevant halves, thirds, quarters, fifths, and so on. As just one example, a range “of from 0.1 to 0.9” may be further delineated into a lower third, i.e., from 0.1 to 0.3, a middle third, i.e., from 0.4 to 0.6, and an upper third, i.e., from 0.7 to 0.9, which individually and collectively are within the scope of the appended claims, and may be relied upon individually and/or collectively and provide adequate support for specific embodiments within the scope of the appended claims. In addition, with respect to the language which defines or modifies a range, such as “at least,” “greater than,” “less than,” “no more than,” and the like, it is to be understood that such language includes subranges and/or an upper or lower limit. As another example, a range of “at least 10” inherently includes a subrange of from at least 10 to 35, a subrange of from at least 10 to 25, a subrange of from 25 to 35, and so on, and each subrange may be relied upon individually and/or collectively and provides adequate support for specific embodiments within the scope of the appended claims. Finally, an individual number within a disclosed range may be relied upon and provides adequate support for specific embodiments within the scope of the appended claims. For example, a range “of from 1 to 9” includes various individual integers, such as 3, as well as individual numbers including a decimal point (or fraction), such as 4.1, which may be relied upon and provide adequate support for specific embodiments within the scope of the appended claims. The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. The invention may be practiced otherwise than as specifically described. | 16,206 |
11859768 | For clarity purposes, all reference numerals may not be included in every FIGURE. DETAILED DESCRIPTION OF THE INVENTION As illustrated inFIG.1, an embodiment of the present invention is a volatile organic compounds (VOC) collection system100comprising an inlet110, a positive displacement pump120, a first automated control valve130, a pressure vessel140(e.g., a tank for fluids under pressure), a pressure vessel top portion outlet150, and a pressure vessel bottom portion outlet160. The pressure vessel140comprises a pressure vessel top portion142and a pressure vessel bottom portion144. The inlet110receives a VOC emission. The inlet110is in fluid communication with the positive displacement pump120through an inlet-positive displacement pump connector122. The positive displacement pump120is in fluid communication with the pressure vessel140through a positive displacement pump-pressure vessel connector124. The first automated control valve130is in fluid communication with the positive displacement pump-pressure vessel connector124. The pressure vessel top portion142is in fluid communication with the pressure vessel top portion outlet150. The pressure vessel bottom portion144is in fluid communication with the pressure vessel bottom portion outlet160. The inlet-positive displacement pump connector122is under a pressure that keeps the VOC emission in a vapor phase, for example 0.15 psi. The positive displacement pump-pressure vessel connector124and the pressure vessel140are under a pressure that condenses the VOC emission and separates the VOC emission into a gas phase and a liquid phase. One of ordinary skill in the art would appreciate what pressure is required to keep the VOC emission in a vapor phase and what pressure would condense the VOC emission and separate it into a gas phase and a liquid phase. These pressures are dependent on various factors, including the type of VOCs in the VOC emission and temperature. For the pressure that would condense the VOC emission, it is preferable for this pressure to be around 135 psi. However, for some VOC emissions, the pressure may be around 300 psi, and possibly greater than 600 psi. In these higher pressure-required situations, it may be desirable to cool the system using known cooling methods to utilize a lower temperature, as condensation pressure may be dependent upon temperature. The VOC collection system100may further comprise a blanket gas manifold170. The blanket gas manifold170is in fluid communication with the inlet-positive displacement pump connector122. The blanket gas manifold170allows the introduction of an inert blanket gas into the system to avoid potential explosion, fire or other hazards. For example, the blanket gas manifold170may introduce an inert gas, such as nitrogen, into a system for extractingCannabisfor fire suppression. One advantage of the present invention, for this example, is thatCannabisextract contains terpenes (a type of VOCs), which may pose a fire hazard. An inert blanket gas would reduce the risk of fire and may be used for fire suppression. The VOC collection system100may further comprise a first pressure sensor180. The first pressure sensor180is in fluid communication with the inlet-positive displacement pump connector122. The first pressure sensor180may be connected to a control system, which an operator may regulate and set the pressure in the system from the inlet110to the positive displacement pump120, for example, by regulating the pressure of the incoming fluid through the inlet, or by controlling, adjusting, or operating, the positive displacement pump120. The VOC collection system100may further comprise at least one first manual control valve190. The at least one first manual control valve190is in fluid communication with the inlet-positive displacement pump connector122. The at least one first manual control valve190may be utilized for maintenance of the system.FIG.1illustrates an embodiment with two first manual control valves190, although the system may be configured with less than or more than two first manual control valves190. The VOC collection system100may further comprise a bladder tank200having an atmosphere port202. The bladder tank200is in fluid communication with the inlet-positive displacement pump connector122through a bladder connector204. The bladder tank200may interact with the atmosphere through atmosphere port202, which allows for the filling and emptying of bladder tank200that further allows for the equalization of blanket gas (if blanket gas is used with the VOCs) and allows for the filling and emptying in tanks that are connected to the blanket gas manifold170in an adjacent processing system, for example, an adjacent processing system (not shown) which feeds VOCs to the collection system according to the present invention. The filling and emptying of the bladder tank200, inflates and deflates the bladder206when the adjacent processing system tanks are filled or emptied, respectively. This maintains the pressure in bladder connector204and pump connector122by responding to atmospheric pressure changes analogous to open tanks, while the bladder completely isolates bladder connector204and pump connector122from the atmosphere. The size of the bladder206is determined by the size of the largest tank in the adjacent processing system (not shown) so that the bladder tank200can be filled completely and/or emptied completely without over pressuring the bladder206and kicking on the positive displacement pump120so that the positive displacement pump120would only be activated if there was an event in the adjacent processing system (not shown) such as a leak from a high pressure vessel which may also affect the pressure in the inlet-positive displacement pump connector122that would be measured by first pressure sensor180. The system may comprise one or more bladder tank manual control valves205that in fluid communication with the bladder connector204and the bladder tank200. The VOC collection system100may further comprise a second pressure sensor210. The second pressure sensor210is in fluid communication with the positive displacement pump-pressure vessel connector124. The second pressure sensor210may be connected to a control system, which an operator may regulate and set the pressure in one or more of the positive displacement pump-pressure vessel connector124, the pressure vessel top portion outlet-volatile organic compound digester connector154, the pressure vessel top portion142, and the second automated control valve260. The operator sets the pressure to the pressure that separates the VOC emission into a gas phase and a liquid phase. In the pressure vessel140, the VOC emission is compressed to a gas phase and a liquid phase separation. Compounds that do not condense at the set condensation pressure form a gas in the pressure vessel top portion142. Compounds that condense at the set pressure form a liquid phase in the pressure vessel bottom portion144. The VOC collection system100may further comprise at least one second manual control valve220. The at least one second manual control valve220is in fluid communication with the positive displacement pump-pressure vessel connector124. The at least one second manual control valve220may be utilized for maintenance of the system.FIG.1illustrates an embodiment with four second manual control valves220, although the system may be configured with less than or more than four second manual control valves220. The VOC collection system100may further comprise a backflow prevention valve230. The backflow prevention valve230is in fluid communication with the positive displacement pump-pressure vessel connector124and the pressure vessel top portion142. The pressure vessel140may further comprise a sight glass146and a level sensor148. An operator may utilize the sight glass146to observe and monitor the gas and liquid phase levels. The level sensor148may be connected to a control system, which an operator may regulate and control the gas and liquid phase levels. The VOC collection system100may further comprise a liquid phase pump240. The liquid phase pump240is in fluid communication with the pressure vessel bottom portion outlet160through a pressure vessel bottom portion outlet-liquid phase pump connector162. The liquid phase pump240is in fluid communication with a liquid phase storage tank164through a liquid phase pump-liquid phase storage tank connector166. The liquid phase pump240may be utilized to pump the liquid phase to the liquid phase storage tank164. The VOC collection system100may further comprise at least one third control valve250, which maybe automated or manual valve. The at least one third control valve250is in fluid communication with the pressure vessel bottom portion outlet-liquid phase pump connector162. The at least one third control valve250may be utilized for maintenance of the system.FIG.1illustrates an embodiment with one third control valve250, although the system may be configured with less than or more than one third control valve250. The pressure vessel top portion outlet150may be in fluid communication with a VOC digester (not shown) through a pressure vessel top portion outlet-VOC digester connector154, and outlet152. The VOC collection system100may further comprise a second automated control valve260. The second automated control valve260is in fluid communication with the pressure vessel top portion outlet-VOC digester connector154. The second automated control valve260may be connected to a control system, which an operator may regulate the pressure within the pressure vessel top portion outlet-volatile organic compound digester connector154. The VOC collection system100may further comprise at least one fourth manual control valve270. The at least one fourth manual control valve270is in fluid communication with the pressure vessel top portion outlet-VOC digester connector154. The at least one fourth manual control valve270may be utilized for maintenance of the system.FIG.1illustrates an embodiment with three fourth manual control valves270, although the system may be configured with less than or more than three fourth manual control valves270. The VOC collection system may further comprise a manual overpressure valve280. The manual overpressure valve280is in fluid communication with the pressure vessel top portion outlet-VOC digester connector154through a first manual pressure valve connector282. The manual overpressure valve280is in fluid communication with the pressure vessel top portion outlet-VOC digester connector154through a second manual pressure valve connector284. The first manual pressure valve connector282is fluid communication with the pressure vessel top portion outlet-VOC digester connector154between the pressure vessel140and the second automated control valve260. The second manual pressure valve connector284is in fluid communication with the pressure vessel top portion outlet-VOC digester connector154between the second automated control valve260and the outlet152to a VOC digester. The manual overpressure valve280may allow the transfer of the gas phase containing the VOC if the second automated control valve260should fail. For very toxic VOC, the system may further comprise additional automated control valves and safety overflow valves. Another embodiment of the present invention is a method of collecting and processing VOC comprising receiving a VOC emission through an inlet110; processing the VOC emission through a VOC collection system100; establishing fluid communication between the inlet110and the positive displacement pump120through an inlet-positive displacement pump connector122; establishing fluid communication between the positive displacement pump120, the first automated control valve130, the pressure vessel140, the pressure vessel top portion outlet150, and the pressure vessel bottom portion outlet160; maintaining the inlet-positive displacement pump connector under a pressure that keeps the VOC emissions in a vapor phase; and, separating the VOC emission into a gas phase and a liquid phase in the pressure vessel140under a pressure that condenses the VOC emission and separates the VOC emission into the gas phase and the liquid phase. The VOC collection system100comprises the inlet110, a positive displacement pump120, a first automated control valve130, a pressure vessel140, a pressure vessel top portion outlet150, and a pressure vessel bottom portion outlet160. The pressure vessel comprises140a pressure vessel top portion142and a pressure vessel bottom portion144. As an example, the VOC collection system100may be utilized to recover solvent used in a system that extracts cannabidiol (CBD) fromCannabisand/or hemp. A VOC emission containing the solvent is introduced into the VOC collection system100through the inlet110. As a potential fire hazard is present, an inert gas, such as nitrogen, is introduced through the blanket gas manifold170. The pressure in the inlet-positive displacement pump connector122, from the inlet110to the positive displacement pump120, may be set at pressure P1that preferably keeps the VOC emission in a vapor or gas phase. Pressure P1will be determined by the operator based on various factors, including temperature, system components (e.g., is a bladder tank used), content of the VOC, and others, and may range from 0.01 psi to over 1000 psi. The first pressure sensor180may be utilized to monitor pressure P1. The first manual control valve(s)190may be utilized for maintenance. As the VOC emission is pumped into the positive displacement pump-pressure vessel connector124and pressure vessel140, the VOC emission may be condensed into a gas phase and a liquid phase as the pressure in the positive displacement pump-pressure vessel connector124, the pressure vessel140, and the pressure vessel top portion outlet-volatile organic compound digester connector154may be set at pressure P2at which the VOC would condense and encourage separation of the desired liquid phase (solvent in this CBD extraction example, e.g., alcohol) from the rest of the VOCs or any blanket gases. Pressure P2will also be determined by the operator based on various factors, including temperature, system components, content of the VOC, desired liquid to be separated, and other factors, and may vary widely. The second pressure sensor210may be utilized to monitor pressure P2. The second manual control valve(s)220and the fourth manual control valve(s)270may be utilized for maintenance of the VOC collection system100. The first automated control valve130and the second automated control valve260may work independently or together to regulate and control pressure P2. The second pressure sensor210, the first automated control valve130, and the second automated control valve260may be connected to a control system. An operator/user may set pressure P2in the control system and the second pressure sensor210measures pressure P2and relays back to the control system whether the first automated control valve130and/or the second automated control valve260need to be adjusted to alter the pressure. The backflow prevention valve230may be utilized for safety reasons. For example, the backflow prevention valve230may prevent high pressure fluid from flowing back into the positive displacement pump120. As the VOCs enter through the top of the pressure vessel140, the liquid phase falls to the pressure vessel bottom portion144and the gas phase collects in the pressure vessel top portion142. The gas phase exits the pressure vessel140through the pressure vessel top portion outlet150into the pressure vessel top portion outlet-volatile organic compound digester connector154. The gas phase then exits the VOC collection system100through the outlet152. The gas phase may then be further processed through a digester. The manual overpressure valve280may be utilized as a fail-safe backup valve or for safety reasons. For example, in the event of a malfunction of the second automated control valve260, the gas phase may flow from the pressure vessel140, through the pressure vessel top portion outlet152, into the pressure vessel top portion outlet-volatile organic compound digester connector154, into the first manual pressure valve connector280, through the manual overpressure valve280, into the second manual pressure valve connector284, and then to the outlet152, thereby bypassing the malfunctioning second automated control valve260. The liquid phase exits the pressure vessel140through the pressure vessel bottom portion outlet160into the pressure vessel bottom portion outlet-liquid phase pump connector162. The liquid phase pump240pumps the liquid phase from the pressure vessel bottom portion outlet-liquid phase pump connector162into the liquid phase pump-liquid phase storage tank connector166. The liquid phase then is collected into the liquid phase storage tank164. The third control valve(s)250may be utilized for maintenance, and/or to control the flow of the liquid phase from connector162to pump240. An operator/user may utilize the sight glass146and the level sensor148to determine the amount of the liquid phase in the pressure vessel140. Based upon the operator's observations may operate the liquid phase pump240to pump the liquid phase into the liquid phase storage tank166. In another example, the VOC collection system100may be utilized to convert waste into energy (e.g., to convert or separate waste into or from fuel or flammable fluids). A VOC emission from waste processing, or VOC emission containing waste, is introduced into the VOC collection system100through the inlet110. The pressure in the inlet-positive displacement pump connector122, from the inlet110to the positive displacement pump120, is set at pressure P1that preferably keeps the VOC emission in a vapor or gas phase. Pressure P1will be determined by the operator based on various factors, including temperature, system components (e.g., is a bladder tank used), content of the VOC, and others, and may range from 0.01 psi to over 1000 psi, or even several thousand psi if, for example, methane or similar fluids, need to be liquefied or are being collected. The first pressure sensor180may be utilized to monitor pressure P1. The first manual control valve(s)190may be utilized for maintenance. As the VOC emission is pumped into the positive displacement pump-pressure vessel connector124and pressure vessel140, the VOC emission may be condensed into a gas phase and a liquid phase as the pressure in the positive displacement pump-pressure vessel connector124, the pressure vessel140, and the pressure vessel top portion outlet-volatile organic compound digester connector154may be set at pressure P2. In the waste to energy conversion example. pressure P2will be determined by the operator based on various factors, including temperature, system components, content of the VOC, desired liquid to be separated, and other factors, and may vary widely. The second pressure sensor210may be utilized to monitor pressure P2. The second manual control valve(s)220and the fourth manual control valve(s)270may be utilized for maintenance of the VOC collection system100. The first automated control valve130and the second automated control valve260may work independently or together to regulate and control pressure P2. The second pressure sensor210, the first automated control valve130, and the second automated control valve260may be connected to a control system. An operator/user may set pressure P2in the control system and the second pressure sensor210measures pressure P2and relays back to the control system whether the first automated control valve130and/or the second automated control valve260need to be adjusted to alter the pressure. The backflow prevention valve230may be utilized for safety reasons. For example, the backflow prevention valve230may prevent high pressure fluid from flowing back into the positive displacement pump120. As the VOCs enter through the top of the pressure vessel140, the liquid phase falls to the pressure vessel bottom portion144and the gas phase collects in the pressure vessel top portion142. The gas phase exits the pressure vessel140through the pressure vessel top portion outlet150into the pressure vessel top portion outlet-volatile organic compound digester connector154. The gas phase then exits the VOC collection system100through the outlet152. The gas phase may then be further processed through a digester. The manual overpressure valve280may be utilized for as a fail-safe backup valve or safety reasons. For example, in the event of a malfunction of the second automated control valve260, the gas phase may flow from the pressure vessel140, through the pressure vessel top portion outlet152, into the pressure vessel top portion outlet-volatile organic compound digester connector154, into the first manual pressure valve connector280, through the manual overpressure valve280, into the second manual pressure valve connector284, and then to the outlet152, thereby bypassing the malfunctioning second automated control valve260. The liquid phase, which in this example may comprise fuel extracted from the VOC emission (including, for example, methane, butane, propane, and other fuels or flammable fluids), exits the pressure vessel140through the pressure vessel bottom portion outlet160into the pressure vessel bottom portion outlet-liquid phase pump connector162. The liquid phase pump240pumps the liquid phase from the pressure vessel bottom portion outlet-liquid phase pump connector162into the liquid phase pump-liquid phase storage tank connector166. The liquid phase then is collected into the liquid phase storage tank164. In this example a system according to the present invention maybe used to separate different fluids (e.g., methane, butane, propane) in pressure vessel140by liquefying on or more of them in liquid phase (e.g., propane and butane) while others remain in the gas phase (e.g., methane). Pressures P1and P2will be selected as needed to achieve the desired separation, as would be known to a person skilled in the art. The third control valve(s)250may be utilized for maintenance, and/or to control the flow of the liquid phase from connector162to pump240. An operator/user may utilize the sight glass146and the level sensor148to determine the amount of the liquid phase in the pressure vessel140. Based upon the operator's observations may operate the liquid phase pump240to pump the liquid phase into the liquid phase storage tank166. While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes, omissions, and/or additions may be made and equivalents may be substituted for elements thereof without departing from the spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Moreover, unless specifically stated any use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. | 23,536 |
11859769 | DETAILED DESCRIPTION OF EXEMPLARY IMPLEMENTATIONS The detailed description explains exemplary embodiments of the present invention, together with advantages and features, by way of example with reference to the drawings, in which similar numbers refer to similar parts throughout the drawings. Any schematics, charts or flow diagrams depicted or process descriptions disclosed herein are examples. There may be many variations to these diagrams or descriptions, or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order, or steps may be added, deleted, or modified. All these variations are considered to be within the scope of the claimed invention. Like reference symbols in the various drawings indicate like elements. FIG.1depicts a schematic view of an exemplary relief management system implementation comprising a sealed and evacuated containment vessel preloaded with a low-vapor-pressure (LVP) liquid at initial conditions and connected to an exemplary process relief device (PRD). InFIG.1the relief management system100comprises the containment vessel103. The containment vessel103is operably coupled with the process relief device (PRD)106. The PRD106outlet is connected through the sealed relief header109in fluid communication with the containment vessel103. In the depicted implementation the vent112is in fluid communication with the vent valve115. In the depicted implementation the vent valve115may be open or closed. In the depicted implementation the vent valve115is configured to fluidly couple the containment vessel103with the atmosphere through the vent112when the vent valve is open. In the depicted implementation the vent valve115is configured to seal the containment vessel103from the atmosphere when the vent valve115is closed. In the implementation depicted byFIG.1the draw pump118is in fluid communication with the drain valve121. In the depicted implementation the drain valve121may be open or closed. In the depicted implementation the drain valve121is configured to fluidly couple the containment vessel103with the draw pump118when the drain valve121is open. In the depicted implementation the drain valve121is configured to seal the containment vessel103from the draw pump118when the drain valve121is closed. In the depicted implementation the draw pump118may be activated or stopped. In the implementation depicted byFIG.1the low-vapor-pressure (LVP) liquid fill valve124is configured to be opened to fluidly couple the containment vessel103with the LVP liquid source127. In the depicted implementation the LVP liquid fill valve124is configured to seal the containment vessel103from the LVP liquid source127when the LVP liquid fill valve124is closed. The LVP liquid fill valve124may be opened to introduce LVP liquid from the LVP liquid source127into the containment vessel103. With continuing reference toFIG.1the containment vessel103may be prepared for service based on preloading the containment vessel103with material. The containment vessel103may be preloaded with LVP material. Prior to placing the containment vessel103into service, the containment vessel103pressure may be equalized with ambient conditions by opening the vent valve115. The containment vessel103may then be fully filled with LVP liquid from the LVP liquid source127using the LVP liquid fill valve124. When the containment vessel103is fully filled with LVP liquid, the vent valve115is closed and the LVP liquid level in the containment vessel103is drawn down by the draw pump118using the drain valve121. The vent valve115remains closed as the LVP liquid inventory130within the containment vessel103is withdrawn. The outlet elevation of the PRD106may be maintained at a higher elevation than the containment vessel103so that liquids from the containment vessel103cannot flow backward to the PRD106. When liquid is present in the containment vessel103, this elevation difference between the containment vessel103and the PRD106outlet forms the seal leg133in the relief header109. As the LVP liquid inventory130within the containment vessel103is withdrawn, the headspace136will form above the LVP liquid level in the containment vessel103and the headspace vacuum139will form in the headspace136. In an illustrative example the headspace136is a volume that is a portion of the containment vessel103volume. The headspace136volume may be under vacuum pressure from the headspace vacuum139. In the depicted implementation the LVP liquid has virtually no measurable vapor pressure. The low vapor pressure of the LVP liquid at ambient or similar temperatures for which the system is designed prevents the LVP liquid from flashing to vapors in the containment vessel103headspace136. Note that the LVP liquid vapor pressure would increase if the temperature were increased to temperatures far above any reasonable operating pressure, such as hundreds of degrees C. in an illustrative example scenario. The low vapor pressure of the LVP liquid that prevents the LVP liquid from flashing to vapors in the containment vessel103headspace136also prevents the headspace136from filling with flashed vapors as the LVP liquid is pumped out of the containment vessel103. In the depicted implementation the vacuum pressure in the headspace136will increase as the LVP liquid level in the containment vessel103decreases. The vacuum pressure in the headspace136may increase to a very high level. The LVP liquid pumped out of the containment vessel103may be recovered in a transfer tank using the LVP liquid transfer outlet142and the LVP liquid transfer valve145. When the desired level of headspace vacuum pressure is reached, the draw pump118is stopped and the drain valve121is closed. The LVP liquid level in the containment vessel103is higher than the elevation level at which the relief header109connects to the containment vessel103. The volume of LVP liquid that flows from the containment vessel103into the relief header109and equalizes with the level of LVP liquid in the containment vessel103forms the seal-leg133. The containment vessel103is then ready for service. With continuing reference toFIG.1the depicted relief management system100further comprises the processing unit148. The processing unit148may be a generic hydrocarbon processing unit. The processing unit148may be part of an integrated hydrocarbon processing unit. In the depicted implementation the processing unit148comprises the heater151. In the depicted implementation the heater151is a fuel-fired heater. The heater151may be, for example, an electric heater, or a heater using hot fluids from some other part of an exemplary process or plant. The heater151may be any heat source configured to inject energy into the process. In the depicted implementation the processing unit148further comprises the process vessel154. In the depicted implementation the fired heater151receives the feed157comprising incoming liquid hydrocarbon material from storage or other upstream equipment. In the depicted implementation the fired heater151heats the feed157. The heated feed material exits the fired heater151through the heater process outlet160. In the depicted example the feed157is heated by the fired heater151using fuel supplied to the heater fuel inlet163. The heated feed material from the heater process outlet160flows into the process vessel154. In the depicted implementation the process vessel154has a maximum allowable work pressure (MAWP), which is protected by the normally closed PRD106in fluid communication with the process vessel154through the sealed conduit166. In an illustrative example the processing unit148may comprise functional units configured to implement an exemplary process in collaboration with the process vessel154. All such functional units configured to implement an exemplary process using the processing unit148may be considered as protected from overpressure by the process relief system100. The process vessel154and the functional units comprising the processing unit148may be configured to implement an exemplary process wherein something other than a combustible fuel may be a source of energy input. For example the depicted processing unit148includes the process control valve169configured to govern material flow to the product outlet172. The material flow from the product outlet comprises the product175. In the depicted example the pressure within the process vessel154may be determined using the product pressure indicator for process pressure control (PC)176. In the depicted example the processing unit148also includes exemplary by-product composition control (LC) valve178configured to govern composition of a by-product stream through the by-product outlet181. In some examples the composition of the by-product stream may be adjusted using the LC valve178based on a composition measurement from the by-product composition indicator184. In an illustrative example the processing unit148may comprise a reactor187, a separator190, a phase separation drum or a distillation column operably coupled with the process vessel154. In some examples one or more by-products may comprise wastewater193. In continuing reference toFIG.1the containment vessel103may be located a safe distance away from the processing unit148such that any scenario in the processing unit148that might cause the PRD106to relieve material will not be a scenario that also affects or compromises the containment vessel103(such as a localized process fire). Prior to starting the processing unit148, the containment vessel103may be preloaded with LVP liquid in line with what has been described herein, to prepare the processing unit148for service with over pressure protection provided by the containment vessel103. When the processing unit148is in normal operation, the containment vessel103is sealed and all of the inlet and outlet valves are closed. A typical relief scenario where the PRD106may relieve material from the process vessel154into the sealed relief header109may occur when a pressure valve mis-operates. The root cause of a relief scenario may be more than one specific action, but the net process effect is that the process vessel154is “blocked-in” and the heater151continues to input heat into the system. Under this scenario, the pressure inside the process vessel154will quickly climb to the MAWP. In an illustrative example the PRD106may be considered as a process relief valve that is kept normally closed by the force of an internal spring opposing the pressure inside the process vessel154. In this example when the pressure force inside the process vessel154exceeds the resisting force of the spring, the process relief valve will open and allow material to flow out of the process vessel154and into the sealed relief header109. The PRD106may comprise a spring-loaded pressure safety valve (PSV). The PRD106may comprise a pilot-operated PSV. When the causes of the relief scenario are remedied and the process vessel154returns to normal operating pressure, the PRD106will automatically close and cease allowing material to flow into the sealed relief header109. For example in the case of a spring-loaded PRD, the internal PRD spring will automatically close and stop permitting material flow into the sealed relief header109. In an exemplary relief scenario, material exiting the PRD106and flowing through the sealed relief header109toward the containment vessel103may be a hot vapor stream because the sealed relief header109would be at a lower pressure than the process vessel154. In continuing reference toFIG.1hot vapors entering the sealed relief header109flow toward the containment vessel103due to the pressure gradient between the process vessel154and the containment vessel103. As the hot vapors flow through the liquid material in the seal leg133and the containment vessel103, the preloaded LVP liquid absorbs the thermal energy from the hot relieving vapors which cools and condenses the relieving vapors. In an illustrative example the minimum mass of the LVP liquid maintained within the containment vessel103while the process is operating may be such a mass of LVP liquid that has been determined to be able to absorb and condense the maximum mass of relief vapors entering the system. Therefore, once all of the process vapor relief sizing cases are calculated (including normal allowances for load-mitigation measures), the largest relief scenario (for example a power-failure, or pool-fire) may determine the size of the containment vessel103and quantity of LVP liquid contained therein (for example the LVP liquid inventory130, depicted at least byFIGS.1-3) plus a safety margin. Some additional system absorption/condensation capacity of the containment vessel103may occur by allowing the containment vessel103pressure to increase to the maximum allowable backpressure of any pressure safety valve (PSV) or process relief device (PRD) connected to the sealed relief header109. The maximum containment vessel103working pressure may be less than 1,515 mmHg(a), which would not qualify the containment vessel103as subject to the rules and regulations of any “Pressure Vessel Code.” In an illustrative example the containment vessel103and relief management system100may be designed to implement a maximum containment vessel103working pressure less than a particular pressure vessel code enforced within a specific jurisdiction or region. Once all of the process relief contingencies are analyzed and PRD sized to safely manage these contingencies, an exemplary procedure for calculating the minimum residual mass of the LVP liquid inventory130in an exemplary containment vessel103when in service may be determined as follows:Select which relief scenarios generate the highest thermal mass rate of vapor from the process (peak relief rate).At the relief conditions, calculate the steady-state rate of ambient LVP liquid such that a single stage flash produces no residual vapor (i.e., all vapor is condensed and absorbed by the liquid).Example: 9,873 kg/hr of vapor @180° F. mixing with 32,575 kg/hr produces no residual vapor at 1,515 mmHg (a). This equates to 3.3 kg LVP liquid per kg of relief vapor.Estimate the maximum reasonable duration of the relief event at peak relief loads or the maximum stored inventory of relieving material inside the relieving vessel (whichever is largest).Example: Process inventory in relieving vessel is 500 kg or average duration at peak relief rate is 3 minutes until inventory is emptied, contingency mitigation measures are implemented and the mass flow rate through the PRD falls to near zero.Multiply the estimated total process mass relieved through the PRD times the vapor absorption factor determined earlier.Example: 500 kg*3.3 kg liquid/kg Vapor=1,650 kg LVP liquid (˜12 bbls)Multiply the calculated minimum mass sponge oil mass by safety design factor.Example 12 bbls*1.5=18 bbls or 750 gals or ˜2.8 m3 In this exemplary procedure for calculating the minimum residual mass of the LVP liquid inventory130in an exemplary containment vessel103when in service, the remaining volume of the containment vessel103is headspace136above the static LVP liquid inventory130. The headspace volume may be greater than the total volume of the process equipment being protected by the PRD. FIG.2depicts a schematic view of the exemplary relief management system implementation ofFIG.1at static conditions after a relief event showing the containment vessel having an increased liquid level and a headspace at higher pressure with any uncondensed vapors. InFIG.2the exemplary relief management system100is shown in an exemplary static state after an exemplary relief event has subsided. The LVP liquid inventory130within the containment vessel103has been heated by the incoming hot vapor from the PRD106. The heated LVP liquid inventory130is the LVP Liquid Phase and Condensed PRD Vapors200depicted byFIG.2. The LVP Liquid Phase and Condensed PRD Vapors200has been heated but is not vaporized since the sensible heat capacity of the mass inside the containment vessel103is greater than the thermal mass vented from the process, by design. Moreover, because the vapor pressure of LVP liquid is nearly zero, extremely high temperatures would be required for the LVP liquid within the containment vessel103to enter a vapor state. The liquid volume of the LVP liquid comprising the LVP Liquid Phase and Condensed PRD Vapors200within the containment vessel103has increased, reflecting the absorption of PRD vapors that are condensed as they bubble up through the cooler LVP liquid. As the vapors condense, the warm PRD vapors at containment vessel Maximum Allowable Working Pressure (MAWP)203(depicted byFIG.2) will form within the containment vessel103above the LVP liquid comprising the LVP Liquid Phase and Condensed PRD Vapors200. PRD vapors not initially condensed by contact with the LVP liquid may condense directly from the headspace136as the pressure inside the containment vessel103begins to elevate. The headspace136will contain any residual PRD vapors in equilibrium with the final temperature of the LVP liquid phase and the MAWP of the containment vessel103, depicted byFIG.2as residual PRD vapors in equilibrium with final temperature206. For example, at 1,515 mmHg(a) pressure, n-pentane has a bubble point temperature of around 36° C. Consequently, if the LVP bulk temperature is maintained below 36° C., n-pentane will be in the liquid phase and remain dissolved within the LVP mass. Only above 36° C. will the temperature be high enough for n-pentane to begin raising the pressure inside the headspace136. For n-hexane, the maximum LVP liquid phase temperature increases to 69° C. As the hydrocarbon molecular weight of the relieving hot vapor increases, the containment system's maximum heat absorption capacity also increases. Moreover, as the relief vapor molecular weight increases, the hydrocarbon vapor pressure decreases, which further increases the capacity of the system to safely contain the relief event. These technical effects make exemplary implementations particularly suited to hydrocarbon processing units that do not contain appreciable amounts of n-butane or lighter hydrocarbons in their feedstock. FIG.3depicts a schematic view of an exemplary relief management system implementation comprising a radiator coil and a connection to introduce a high-vapor-pressure (HVP) liquid into the containment vessel that flashes during evacuation that increase the headspace volume and occupies the headspace to provide additional heat rejection capacity and volume. InFIG.3the headspace136of the evacuated containment vessel103is partially filled with a high-vapor pressure (HVP) material300. The HVP material300may comprise liquid. The HVP material300may comprise a plurality of hydrocarbons. The HVP material300may comprise C5-C6 hydrocarbons. The HVP material300may consist of material that does not comprise hydrocarbons. The HVP300material that does not comprise hydrocarbons may comprise other HVP liquids such as alcohols, aldehydes, ketones, inorganic liquids, or water. The HVP material300may comprise C4-C10 hydrocarbons. The HVP material300may comprise at least two hydrocarbons selected from any of C4, C5, C6, C7, C8, C9 or C10. The containment vessel103may be partially filled with the HVP material300by introducing the HVP material into the containment vessel103during an exemplary initial fill operation. The containment vessel103may be partially filled with the HVP material300by introducing the HVP material300into the containment vessel103after an exemplary evacuation operation. The evacuation operation may be a partial evacuation. In the implementation depicted byFIG.3the HVP liquid fill valve303is configured to permit introducing HVP material300into the containment vessel103from the HVP liquid source306. As the HVP material300is introduced into the evacuated containment vessel103, the HVP material300may flash into a vapor phase and cause the containment vessel103pressure to begin rising to toward ambient pressure while remaining under vacuum. The containment vessel103pressure may rise to toward ambient pressure while remaining under modest vacuum. The residual level of vacuum may still be deep vacuum. The deeper the vacuum the greater will be the driving force causing relieved material to flow from process vessel154via PRD106to a recovery vessel. In an illustrative example the static containment vessel103pressure after initial evacuation of the LVP liquid to the normal liquid level (NLL) will be proportional to the quantity of HVP material300added and partly dependent on ambient temperature. In an illustrative example when a process relief event occurs and the relief material enters the containment vessel103, the pressure within the containment vessel103will rise and the vaporized HVP material300in the containment vessel103headspace136will begin condensing and as a result tend to sustain the head space volume for occupation by relieved material. An exemplary pressure-condensation implementation using HVP material300disclosed herein may provide an exemplary containment vessel103implementation with additional heat absorption capacity. The additional heat absorption capacity added to the containment vessel103by the HVP material300may permit more efficient utilization of containment vessel103capacity and may increase the amount of energy that can be absorbed from a relief event, increasing safety margins and reducing equipment and material cost. In an illustrative example the additional heat absorption capacity added to an exemplary containment vessel103implementation according to the present disclosure may be equivalent to the “latent heat” of HVP material300added to the containment vessel103. For example, if a 50/50 mixture of isopentane and n-pentane comprised the HVP material300, and the containment vessel103initial pressure was drawn down to 9.7 psia, the HVP material300would occupy most of the vapor space at 80° F. as a vapor at ambient conditions. At these initial conditions, if a relief event occurred and the containment vessel103pressure increased to 29.7 psia, most of the HVP material300would condense back into a liquid phase and absorb an additional 123 btu/lb of heat from the relieving vapor mass. This extra heat absorption capacity is in addition to the sensible heat absorption capacity of the LVP liquid inventory130within the containment vessel103. In the implementation depicted byFIG.3, the sealed relief header109flows toward the containment vessel103through the radiator coil vapor cooler309to add additional heat rejection capacity to the containment vessel103. The HVP material300may comprise compounds having range of normal boiling points, such as C5 to C10 hydrocarbons that are completely soluble in the LVP liquid inventory130. In an illustrative example these compounds have normal boiling points between 38-105° C. at ambient pressure. When a relief event occurs, as the evacuated containment vessel103begins receiving hot relief vapor from the PRD106, the LVP liquid phase temperature will begin to rise. The lighter-boiling fractions of the HVP material will begin to vaporize into the headspace136of the containment vessel103, causing the containment vessel103pressure to begin rising and LVP liquid phase temperature to rise at a slower rate. As the containment vessel103pressure continues to rise, pressure-condensation of the lighter boiling compounds slows the rate of the pressure rise. As LVP liquid temperature within the containment vessel103continues to rise, the system pressure begins to condense the higher boiling compounds within the added HVP material300. If the HVP material300contains n-pentane, the containment vessel103LVP oil may condense relief vapors up to around 60° C. before the containment vessel103pressure reaches 15 psig. HVP liquid may be referred to as sponge oil. For n-Hexane, temperatures can be as high as 93° C. before the containment vessel103pressure reaches 15 psig. The containment vessel103pressure rise during an exemplary relief event may be controlled by pumping a portion of the heated LVP liquid inventory130to an exemplary liquid transfer tank using the LVP liquid transfer outlet142and the LVP liquid transfer valve145. Fresh LVP liquid initially at ambient conditions may be added to the containment vessel103during a relief event. In an illustrative example fresh LVP liquid to be added to the containment vessel103may be stored in an exemplary LVP liquid storage vessel separate from the containment vessel103. Adding LVP liquid initially at ambient conditions to the containment vessel103during a relief event may replace any heated LVP liquid inventory130transferred out of the containment vessel103. Replacing heated LVP liquid inventory130transferred out of the containment vessel103may help to maintain system pressure below maximum allowable operating pressure. In illustrative examples controlling the containment vessel103pressure rise during an exemplary relief event using a portion of the heated LVP liquid inventory130, or adding fresh LVP liquid initially at ambient conditions, may be implemented as passive operations using LVP storage tanks. The additional LVP material may be transferred to a storage tank that is below the liquid level via a relief valve set to open at ˜1.515 mmHg. The LVP material may be stored at a slight elevation such that at ˜1.515 mmHg material could be drawn from a second storage tank above the liquid level in the containment vessel103. Such an implementation may provide a passive operation adding significantly to the capacity of the system to absorb material from a relief event. FIG.4depicts a chart view of mass change data illustrating exemplary mass oscillations of liquid phase species over time. InFIG.4, the vertical axis represents delta changes in mass (M) between liquid and vapor with respect to time (t), dM/dt in units of LBS/SEC, and the horizontal axis represents time in units of Seconds. The mass change data charted byFIG.4illustrate change in mass with respect to time for iC4-L400, nC4-L403, iC5-L406, nC5-L409, CYC5-L412, nC6-L415, CYC6-L418, nC7-L421and Tol-L424. InFIGS.4and6-12plots designated with a label that includes an “L” represent a liquid (e.g. iC4-L400inFIG.4) and plots designated with a label that includes a “V” represent a vapor (e.g. iC5-V inFIG.6). The mass oscillations depicted byFIG.4show each species of a multi-component design comprising a plurality of species vaporizes and condenses on a pathway that is substantially unique with respect to the other species. For example, some patterns may be similar between species, but each species tends to either vaporize or condense at their unique rate. In an illustrative example, the directions of “humps” in the mass oscillations illustrated byFIG.4show the net evaporation or condensation of each species. In the mass oscillation data charted byFIG.4, a “hump” pointing up (a local peak or maximum) is net evaporation and a “hump” pointing down (a local valley or minimum) is net condensation. The net effect for a multi-component design is that the heat absorbed by the liquid mass is distributed to the vapor phase more evenly in a plurality of energy absorption processes over time for a multi-component mixture and not in sudden surges as with a single or dual compound. In the example depicted byFIG.4the iC5/nC5 surge is partially offset by a decrease in iC4/nC4 vaporization rate. In the example depicted byFIG.4the short-term surge in vaporization as the rate of iC5/nC5 mass loss accelerates substantially coincides in time with the decrease in iC4/nC4 vaporization rate that partially offsets the vapor space compression from the iC5/nC5 surge. FIG.5depicts a visualization of an exemplary model of energy dissipation potential via kinetic mass oscillations at an exemplary containment vessel liquid/vapor interface. InFIG.5the exemplary containment vessel model500visualization depicts enthalpy dissipation involving the kinetic/potential energy exchange of a multi-component mixture of a plurality of species modeled by a respective plurality of exemplary mass and spring models. In the example depicted byFIG.5the containment vessel model500comprises the process relief mass503incoming to the containment vessel103. The bulk liquid phase (string node 1)506representing the incoming enthalpy of the relief mass503binds each individual component species at the first end of the liquid/vapor interface509. In the depicted example each individual component species is modeled by an energy absorption process/string model512. In the depicted example each individual component species is bound at the second end of the liquid/vapor interface509by the bulk vapor phase (string node 2)515. In an illustrative example the “strings” here are defined as modeling the individual component species bound on one end by the incoming enthalpy of the relief mass and on the other end by a “spring,” represented by the ever-compressing vapor space within the containment vessel103. The “oscillating mass” here is the net movement of a quantity from vapor to liquid and liquid to vapor. The depicted containment vessel model500demonstrates that multi-component mixtures, with distributed and diverse boiling points between the condensation temperature of the relief mass and the final state, may be designed and configured to be stable at absorbing and dissipating the energy over time in a plurality of absorption processes. In some example implementations the multi-component mixtures may be designed and configured with diverse boiling points that are evenly distributed between the condensation temperature of the relief mass and the final state of the relief mass. FIGS.6to12depict exemplary chart views of data representing vapor/liquid phase mass change due to pressurized condensation for a plurality of hydrocarbons, in line with the example chart depicted byFIG.4and in accordance with the model depicted byFIG.5. InFIG.6, the vertical axis represents delta changes in mass (M) between liquid and vapor with respect to time (t), dM/dt in units of LBS/SEC, and the horizontal axis represents time in units of Hours. The mass change data charted byFIG.6illustrates change in mass with respect to time for iC5-V600, nC5-V603, nC6-V606, nC4-L403, iC5-L406, nC5-L409and nC6-L415. InFIGS.4and6-12plots designated with a label that includes an “L” represent a liquid (e.g. iC4-L400inFIG.4) and plots designated with a label that includes a “V” represent a vapor (e.g. iC5-V inFIG.6). InFIG.7, the vertical axis represents delta changes in mass (M) between liquid and vapor with respect to time (t), dM/dt in units of LBS/SEC, and the horizontal axis represents time in units of Hours. The mass change data charted byFIG.7illustrates change in mass with respect to time for iC5-V600, nC5-V603, nC6-V606, nC4-L403, iC5-L406, nC5-L409, nC6-L415and nC4-V700. The example depicted byFIG.7illustrates the iC5-L406surge to vapor phase is offset by the net positive condensation of nC5-L409. InFIG.8, the vertical axis represents mass in units of LBS with the left vertical scale showing liquid phase mass in LBS and the right vertical scale showing vapor phase mass in LBS, and the horizontal axis represents time in units of Hours. The mass change data charted byFIG.8illustrates change in mass with respect to time for nC4-L403, iC5-L406, nC5-L409, nC6-L415, iC5-V600, nC5-V603, nC6-V606and nC4-V700. InFIG.9, the vertical axis represents delta changes in mass (M) between liquid and vapor with respect to time (t), dM/dt in units of LBS/SEC with the left vertical scale showing Bulk Phase Inventory Change, LBS per 2 Second Interval and the right vertical scale showing Interval Change in Pressure, PSIA, and the horizontal axis represents time in units of Hours. The mass change data charted byFIG.9illustrates change in mass with respect to time for iC5-V600, nC5-V603, nC6-V606, nC4-L403, iC5-L406, nC5-L409, nC6-L415, nC4-V700, nC8-V900and Equil Pres903. The example depicted byFIG.9illustrates the sudden condensation of nC8-V900into a liquid phase condenses additional C4-C6 as the equilibrium pressure (Equil Pres903) spikes. InFIG.10, the vertical axis represents delta changes in mass (M) between liquid and vapor with respect to time (t), dM/dt in units of LBS/SEC with the left vertical scale showing Bulk Phase Inventory Change, LBS per 2 Second Interval and the right vertical scale showing Interval Change in Presssure, PSIA, and the horizontal axis represents time in units of Hours. The mass change data charted byFIG.10illustrates change in mass with respect to time for C4-C6-V1000, C4-C6-L1003and Equil Pres903. InFIG.11, the vertical axis represents delta changes in mass (M) between liquid and vapor with respect to time (t), dM/dt in units of LBS/SEC with the left vertical scale showing Bulk Phase Inventory Change, LBS per 2 Second Interval and the right vertical scale showing Interval Change in Presssure, PSIA, and the horizontal axis represents time in units of Hours. The mass change data charted byFIG.11illustrates change in mass with respect to time for C4-C6-V1000, C4-C6-L1003and Equil Pres (Equilibrium Pressure)903. The example depicted byFIG.11illustrates the C4-C6-V1000vapor phase inventory gain from relief enthalpy absorbed and the equilibrium pressure (Equil Pres903) rises from the C4-C6-V1000vapor phase mass gain. In the example depicted byFIG.11the rise of Equil Pres903also collapses emerged C4-C6-V1000and C4-C6-L1003vapor pockets back into a liquid phase. InFIG.12, the vertical axis represents phase mass change in units of LBS and the horizontal axis represents time in units of Hours. The mass change data charted byFIG.12illustrates change in mass with respect to time for nC4-L400, iC5-L406, nC5-L409, nC6-L415, nC4-V700, iC5-V600, nC5-V603and nC6-V606. FIG.13depicts exemplary models of physics variables that may be measured, manipulated or enhanced to govern or describe the operation of various implementations.FIG.13shows an exemplary chart of process variables/equations 1300 governing system design variables that can be manipulated or enhanced to extend the Total Absorbed Energy of the system at the “final state.” For example at small-scales, embodiments with enhanced ambient heat leakage and containment mass might be preferred over enhancing total volumetric capacity. However at larger scales, increasing the plurality of high-boiling species and total volume available may be more important to the ultimate thermal capacity. The depicted process variables/equations 1300 include the energy sinks 1303 and the material sinks 1306. These process variables/equations 1300 shown inFIG.13are also presented below by written description. Energy Sinks 1303 Enthalpy Gain of Liquid Phase 1306a ΔHL=ΔUL+ΔPS*V1306b Large volume of Low-Vapor-Pressure (LVP) Liquid provides stable liquid mass to absorb energy over time. Solvent Latent Heat of Vaporization 1309a ΔHS=MSV2*S(p) 1309b A Soluble High-Vapor-Pressure (HVP) Liquid will periodically flash to transfer the absorbed energy to the vapor phase. Varying the boiling points of the HVP Liquids will significantly stabilize the energy transfer at the phase boundary. Latent Heat of Condensation Relief Vapors 1312a ΔHR=MRV*R(p) 1312b Selecting the proper LVP Liquid to use based on the physical properties of the relief material. Ambient Heat Losses 1315a ΔHA=UO*AS*((T2+T1)/2−TAMB) 1315b Additional surface area added to vessel specifically for maximizing local convective losses. Vessel Mass Temperature Gain 1318a QVS=MV*CP,AV*(Ti−T0) 1318b Vessel material properties thickness selection, vessel jacketing with circulation to enhance convective losses. Enthalpy Gain of Vapor Phase 1321a ΔHV=ΔUV+ΔP*V1321b At the initial state, at least one compressible gas must be present to form a stable vacuum. In moving toward the final state of the relief event, the vapor phase continuously changes in equilibrium composition moving from lighter components to heavier ones, which slows and stabilizes the vessel pressure. Vapor Phase Compression 1324a Pc=[γ′Q1P1/(γ′−1)][(P2/P1)((γ′−1)/γ′)] 1342b Starting at the lowest arming pressure to provide the most delta-p between initial and final states. Filling vapor space with gases that can condense as they pressurize, automatically minimizes rate of pressure rise allowing for longer relief event times. Emitted Acoustic Energy 1327a Wp,i=Σ½μiωi2ν2λi1327b Vessel may be constructed with acoustic dampening elements to prevent resonance that could destabilize the system mechanically. Radiation Loss 1330a PNET=Aσε(T4−T04) 1330b Extra Sensible Loss Contributors 1333a ΔHx=MV*CP,AV*(T0−T1) 1333b Addition of either passive or active mechanical elements, such as a radiator coil, or forced-convection fan cooler will extend time to reach final state. Material Sinks 1306 Vapor Phase Densification 1336a ΔMV=VV2*Γ2−VV1*Γb1336b Liquid Phase Densification 1339a ΔML=π*DV2/4*(LMAX−L1) 1342b Total Volumetric Capacity Available 1342a ΔML=πDVv2/4*(LMAX−L1) 1342b Largely a capacity factor that is determined from the relief event and maximum safe duration allowed. See basis for sizing examples in the specification. Direct Mass Transfers 1345a ΔMRLF=variable 1345b The embodiment where accumulated Low-Vapor-Pressure (LVP) and Condensed Relief Liquids are discharged from the container while ambient fresh LVP Material is added to extend the relief capacity of the system. This step may be accomplished passively. Although various features have been described with reference to the Figures, other features are possible. In an illustrative example, preparing an exemplary containment vessel in accordance with what has been disclosed herein may be referred to as an arming process. Multiple features have been designed into the process relief system disclosed herein to provide the system with advantageous self-regulating properties. For example, because the vapor pressure of the LVP fluid is so low, removing a small amount will result in a deep vacuum in the head space as the head space forms when the LVP liquid is removed. This deep vacuum may cause the LVP extraction/drain pump to cavitate and lose suction. The initial head space volume may be too small to contain the volume of material relieved from the process. Admitting some HVP liquid into the very small head space, which is under deep vacuum due to removing LVP fluid from the sealed system, would cause the HVP fluid to flash/evaporate and cause the pressure to rise enough for the LVP fluid drain pump to regain suction. Regaining suction with a pump may be referred to as having adequate net positive suction head (NPSH). A pump may have a minimum NPSH requirement. This is how head space volume is increased (the hole) and will be determined by the target pressure, shown for example as 10 psia (a vacuum). Allowing pressure to rise enough for the LVP fluid drain pump to regain suction illustrates an example scenario using an exemplary self-regulating property of the system and permits a system design to use a moderately sized vessel capable of containing the much larger volume of material relieved from the entire facility. Increasing HVP fluid inventory, as a vapor, increases the volume available for the relieved material, the hole. This is because the HVP fluid is essentially 100% vapor at an exemplary target pressure: 10 psia. At ambient temperatures, pentane is a gas at 10 psia. Raising the pressure, caused by the relief event, results in the HVP fluid, a vapor, condensing to a liquid. An exemplary rule of thumb ratio of light HC vapor to liquid is ˜300:1. This ratio is why the capacity to absorb relieved material may be much larger than the physical volume of an exemplary relief vessel implementation. This gives the system a tendency toward maintaining the volume of the hole as the relief event unfolds; providing an example of the self-regulating property of the system. In an illustrative example, using a multi-component mixture to distribute relief mass energy over time using a plurality of energy absorption processes in a respective plurality of component hydrocarbons may reduce the peak energy to be absorbed by a containment vessel. For example, a multicomponent mixture may be designed and configured with component hydrocarbon species selected and their mass ratios adjusted to achieve particular design objectives. In some simulation scenarios based on the string model disclosed byFIG.5, the oscillating masses were calculated to generate around 300 watts of net sonic power, which explains the low-frequency drone known to occur in blocked-in vessels absorbing energy. Some implementations may comprise a multi-component mixture designed and configured to mitigate impact by this sonic component, especially at scale. For example at small scales, a multi-component mixture implementation with enhanced ambient heat leakage and containment mass might be preferred over enhancing total volumetric capacity. However at larger scales, increasing the plurality of high-boiling species and total volume available may be more important to the ultimate thermal capacity. In an illustrative example HVP material may be used to supplement or enhance an exemplary head space in the containment vessel. Without the presence of the HVP material the head space volume may be very low as when, for example, LVP fluid is pumped from the system (for example during an exemplary arming procedure) a vacuum is created. Not much LVP fluid would need to be removed before an LVP extraction pump may lose suction. By admitting a small amount of HVP into the head space where the HVP material flashes to a vapor (for example due to very low pressure in the head space, causing an increase in pressure (still under vacuum)) which would allow more HVP fluid to be removed and also increasing head space volume while remaining under vacuum. An exemplary implementation may comprise usage or configuration of various sensors configured to measure one or more physical quantity such as, for example, temperature, pressure, flow rate, and the like. An exemplary implementation may comprise usage or configuration of various actuators configured to activate, open, close, start, or stop various devices such as for example valves, vents, drains and pumps. An exemplary implementation may comprise usage or configuration of a controller or control system designed to sense input, determine conditions, and implement actions based on the input or programmed rules or procedures. For example an exemplary implementation may comprise usage or configuration of a sensor configured to permit determining the headspace vacuum pressure. An exemplary implementation may comprise a controller configured to determine if a particular pressure value of headspace vacuum pressure has been reached. The controller may be configured to use a vacuum pressure sensor and a predetermined threshold vacuum pressure to determine whether a particular pressure value of headspace vacuum pressure has been reached. The controller may be configured to determine the run time of a draw pump governed by the controller, and to use the pump run time to estimate whether the desired initial pressure of a headspace vacuum has been reached based on run time of the draw pump. As used herein, the term “high-vapor-pressure (HVP) refers to fluids with a vapor pressure at ambient pressures and temperatures of less than 10 psia. For example, normal pentane has a vapor pressure of about 60 kPa(g) at 20° C. As used herein, the term “low-vapor-pressure (LVP) refers to but not limited to very heavy oils such as petroleum derived vacuum gas oils having negligible vapor pressures at ambient conditions and with boiling points at ambient pressure in excess of 400° C. As used herein, the term hydrocarbon refers to saturated hydrocarbons as used as examples in this document but could be extended to unsaturated hydrocarbons, alcohols, aldehydes, ketones, carboxylic acids etc. An exemplary method may comprise: fluidly coupling a pressure-equalized containment vessel (103) to a Process Relief Device (PRD) (106), wherein the PRD (106) is configured to fluidly couple the containment vessel (103) with a process vessel (154) in response to a process relief event in the process vessel (154); preloading the pressure-equalized containment vessel (103) with a Low Vapor Pressure (LVP) liquid (130); partially filling an evacuated headspace (136) above the LVP liquid (130) in the containment vessel (103) with a High Vapor Pressure (HVP) material (300) configured to flash to HVP material (300) vapors and occupy the headspace (136); relieving a process relief mass (503) from the process vessel (154) into the containment vessel (103) during a process relief event in the process vessel (154), using the PRD (106); and permitting the HVP material (300) vapors to mix with the process relief mass (503) and condense to liquid in the containment vessel (103). The HVP material (300) may further comprise a plurality of hydrocarbons. The method may further comprise equalizing pressure in the containment vessel (103) with ambient conditions outside the containment vessel (103), using a vent (112). Equalizing pressure in the containment vessel (103) may further comprise opening the vent (112), using a vent valve (115). The method may further comprise preloading the containment vessel (103) with the LVP liquid (130) after equalizing pressure in the containment vessel (103). Preloading the containment vessel (103) may further comprise filling the containment vessel (103) with the LVP liquid (130), using a fill valve (124). The method may further comprise sealing the containment vessel (103) from ambient conditions outside the containment vessel (103), using a vent (112), after preloading the containment vessel (103). Sealing the containment vessel (103) may further comprise closing the vent (112), using a vent valve (115). The method may further comprise forming the evacuated headspace (136) above the LVP liquid (130) in the containment vessel (103) after sealing the containment vessel (103). The method may further comprise forming the evacuated headspace (136) above the LVP liquid (130) in the containment vessel (103) by drawing down the LVP liquid (130) in the containment vessel (103), using a drain valve (121). Drawing down the LVP liquid (130) in the containment vessel (103) may further comprise evacuating at least a portion of the LVP liquid (130) from the containment vessel (103) through the drain valve (121), using a draw pump (118). Evacuating the at least the portion of the LVP liquid (130) from the containment vessel (103) may further comprise opening the drain valve (121) and activating the draw pump (118). Forming the evacuated headspace (136) may further comprise forming a headspace vacuum (139) in the headspace (136) above the LVP liquid (130) in the containment vessel (103). The method may further comprise drawing down the LVP liquid (130) in the containment vessel (103) until a desired initial headspace vacuum (139) pressure has been reached. The desired initial headspace vacuum (139) pressure may be less than a predetermined target vacuum pressure. The method may further comprise determining if the desired initial headspace vacuum (139) pressure has been reached. The method may further comprise determining if the desired initial pressure of the headspace vacuum (139) has been reached using a vacuum pressure sensor and a predetermined threshold vacuum pressure. The method may further comprise determining if the desired initial pressure of the headspace vacuum (139) has been reached based on run time of a draw pump (118). The method may further comprise in response to determining the desired initial pressure of the headspace vacuum (139) has been reached, closing the drain valve (121) and stopping a draw pump (118). The process relief mass (503) may be relieved from the process vessel (154) through an outlet of the PRD (106) into the containment vessel (103), using a sealed relief header (109). The method may further comprise configuring the outlet of the PRD (106) at an elevation higher than the containment vessel (103). Preloading the pressure-equalized containment vessel (103) with the LVP liquid (130) may further comprise configuring an LVP liquid (130) level higher than an elevation level at which the sealed relief header (109) connects to the containment vessel (103). The plurality of hydrocarbons may further comprise a 50/50 mixture of isopentane and n-pentane. The plurality of hydrocarbons may further comprise at least three hydrocarbons. The plurality of hydrocarbons may further comprise C4, C5 and C6. The plurality of hydrocarbons may further comprise C4, C5, C6, C7, C8, C9 and C10. The plurality of hydrocarbons may further comprise at least two of C4, C5, C6, C7, C8, C9 and C10. The method may further comprise recovering at least a portion of the process relief mass (503) in a liquid state from the containment vessel (103). The method may further comprise recovering the at least the portion of the process relief mass (503) in a mixture with at least a portion of the HVP material (300). The method may further comprise returning the at least the portion of the process relief mass (503) recovered from the containment vessel (103) to a processing unit (148). An exemplary apparatus may comprise: a pressure-equalized containment vessel (103) fluidly coupled to a Process Relief Device (PRD) (106), wherein the PRD (106) is configured to fluidly couple the containment vessel (103) with a process vessel (154) in response to a process relief event in the process vessel (154), and wherein the pressure-equalized containment vessel (103) is preloaded with a Low Vapor Pressure (LVP) liquid (130); and an evacuated headspace (136) above the LVP liquid (130) in the containment vessel (103), wherein the evacuated headspace (136) above the LVP liquid (130) has been partially filled with a High Vapor Pressure (HVP) material (300) configured to flash to HVP material (300) vapors and occupy the headspace (136), and wherein the PRD (106) is configured to relieve a process relief mass (503) from the process vessel (154) into the containment vessel (103) during the process relief event and permit the HVP material (300) vapors to mix with the process relief mass (503) and condense to liquid in the containment vessel (103). The HVP material (300) may further comprise a plurality of hydrocarbons. The apparatus may further comprise a vent (112) configured to fluidly couple the containment vessel (103) with ambient conditions outside the containment vessel (103) to equalize pressure in the containment vessel (103) with the ambient conditions. The apparatus may further comprise a vent valve (115) configured to open or close the vent (112). The apparatus may further comprise the vent (112) is open. The apparatus may further comprise a fill valve (124) operably coupled with the containment vessel (103) to permit filling the containment vessel (103) with the LVP liquid (130). The apparatus may further comprise the containment vessel (103) is sealed from ambient conditions outside the containment vessel (103). The apparatus may further comprise a vent valve (115) configured to seal the containment vessel (103) from the ambient conditions based on closing a vent (112) configured to fluidly couple the containment vessel with the ambient conditions outside the containment vessel (103). The apparatus may further comprise a headspace vacuum (139) in the evacuated headspace (136) above the LVP liquid (130) in the containment vessel (103). The apparatus may further comprise a drain valve (121) in fluid communication with the containment vessel (103), wherein the drain valve (121) is configured to be open or closed, and wherein the drain valve (112) when open is operable to permit drawing down the LVP liquid (130) in the containment vessel (103) and form the evacuated headspace (136) above the LVP liquid (130) in the containment vessel (103). The apparatus may further comprise a draw pump (118) in fluid communication with the drain valve (121), wherein the draw pump (118) is configured to evacuate at least a portion of the LVP liquid (130) from the containment vessel (103) through the drain valve (121). The apparatus may further comprise the draw pump (118) is activated and the drain valve (112) is open. The evacuated headspace (136) may further comprise a headspace vacuum (139) and wherein the apparatus further comprises a source of HVP material configured to introduce HVP liquid into the evacuated headspace (136). The apparatus may further comprise a desired initial headspace vacuum (139) pressure in the evacuated headspace (136). The desired initial headspace vacuum (139) pressure may be less than a predetermined target vacuum pressure. The apparatus may further comprise a vacuum pressure sensor configured to permit determining the headspace vacuum (139) pressure. The apparatus may further comprise a controller configured to determine if the desired initial pressure of the headspace vacuum (139) has been reached using the vacuum pressure sensor and a predetermined threshold vacuum pressure. The apparatus may further comprise a controller configured to determine if the desired initial pressure of the headspace vacuum (139) has been reached based on using run time of a draw pump (118). The apparatus may further comprise a controller configured to determine if the desired initial pressure of the headspace vacuum (139) has been reached, and in response to determining the desired initial pressure of the headspace vacuum (139) has been reached, closing the drain valve (121) and stopping a draw pump (118). The apparatus may further comprise a sealed relief header (109) operably coupling an outlet of the PRD (106) into the containment vessel (103), wherein the process relief mass (503) is relieved from the process vessel (154) through the sealed relief header (109). The apparatus may further comprise the outlet of the PRD (106) is at an elevation higher than the containment vessel (103). The apparatus may further comprise the pressure-equalized containment vessel (103) is preloaded with the LVP liquid (130) having an LVP liquid (130) level higher than an elevation level at which the sealed relief header (109) connects to the containment vessel (103). The plurality of hydrocarbons may further comprise a 50/50 mixture of isopentane and n-pentane. The plurality of hydrocarbons may further comprise at least two hydrocarbons. The plurality of hydrocarbons may further comprise at least three hydrocarbons. The plurality of hydrocarbons may further comprise C4, C5 and C6. The plurality of hydrocarbons may further comprise C4, C5, C6, C7, C8, C9 and C10. The plurality of hydrocarbons may further comprise at least two of C4, C5, C6, C7, C8, C9 and C10. The apparatus may further comprise at least a portion of the process relief mass (503) in a liquid state within the containment vessel (103), wherein the at least a portion of the process relief mass (503) in the liquid state within the containment vessel (103) is in equilibrium with an LVP liquid phase final temperature. The apparatus may further comprise the containment vessel (103) configured to be fluidly coupled to a processing unit (148) to return the at least a portion of the process relief mass (503) recovered from the containment vessel (103) to the processing unit (148). An exemplary method may comprise: configuring a high-vapor-pressure (HVP) material (300) comprising a plurality of component hydrocarbons; flashing the HVP material (300) from an HVP material (300) liquid to an HVP material (300) vapor as the HVP material (300) liquid is introduced into an evacuated portion of a containment vessel (103); introducing a process relief mass (503) from a process relief event occurring outside the containment vessel (103) to mix with the HVP material (300) vapor in the containment vessel (103); and distributing energy from the process relief mass (503) within the containment vessel (103) using a plurality of individual energy absorption processes as the plurality of component hydrocarbons respectively condense to liquid phases over time. The plurality of component hydrocarbons may further comprise at least two hydrocarbons. The plurality of component hydrocarbons may further comprise at least three hydrocarbons. The plurality of component hydrocarbons may further comprise n-hexane. The plurality of component hydrocarbons may further comprise isopentane. The plurality of component hydrocarbons may further comprise n-pentane. The plurality of component hydrocarbons may further comprise a mixture comprising isopentane and n-pentane. The mixture comprising isopentane and n-pentane may further comprise a 50/50 mixture of isopentane and n-pentane. The plurality of component hydrocarbons may further comprise C4, C5 and C6. The plurality of component hydrocarbons may further comprise C4, C5, C6, C7, C8, C9 and C10. The plurality of component hydrocarbons may further comprise at least two of C4, C5, C6, C7, C8, C9 and C10. The plurality of component hydrocarbons may further comprise at least three of C4, C5, C6, C7, C8, C9 and C10. The plurality of component hydrocarbons may further comprise nC4. The plurality of component hydrocarbons may further comprise nC5. The plurality of component hydrocarbons may further comprise nC6. The plurality of component hydrocarbons may further comprise nC4, nC5 and nC6. The plurality of component hydrocarbons may have boiling points from 38° C. to 105° C. at ambient pressure. The evacuated portion of the containment vessel (103) may further comprise an evacuated headspace (136) disposed above a Low Vapor Pressure (LVP) liquid (130) retained by the containment vessel (103). The evacuated headspace (136) may have a headspace vacuum (139) pressure low enough to cause the plurality of component hydrocarbons to flash to a vapor in the headspace (136). The method may further comprise forming the evacuated headspace (136) above the LVP liquid (130) in the containment vessel (103) by drawing down the LVP liquid (130) in the containment vessel (103) through a drain valve (121), using a draw pump (118). The method may further comprise drawing down the LVP liquid (130) in the containment vessel (103) until a headspace vacuum (139) pressure low enough to cause the plurality of component hydrocarbons to flash to a vapor in the headspace (136) has been reached. The method may further comprise determining if a headspace vacuum (139) pressure low enough to cause the plurality of component hydrocarbons to flash to a vapor in the headspace (136) has been reached. The method may further comprise determining if a headspace vacuum (139) pressure low enough to cause the plurality of component hydrocarbons to flash to a vapor in the headspace (136) has been reached, using a vacuum pressure sensor and a predetermined threshold vacuum pressure. The predetermined threshold vacuum pressure may be not greater than 10.0 psia. The predetermined threshold vacuum pressure may be determined as a function of a vapor pressure of at least one hydrocarbon of the plurality of hydrocarbons. The method may further comprise determining if a headspace vacuum (139) pressure low enough to cause the plurality of component hydrocarbons to flash to a vapor in the headspace (136) has been reached based on run time of a draw pump (118). The plurality of component hydrocarbons may have a respective plurality of boiling point temperatures distributed from a condensation temperature of the process relief mass (503) to a final-state temperature of the process relief mass (503). The method may further comprise recovering at least a portion of the process relief mass (503) in a liquid state from the containment vessel (103). The method may further comprise recovering the at least the portion of the process relief mass (503) in a mixture with at least a portion of the HVP material (300). The method may further comprise returning the at least the portion of the process relief mass (503) recovered from the containment vessel (103) to a processing unit (148). The process relief event may further comprise a result of an overpressure event. The process relief event may further comprise a result of a planned relieve event. An exemplary apparatus may comprise: a high-vapor-pressure (HVP) material (300) comprising a plurality of component hydrocarbons; a containment vessel (103), wherein an evacuated portion of the containment vessel (103) has a vacuum pressure low enough to cause the HVP material (300) to flash to an HVP vapor when the HVP material (300) is introduced into the evacuated portion of the containment vessel (103); a Process Relief Device (PRD) (106) configured to introduce a process relief mass (503) into the containment vessel (103) from a process relief event occurring outside the containment vessel (103), and mix the process relief mass (503) with the HVP material (300) vapor in the containment vessel (103); and a plurality of individual energy absorption processes configured to distribute energy from the process relief mass (503) over time within the containment vessel (103) as the plurality of component hydrocarbons respectively condense to liquid phases. The plurality of component hydrocarbons may further comprise at least two hydrocarbons. The plurality of component hydrocarbons may further comprise at least three hydrocarbons. The plurality of component hydrocarbons may further comprise n-hexane. The plurality of component hydrocarbons may further comprise isopentane. The plurality of component hydrocarbons may further comprise n-pentane. The plurality of component hydrocarbons may further comprise a mixture comprising isopentane and n-pentane. The mixture comprising isopentane and n-pentane may further comprise a 50/50 mixture of isopentane and n-pentane. The plurality of component hydrocarbons may further comprise C4, C5 and C6. The plurality of component hydrocarbons may further comprise C4, C5, C6, C7, C8, C9 and C10. The plurality of component hydrocarbons may further comprise at least two of C4, C5, C6, C7, C8, C9 and C10. The plurality of component hydrocarbons may further comprise at least three of C4, C5, C6, C7, C8, C9 and C10. The plurality of component hydrocarbons may further comprise nC4. The plurality of component hydrocarbons may further comprise nC5. The plurality of component hydrocarbons may further comprise nC6. The plurality of component hydrocarbons may further comprise nC4, nC5 and nC6. The plurality of component hydrocarbons may have boiling points from 38° C. to 105° C. at ambient pressure. The evacuated portion of the containment vessel (103) may further comprise an evacuated headspace (136) disposed above a Low Vapor Pressure (LVP) liquid (130) retained by the containment vessel (103). The evacuated headspace (136) may have a headspace vacuum (139) pressure low enough to cause the plurality of component hydrocarbons to flash to a vapor in the headspace (136). The apparatus may further comprise a drain valve (121) configured to fluidly couple the containment vessel (103) with a draw pump (118) configured to draw down the LVP liquid (130) in the containment vessel (103) through the drain valve (121), thereby forming the evacuated headspace (136) above the LVP liquid (130) in the containment vessel (103). The apparatus may further comprise a controller configured to draw down the LVP liquid (130) in the containment vessel (103) until a headspace vacuum (139) pressure low enough to cause the plurality of component hydrocarbons to flash to a vapor in the headspace (136) has been reached. The apparatus may further comprise a controller configured to determine if a headspace vacuum (139) pressure low enough to cause the plurality of component hydrocarbons to flash to a vapor in the headspace (136) has been reached, based on measurement input to the controller from a vacuum pressure sensor. The apparatus may further comprise the controller configured to determine if the headspace vacuum (139) pressure low enough to cause the plurality of component hydrocarbons to flash to a vapor in the headspace (136) has been reached, using the vacuum pressure sensor and a predetermined threshold vacuum pressure. The predetermined threshold vacuum pressure may be not greater than 10.0 psia. The predetermined threshold vacuum pressure may be determined as a function of a vapor pressure of at least one hydrocarbon of the plurality of hydrocarbons. The apparatus may further comprise the controller configured to determine if the headspace vacuum (139) pressure low enough to cause the plurality of component hydrocarbons to flash to a vapor in the headspace (136) has been reached based on run time of a draw pump (118). The plurality of component hydrocarbons may have a respective plurality of boiling point temperatures distributed from a condensation temperature of the process relief mass (503) to a final-state temperature of the process relief mass (503). The apparatus may further comprise at least a portion of the process relief mass (503) in a liquid state within the containment vessel (103), wherein the at least a portion of the process relief mass (503) in the liquid state within the containment vessel (103) is in equilibrium with an LVP liquid phase final temperature. The apparatus may further comprise the containment vessel (103) configured to be fluidly coupled to a processing unit to return the at least a portion of the process relief mass (503) recovered from the containment vessel (103) to the processing unit. The process relief event may further comprise a result of an overpressure event or a planned relieve event. In the Summary above and in this Detailed Description, and the Claims below, and in the accompanying drawings, reference is made to particular features of various implementations. It is to be understood that the disclosure of particular features of various implementations in this specification is to be interpreted to include all possible combinations of such particular features. For example, where a particular feature is disclosed in the context of a particular aspect or implementation, or a particular claim, that feature can also be used—to the extent possible—in combination with and/or in the context of other particular aspects and implementations, and in an implementation generally. While multiple implementations are disclosed, still other implementations will become apparent to those skilled in the art from this detailed description. Disclosed implementations may be capable of myriad modifications in various aspects, all without departing from the spirit and scope of the disclosed implementations. Accordingly, the drawings and descriptions are to be regarded as illustrative in nature and not restrictive. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and features of one implementation may be employed with other implementations as the skilled artisan would recognize, even if not explicitly stated herein. Descriptions of well-known components and processing techniques may be omitted so as to not unnecessarily obscure the implementation features. In the present disclosure, various features may be described as being optional, for example, through the use of the verb “may;” or, through the use of any of the phrases: “in some implementations,” “in some designs,” “in various implementations,” “in various designs,” “in an illustrative example,” or, “for example.” For the sake of brevity and legibility, the present disclosure does not explicitly recite each and every permutation that may be obtained by choosing from the set of optional features. However, the present disclosure is to be interpreted as explicitly disclosing all such permutations. For example, a system described as having three optional features may be implemented in seven different ways, namely with just one of the three possible features, with any two of the three possible features or with all three of the three possible features. In the present disclosure, the term “system” may be interchangeably used with the term “apparatus” or the term “machine.” In the present disclosure, the term “method” may be interchangeably used with the term “process.” In various implementations, elements described herein as coupled or connected may have an effectual relationship realizable by a direct connection or indirectly with one or more other intervening elements. While various implementations have been disclosed and described in detail herein, it will be apparent to those skilled in the art that various changes may be made to the disclosed configuration, operation, and form without departing from the spirit and scope thereof. In particular, it is noted that the respective implementation features, even those disclosed solely in combination with other implementation features, may be combined in any configuration excepting those readily apparent to the person skilled in the art as nonsensical. Likewise, use of the singular and plural is solely for the sake of illustration and is not to be interpreted as limiting. In the present disclosure, all descriptions where “comprising” is used may have as alternatives “consisting essentially of” or “consisting of.” In the present disclosure, any method or apparatus implementation may be devoid of one or more process steps or components. In the present disclosure, implementations employing negative limitations are expressly disclosed and considered a part of this disclosure. Where reference is made herein to a method comprising two or more defined steps, the defined steps may be carried out in any order or simultaneously (except where the context excludes that possibility), and the method may include one or more other steps which are carried out before any of the defined steps, between two of the defined steps, or after all the defined steps (except where the context excludes that possibility). The phrases “connected to,” “coupled to” and “in communication with” refer to any form of interaction between two or more entities, including mechanical, electrical, magnetic, electromagnetic, fluid, chemical, or thermal interaction. Two components may be functionally coupled to each other even though they are not in direct contact with each other. The terms “abutting” or “in mechanical union” may refer to items that are in direct physical contact with each other, although the items may not necessarily be attached together. The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred over other implementations. While various aspects of the disclosure are presented with reference to drawings, the drawings are not necessarily drawn to scale unless specifically indicated. Reference throughout this specification to “an implementation” or “the implementation’ means that a particular feature, structure, or characteristic described in connection with that implementation is included in at least one implementation. Thus, the quoted phrases, or variations thereof, as recited throughout this specification are not necessarily all referring to the same implementation. Similarly, it should be appreciated that in the above description, various features are sometimes grouped together in a single implementation, Figure, or description thereof for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting an intention that any claim in this or any application claiming priority to this application require more features than those expressly recited in that claim. Rather, as the following claims reflect, inventive aspects may lie in a combination of fewer than all features of any single foregoing disclosed implementation. Thus, the claims following this Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate implementation. This disclosure is intended to be interpreted as including all permutations of the independent claims with their dependent claims. A system or method implementation in accordance with the present disclosure may be accomplished through the use of one or more computing devices. For example, one of ordinary skill in the art would appreciate that an exemplary control system or algorithmic controller appropriate for use with an implementation in accordance with the present application may generally comprise one or more of a Central processing Unit (CPU) also known as a processor. In an illustrative example the processor may be operably coupled with a Random Access Memory (RAM), a storage medium (for example, hard disk drive, solid state drive, flash memory, cloud storage), an operating system (OS), one or more application software, a display element, one or more communications means, or one or more input/output devices/means. An exemplary implementation may comprise processor executable program instructions accessible to the processor, wherein the program instructions are configured cause the implementation to perform operations. The program instructions may be stored in the RAM or other storage medium operably coupled with the processor. An exemplary control system may use any of the disclosed methods or system operations and may combine an implementation of one or more disclosed steps of said methods or system operations into an algorithmic controller. The algorithmic controller may improve redundancy throughout an exemplary system or method implementation. The algorithmic controller may also permit improved reliability and efficiency. The algorithmic controller may furthermore ensure the constant and high quality of any product or by-product. In an example illustrative of various implementations in accordance with the present disclosure, an exemplary control system may be configured to operate, activate, deactivate, adjust, or communicate via sensors, wiring, piping, controls, pumps, or valves with various control, communication, sensing, or processing devices or systems that may be adapted to implement any of the disclosed methods. The controller may be a digital processor that continuously reads the system's instruments and computes outputs to the control elements. An exemplary control system may implement all or a portion of any of the disclosed methods with or without processor-executable program instructions executed by one or more processor. Examples of computing devices usable with implementations of the present disclosure include, but are not limited to, proprietary computing devices, embedded computing devices, personal computers, mobile computing devices, tablet PCs, mini-PCs, servers, or any combination thereof. The term computing device may also describe two or more computing devices communicatively linked in a manner as to distribute and share one or more resources, such as clustered computing devices and server banks/farms. One of ordinary skill in the art would understand that any number of computing devices could be used, and implementation of the present disclosure are contemplated for use with any computing device. Throughout this disclosure and elsewhere, block diagrams and flowchart illustrations may depict methods, apparatuses (i.e., systems), and computer program products. Each element of the block diagrams and flowchart illustrations, as well as each respective combination of elements in the block diagrams and flowchart illustrations, illustrates a function of the methods, apparatuses, and computer program products. Any and all such functions (“depicted functions”) can be implemented by computer program instructions; by special-purpose, hardware-based computer systems; by combinations of special purpose hardware and computer instructions; by combinations of general purpose hardware and computer instructions; and so on—any and all of which may be generally referred to herein as a “circuit,” “module,” or “system.” Each element in flowchart illustrations may depict a step, or group of steps, of a computer-implemented method. Further, each step may contain one or more sub-steps. For the purpose of illustration, these steps (as well as any and all other steps identified and described above) may be presented in an exemplary order. It will be understood that an implementation may include an alternate order of the steps adapted to a particular application of a technique disclosed herein. All such variations and modifications are intended to fall within the scope of this disclosure. The depiction and description of steps in any particular order is not intended to exclude implementations having the steps in a different order, unless required by a particular application, explicitly stated, or otherwise clear from the context. The respective reference numbers and descriptions of the elements depicted by the Drawings are summarized as follows.100relief management system103containment vessel106process relief device (PRD)109sealed relief header112vent115vent valve118draw pump121drain valve124low-vapor-pressure (LVP) liquid fill valve127LVP liquid source130LVP liquid inventory133seal leg136headspace139headspace vacuum142LVP liquid transfer outlet145LVP liquid transfer valve148processing unit151heater154process vessel157feed160heater process outlet163heater fuel inlet166sealed conduit169process control valve172product outlet175product176product pressure indicator for process pressure control (PC)178by-product composition control (LC) valve181by-product outlet184by-product composition indicator187reactor190separator193wastewater200LVP Liquid Phase and Condensed PRD Vapors203warm PRD vapors at containment vessel Maximum Allowable Working Pressure (MAWP)206residual PRD vapors in equilibrium with the final temperature of the LVP liquid phase and thecontainment vessel MAWP (“residual PRD vapors in equilibrium with final temperature”)300high-vapor-pressure (HVP) material303HVP liquid fill valve306HVP liquid source309radiator coil vapor cooler400iC4-L403nC4-L406iC5-L409nC5-L412CYC5-L415nC6-L418CYC6-L421nC7-L424Tol-L500containment vessel model503process relief mass506bulk liquid phase (string node 1)509liquid/vapor interface512energy absorption process/string model515bulk vapor phase (string node 2)600iC5-V603nC5-V606nC6-V700nC4-V900nC8-V903Equil Pres1000C4-C6-V1003C4-C6-L1300process variables/equations A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made. For example, the steps of the disclosed techniques may be performed in a different sequence, components of the disclosed systems may be combined in a different manner, or the components may be supplemented with other components. Accordingly, other implementations are contemplated, within the scope of the following claims. | 79,483 |
11859770 | DETAILED DESCRIPTION The following detailed description of various embodiments herein makes reference to the accompanying drawings, which show various embodiments by way of illustration. While these various embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, it should be understood that other embodiments may be realized and that changes may be made without departing from the scope of the disclosure. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected, or the like may include permanent, removable, temporary, partial, full or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. It should also be understood that unless specifically stated otherwise, references to “a,” “an” or “the” may include one or more than one and that reference to an item in the singular may also include the item in the plural. Further, all ranges may include upper and lower values and all ranges and ratio limits disclosed herein may be combined. An actuation device for opening a hermetically sealed compressed gas cylinder is disclosed herein. The hermetically sealed compressed gas cylinders may be used aboard aircraft with inflatable evacuation slides, inflatable life rafts, and oxygen systems, among other uses. Accordingly, storage of the hermetically sealed compressed gas cylinder is designed for maximum service life with little to no leakage. The hermetically sealed compressed gas cylinder, in various embodiments, utilizes a welded construction including a thin metallic fracture disk, or diaphragm, to seal the cylinder. The fracture disk may be fusion or cold welded to the cylinder, in various embodiments. Gas is released from the compressed gas cylinder in response to the fracture disk being broken or opened. This reduces the need for or eliminates the static non-metallic seal that is commonly used in compressed gas cylinders aboard aircraft, exhibiting little to no leakage and reducing the need for or eliminating the use of elastomeric seals. In various embodiments, the hermetically sealed compressed gas cylinder may be filled from a port in the bottom of the cylinder or similar method. The port may be designed such that the cylinder is sealed after being filled. In various embodiments, the actuation device disclosed herein uses a solenoid operated pressure cartridge to operate a cutter having a knife edge interface. In various embodiments, the cutter is assembled inside a manifold that is connected to the hermetically sealed compressed gas cylinder. In various embodiments, the cutter knife edge is initially located a distance away from the fracture disk. In various embodiments, the cutter knife edge is pushed toward the fracture disk in response to pressurized gas being released from the pressure cartridge by the solenoid. This ruptures the fracture disk and allows the gas in the hermetically sealed compressed gas cylinder to flow out. As the size of the hermetically sealed compressed gas cylinder increases, the diameter of the fracture disk may increase. This may introduce a higher stress on the fracture disk causing the fracture disk to bulge or bow outward. In various embodiments, the actuation device may include a stem that interfaces with the fracture disk and counteracts the bulge of the fracture disk. In various embodiments, the stem may be spring loaded. Referring now toFIGS.1A and1B, in accordance with various embodiments, cross section views of an actuation device100for opening a pressurized cylinder102is illustrated.FIG.1Aillustrates actuation device100in a closed position.FIG.1Billustrates actuation device100in an open position. Pressurized cylinder102includes an opening104, metal inserts106, and a fracture disk108. Metal inserts106are connected to opening104and around the circumference of opening104. In various embodiments, metal inserts106may be welded to opening104of pressurized cylinder102. Fracture disk108, also referred to as a diaphragm, is connected to metal inserts106. In various embodiments, metal inserts106may be formed of a single piece. In various embodiments, fracture disk108may be cold welded or fusion welded to metal inserts106. In various embodiments, pressurized cylinder102is hermetically sealed. In various embodiments, pressurized cylinder102may be filled with pressurized gas from a bottom portion (e.g., the negative y-direction) of pressurized cylinder102. Opening104has a diameter d1that may be any suitable size for a pressurized cylinder. In various embodiments, diameter d1may be about 3 cm (about 1.18 inches) to about 30 cm (about 11.8 inches), and more specifically, about 7 cm (about 2.76 inches) to about 15 cm (about 5.91 inches). Larger and smaller values for diameter d1are contemplated. Actuation device100includes a pressure cartridge110and a manifold112, where the manifold112is connected to the pressurized cylinder102. In various embodiments, manifold112is threaded onto pressurized cylinder102. Pressure cartridge110includes a fill valve114, a pressure cavity116, a pressure sensor118, a spring120, an air gap122, a plunger124, a bottom wall126(e.g., in the negative y-direction), and an upper wall127(e.g., in the positive y-direction). Fill valve114may be used to introduce air into pressure cavity116and pressurize the air in pressure cavity116. In various embodiments, fill valve114may be a Schrader type valve. In various embodiments, fill valve114may be another type of valve used to fill a pressurized space, such as pressure cavity116. Pressure sensor118monitors the air pressure in pressure cavity116and provides an indication of the readiness of actuation device100for use. In various embodiments, pressure sensor118may be a microelectromechanical system (MEMS) sensor, though other types of pressure sensors are contemplated. Spring120provides a downward force (e.g., the negative y-direction) on plunger124, pressing plunger124onto bottom wall126thereby sealing pressure cartridge110. Air gap122is formed between plunger124and upper wall127. FIG.1Aillustrates actuation device100, and more specifically pressure cartridge110, in a closed position. Actuation device100further includes electromagnets129disposed circumferentially around plunger124. Plunger124and electromagnets129may form a solenoid for actuating actuation device100. Electromagnets129engage in response to an electric current being provided. Plunger124is drawn upward (e.g., in the y-direction), pressure cartridge110, in response to electromagnets129engaging. Plunger124compresses spring120, closing air gap122, to open pressure cartridge110in response to being drawn upward (e.g., in the y-direction).FIG.1Billustrated actuation device100, and more pressure cartridge110, in an open position. In the open position, pressurized air in pressure cavity116pass through an air channel125in plunger124and through an air channel128in bottom wall126, exiting pressure cartridge110and into manifold112. Manifold112includes an actuation chamber130, a leak vent fitting132, a compression spring134, a cutter body136, one or more cutting edges138, and an air outlet140within a manifold body. Pressurized air flows into actuation chamber130from pressure cartridge110through air channel128. The pressurized air exerts a downward force (e.g., in the negative y-direction) on cutter body136, thereby compressing compression spring134and pushing the one or more cutting edges138through fracture disk108. Pressurized air in pressurized cylinder102exerts an upward force (e.g., in the y-direction) on cutter body136, opening air outlet140, and allowing the pressurized air from pressurized cylinder102to flow out air outlet140. An O-ring seal137may be placed around cutter body136to seal actuation chamber130and prevent air from leaking between manifold body142and cutter body136. Leak vent fitting132decreases the chance of an inadvertent actuation of cutter body136by venting gasses that are leaked into actuation chamber130from pressure cartridge110. Leak vent fitting132vents air from actuation chamber130in response to the air being below an actuation pressure Pa. When pressure cartridge110is in the closed state, air may leak into actuation chamber130and leak vent fitting132may vent the air after reaching a leak pressure Pi but before reaching the actuation pressure Pa. That is, leak vent fitting132is able to vent air slowly entering actuation chamber130. When pressure cartridge110is in the open state, leak vent fitting132may vent air but not quick enough to keep the air pressure in actuation chamber below actuation pressure Pa. That is, pressurized air quickly fills actuation chamber130in response to pressure cartridge being activated. Cutting edges138are separated from one another by a distance d2. In various embodiments, distance d2may be about 1 cm (about 0.394 inch) to about 5 cm (about 1.97 inches), and more specifically, about 2 cm (about 0.787 inch) to about 4 cm (about 1.57 inches). In various embodiments, distance d2may be a percentage of d1where d2is about 10% to about 30% of d1, and more specifically, about 15% to about 20% of d1. Cutting edges138are separated from fracture disk108a distance d3(e.g., in the y-direction). Distance d3may be about 0.5 cm (about 0.197 inch) to about 5 cm (about 1.97 inches), and more specifically, about 1 cm (about 0.394 inch) to about 2 cm (about 0.787 inch). Distance d3lessens the chances of cutting edges138inadvertently puncturing, or breaking, fracture disk108. Compression spring134further lessens the chances of cutting edges138inadvertently puncturing fracture disk108. FIG.1Aillustrates actuation device100, and more specifically manifold112, in the closed position with cutting edges138above (e.g., in the negative y-direction) fracture disk108distance d3. Leak vent fitting132vents any air leaked into actuation chamber130prevent actuation of cutter body136, and more specifically, cutting edges138.FIG.1Billustrates actuation device100, and more specifically manifold112, in the open position with cutting edges138pushed through fracture disk108. In the open position, cutting edges138break through fracture disk108thereby opening pressurized cylinder102. The pressurized air in pressurized cylinder102pushes cutter body136upward (e.g., in the y-direction) and away from pressurized cylinder102, allowing the air to exit pressurized cylinder102into manifold112and out through air outlet140. In various embodiments, air outlet140may be connected to an inflatable slide, an inflatable raft, or an oxygen system, among other applications. Referring now toFIGS.2A and2B, in accordance with various embodiments, close up cross section views of actuation device100connected to pressurized cylinder102are illustrated.FIG.2Aillustrates fracture disk108, including metal insert106, connected to opening104of a cylinder102′ that is in an unpressurized condition, that is, before being pressurized. In the depicted embodiments, metal insert106is a unitary piece that extending around the circumference of opening104and is connected to cylinder102′ as described above. Fracture disk108extends over (e.g., in the y-direction) metal insert106and is connected to metal insert106, as described above. There is no force exerted on fracture disk108before cylinder102′ is pressurized, therefore fracture disk108remains horizontal with respect to opening104(e.g., in the x-plane). FIG.2Billustrates fracture disk108′, including metal inserts106, connected to opening104of pressurized cylinder102in a pressurized condition, that is, after being pressurized. As illustrated, fracture disk108′ may bulge, or expand, away from pressurized cylinder102(e.g., in the y-direction). In the pressurized condition, fracture disk108′ is in a deformed condition and a maximum amount of stress on fracture disk108′ is in the central region, as indicated by the bulge. Because the pressure on fracture disk108′ and the result bulge, cutting edge138is a distance d4from fracture disk108′, where distance d4is less than distance d3. Accordingly, as described above, distance d2separates cutting edges138provides a gap between cutting edges138to avoid inadvertently contacting fracture disk108′. It should be noted that as diameter d1of pressurized cylinder102increases, the bulge at the center of fracture disk108′ may increase, further reducing distance d4between fracture disk108′ and cutting edges138. Referring now toFIGS.3A and3B, in accordance with various embodiments, close up cross section views of actuation device100connected to pressurized cylinder102are illustrated.FIG.3Aillustrates a fracture disk308including notches310formed therein connected to cylinder102′ in the unpressurized condition. In the depicted embodiment, two notches310formed in a bottom surface of fracture disk308(e.g., the negative y-direction). In various embodiments, any number of notches310may be formed in the bottom surface of the fracture disk308. In various embodiments, notches310may extend about 10% to about 50% of the thickness of fracture disk308, and more specifically, about 20% to about 30% of the thickness of fracture disk308. In various embodiments, notches310may be formed as inverted “V” shaped along a diameter of fracture disk308. In various embodiments, notches310may be formed as conical shaped in various locations around fracture disk308. In various embodiments, notches310may be rectangular, or another shape. Notches310reduce the cutting force used to rupture fracture disk308. As illustrated, notches310are vertically below (e.g., in the negative y-direction) cutting edges138, further reducing the cutting force used to rupture fracture disk308. FIG.3Billustrates a fracture disk308′ including notches310formed therein connected to pressurized cylinder102in the pressurized condition. As described above, with respect toFIG.2B, the force from pressurized cylinder102may cause bulging, or bowing, of fracture disk308′. Notches310have little to no effect on the integrity of fracture disk308′ allowing fracture disk308′ to remain intact until punctured by cutting edges138. Referring now toFIGS.4A and4B, in accordance with various embodiments, an actuation device400for opening a pressurized cylinder402is illustrated. Actuation device400includes similar components to those described above with respect to actuation device100referenced inFIGS.1A and1B, including pressure cartridge110and manifold112and their respective corresponding components. Actuation device400, similar to actuation device100, is connected to pressurized cylinder402as described above. Description of repeated components may not be repeated here. Pressurized cylinder402has an opening404that is sealed by a fracture disk408. Opening404has a diameter d5that is greater than diameter d1of opening104. Accordingly, fracture disk408is larger than fracture disk108. The increased diameter d5of opening404and increased size of fracture disk408may result in bulging of fracture disk408as described above with respect toFIGS.2B and3B. Actuation device400further includes a central stem450extending through cutter body136and in between cutting edges138to counteract any bulging that may occur in fracture disk408. Central stem450includes a bottom portion450athat is in contact with an upper surface of fracture disk408. Central stem450further includes an upper portion450bthat is in contact with a spring452. Spring provides a downward force (e.g., in the negative y-direction) on central stem450causing central stem450to exert a downward force (e.g., in the negative y-direction) on fracture disk408. An O-ring seal437may be placed between central stem450and cutter body136to seal actuation chamber130and prevent gas from leaking through during actuation. Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosure. The scope of the disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. Different cross-hatching is used throughout the figures to denote different parts but not necessarily to denote the same or different materials. Systems, methods and apparatus are provided herein. In the detailed description herein, references to “one embodiment,” “an embodiment,” “various embodiments,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments. Numbers, percentages, or other values stated herein are intended to include that value, and also other values that are about or approximately equal to the stated value, as would be appreciated by one of ordinary skill in the art encompassed by various embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable industrial process, and may include values that are within 10%, within 5%, within 1%, within 0.1%, or within 0.01% of a stated value. Additionally, the terms “substantially,” “about” or “approximately” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the term “substantially,” “about” or “approximately” may refer to an amount that is within 10% of, within 5% of, within 1% of, within 0.1% of, and within 0.01% of a stated amount or value. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112(f) unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Finally, it should be understood that any of the above described concepts can be used alone or in combination with any or all of the other above described concepts. Although various embodiments have been disclosed and described, one of ordinary skill in this art would recognize that certain modifications would come within the scope of this disclosure. Accordingly, the description is not intended to be exhaustive or to limit the principles described or illustrated herein to any precise form. Many modifications and variations are possible in light of the above teaching. | 20,953 |
11859771 | DETAILED DESCRIPTION OF THE DRAWING The embodiment shown inFIG.1relates to an application of supplying fuel gas from an LNG source tank, but it is appreciated that a person skilled in the art can easily transfer this embodiment to other applications involving other cryogenic liquids or liquid mixtures. FIG.1schematically shows a system100for supplying LNG from a source tank110to a consumer tank200. The source tank110may be installed on the deck of a river barge, while the consumer tank200may be a small tank on a pusher tug. Typically, the small tank on the pusher tug is filled quickly every two days from the LNG source tank110. After pumping any liquid in a downward sloping or flexible pipe or hose, there is inevitably liquid remaining in the pipework after the process is stopped. Since LNG will vaporize and the LNG source tank110cannot contain the volume of boil-off gas which will result if the LNG is allowed to vaporize in the line, it is desirable to return liquid instead of gas back to the original tank110. To solve this problem, the system100according toFIG.1provides a small holding tank120which may be a simple type of sump pot with sufficient volume to contain the contents of all pipework connected to it and with a series of inlet and discharge control valves and a control supply of pressurized gas to provide the motive power to push all residual liquid in the holding tank120back to the top of the LNG fuel tank110. A sequence of valve openings and closings will allow accumulation of the residual liquid prior to removal of the same and later inert gas purging. In more detail, the system100according to the embodiment ofFIG.1comprises a transfer line130,140,210for supplying the consumer tank200with LNG. In order to easily connect and disconnect the consumer tank200to the source tank110, the transfer line comprises two parts connected by a connection member210, namely a first transfer line130and a second transfer line140connected by the connection member210which preferably is flexible and removable. In order to be able to easily remove residual LNG from the first and second transfer lines130and140, at lower ends of the transfer lines, preferably at the lowest ends, drain lines190and180are connected. The drain lines190and180end in a liquefied gas holding tank120where the residual LNG is collected. Valves V1and V2in the drain lines190and180are open during draining. As can be seen fromFIG.1, the first transfer line130extends from the source tank110to the holding tank120, more precisely to the first drain line190at the top of the vessel, and the second transfer line140extends from the consumer tank200to the holding tank120, more precisely to the second drain line180at the top of the vessel. The second drain line180comprises a removable flexible connection (not shown) for disconnecting the second drain line180from the holding tank120. The liquefied gas holding tank120comprises a valve V1on the first drain line inlet at the top of the vessel, a valve V2at the second drain line inlet at the top of the vessel, and a valve V3in the pressurized gas feeding line150connected to the vapor space of the holding tank120. After the bunkering process is completed, valves V1and V2are opened and residual liquid will thus accumulate in the small holding tank120. During bunkering, in this embodiment LNG at approximately −155 degree Celsius will be pumped from the source tank110(original storage tank) to the receiving consumer fuel tank200at a flow in the range of approximately 5 to 20 m3/h at a pressure of 1 to 10 bar to overcome any pressure in the receiving tank200. Lower pressures are preferable for reducing the risk for leaks and product loss in case of a leak. During the bunkering process, valves V1and V2and V3are closed. LNG is conducted through the first transfer line130, the connection member210and the second transfer line140to the receiving tank200. After pumping, ambient temperatures will tend to vaporize the liquid remaining in the pipework. Since LNG has a vapor to liquid ratio of approximately 600:1 it is preferable to return the liquid to the source tank110before it vaporizes. After pumping has stopped, the pressure in the source tank110, pipework and receiving fuel tank200will settle-out to a value lower than the highest pressure of the tank-pipework-tank-network. The liquid remaining in the pipework, typically in the range of 200 l, will run down to the lowest point and—with valves V1and V2open—collect in a suitably sized drain pot in the form of the small holding tank120. In this embodiment, the top of the source tank110is approximately 5 m above the lowest point of the pipework. Thus, in order to raise the liquid column from the lower point of the holding tank120to the top of the source tank110, a pressurized gas supply of approximately 5 bar through the pressurized gas feeding line150with valve V3open should be sufficient, as the density of LNG is in the order of 0.5 kg/m3. Alternatively, compressed boil-off gas from the ullage space of source tank110can be used instead of pressurized inert gas. Introducing inert gas of sufficient pressure through line150into the holding tank120will thus return most of the liquid in the holding tank120back to the source tank110through the return line160(valve V4open). During pressurization via line150valve V4remains closed. The entry of the return line160to the storage tank110can either be separate from the first transfer line130such that the return line160is connected to the ullage space of the storage tank110, or it can be connected to the entry of the first transfer line130to the storage tank110. Both alternatives are shown inFIG.1. Further, the return line160is fitted with an orifice170at a high level to avoid two-phase flow of the return liquid back to the source tank110. The solution described provides a method to completely drain the pipework of system100before LNG starts to vaporize. The described solution avoids the need for a pump and relies on simple valve control and compressed inert gas supply. | 6,068 |
11859772 | DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS The gas network1inFIG.1comprises mainly a source side2, a consumer side3and a network4of pipelines5between the two. The gas network1in this case is a gas network1under pressure. For example, the gas can be air, oxygen or nitrogen. The source side2comprises a number of compressors6, in this case three, which generate compressed air. The consumer side3contains a number of consumers7of compressed air and in this case also three. It is also possible that the compressors6contain compressed air dryers. It is not excluded that there may also be compressors6downstream of the gas network1. This is referred to as “boost compressors”. The compressed air is routed through the network4of pipelines5from the compressors6to the consumers7. This network4is in most cases a very complex network of pipelines5. FIG.1shows this network4in a very schematic and simplified way. In most real situations, the network4of pipelines5comprises a large number of pipelines5and couplings that connect the consumers7in series and in parallel with each other and with the compressors6. It is not excluded that a part of the network4adopts or comprises a ring structure. This is because the gas network1is often extended over time with additional consumers7or compressors6, whereby new pipelines5between the existing pipelines5have to be laid, which leads to a tangle of pipelines5. The gas network1may also be provided with a pressure vessel8, with all compressors6in front of this pressure vessel8. It is not excluded that there may be one or more pressure vessels8downstream of the gas network1. In addition, components18, such as filters, separators, atomizers and/or regulators, can also be provided in the gas network1. These components18can be found in various combinations and can be found both near the buffer tank8and close to the individual consumers7. Network4also includes a number of sensors9a,9b,9c, which are located at different locations in network4. In this case, two flow sensors9ahave been installed, one of which is just after the aforementioned pressure vessel8, which will measure the total flow q provided by all compressors6. It is possible that the flow rates of the compressors6are calculated or measured by themselves. In addition, the figure shows four pressure sensors9b, which measure the pressure at different locations in the network4. A pressure sensor9bto measure the pressure in the pressure vessel8is also recommended to correct the “mass in—mass out” principle for large, concentrated volumes. It is clear that more or less than four pressure sensors9bcan also be provided. In addition, the number of flow sensors9ais not limiting for the invention. In addition to flow sensors9aor pressure sensors9b, additionally, or alternatively, sensors9a,9bmay be used to determine one or more of the following physical parameters of the gas: differential pressure, temperature, humidity, gas velocity and the like. In accordance with the invention, the gas network1is also provided with a number of throttle valves10which are installed in the pipelines5at various locations. These throttle valves10can partially close off the pipelines5to simulate an obstruction, as it were. They are adjustable or controllable, which means that the extent to which they close off the relevant pipeline5can be set or controlled. In addition to the aforementioned sensors9aand9b, which can measure the physical parameters of the gas, there are also a number of sensors9c, or ‘state sensors9c’, which are located at the throttle valves10. These state sensors9ccan measure the state or status, the opening, i.e. the relative increase or decrease of the thus generated obstruction, of the throttle valves10. The state sensors9ccan also be replaced by differential pressure sensors9d, which determine the pressure drop over the throttle valves10. In the example shown, a state sensor of this type9chas been installed for each throttle valve10. Preferably, the sensors9care part of the throttle valve10. The sensor9cis integrated in one module together with the throttle valve10. It is not excluded that at least part of the other sensors9aor9bare integrated in one module together with a throttle valve10. This will make it possible to also measure or determine the flow rate through the relevant throttle valve10. This will also simplify and speed up the installation or integration of the sensors9a,9band/or9cand the throttle valves10. In addition, it can be ensured that a correct and suitable sensor9a,9b,9cfor the throttle valves10is placed together in one module. Although not explicitly indicated inFIG.1, it cannot be excluded that in the gas network1there are additional state sensors9cin the vicinity of the compressors6and the consumers7that determine the on/off state of these components. Preferably, these state sensors are part of the consumers7themselves. The additional state sensors9c(e.g. on/off of the compressors6) then aim to significantly reduce the cross-sensitivity of the model during the training phase16and the operational phase17, as will be explained below. The aforementioned differential pressure sensors9dare preferably placed over filter, separator, atomizer and/or regulator components18. In the current example, four differential pressure sensors9dhave been incorporated into the gas network1. Differential pressure sensors9dcan also be placed over the throttle valves10and then take over the role of the state sensors9c. The aforementioned humidity and temperature sensors should preferably be mounted on the inlet/outlet of compressor plants6and the consumers7. In the example shown, these additional sensors are not all included in the gas network1, but it goes without saying that this is also possible. Especially in more extensive and complex gas networks1such sensors9a,9bcan be used, as well as in networks where only the volumetric flow rate is measured instead of the mass flow rate. In accordance with the invention, the gas network1is further provided with a data acquisition control unit11to collect data from the aforementioned sensors9a,9b,9c,9dand also to control the throttle valves10. In other words, sensors9a,9b,9c,9ddetermine or measure the physical parameters of the gas and send this data to the data acquisition control unit11, and the data acquisition control unit11will control or check whether and how many of the throttle valves10are closed to create or simulate an obstruction. In accordance with the invention, the gas network1is further provided with a computing unit12for processing the data from sensors9a,9b,9c,9d, wherein the computing unit12will be able to carry out the method for detecting and quantifying obstructions13in the gas network1in accordance with the invention, as explained below. The aforementioned computing unit12can be a physical module which is a physical part of the gas network1. It cannot be excluded that the computing unit12is not a physical module, but a so-called cloud-based computing unit12, which may or may not be connected wirelessly to the gas network1. This means that the computing unit12or the software of computing unit12is located in the ‘cloud’. In this case, the gas network1is further provided with monitor14to display or signal obstructions13that were detected using the method. The operation of gas network1and the method in accordance with the invention is very simple and as follows. FIG.2schematically illustrates the method for detecting obstructions12in the gas network1ofFIG.1. In the first phase15, the start-up phase15, sensors9a,9b,9c,9d, are calibrated before use if necessary. It goes without saying that if there are other sensors, they can also be calibrated before use. This happens once when the sensors9a,9b,9care placed in the gas network1. Of course, it is possible that sensors9a,9b,9c,9d, may be recalibrated over time. Preferably, at least some of the sensors9a,9b,9c,9d, should be calibrated during operation or by means of an in-situ self-calibration. This means that sensors9a,9b,9c,9d, in the gas network1, i.e. after they have been installed, are calibrated. “In operation” or “in situ” means calibration without removing sensor9a,9b,9c,9d, from the gas network1. Of course, all sensors9a,9b,9c,9d, may be calibrated in operation or in situ by means of self-calibration. In this way you can be sure that the placement and/or possible contamination of the sensors9a,9b,9c,9d, will not affect their measurements, because only after the placement of the sensors9a,9b,9c,9d, will you perform the calibration or repeat the calibration for a certain period of time. Then the second phase16or the training phase16starts. In this phase, a mathematical model is made between the measurements of a first group of sensors9a,9b,9c,9d, or the ‘features’ and a second group of sensors9a,9b,9c,9d, or the ‘targets’. Preferably, the first group of sensors9a,9b,9c,9d, comprises a plurality of pressure sensors9b, possibly a number of flow sensors9aand possibly a number of state sensors9cat different locations in the gas network1, and the second group of sensors9a,9b,9c,9d, comprises a plurality of state sensors9cat different locations in the gas network1. In this case, the flow sensors9a, the pressure sensors9band part of the state sensors9cform the first group of sensors and the remaining state sensors9cform the second group of sensors. For the sake of completeness, it is stated here that the invention is not limited to this. For the first group of sensors9a,9b,9c,9d, and the second group of sensors9a,9b,9c,9d, a random selection can be made, with the only restriction that a sensor from the first group may not be in the second group and vice versa. The aforementioned mathematical model is based on various measurements of sensors9a,9b,9c,9dwhere the adjustable throttle valves10are controlled by the data acquisition control unit11to simulate or generate obstructions13. In other words, the data acquisition control unit11collects data or measurements from sensors9a,9b,9c,9d, where the data acquisition control unit11will control the throttle valves10to close them so that obstructions are created in the gas network1so that data can be collected from sensors9a,9b,9c,9d, when obstructions13occur in the gas network1. In this way, a whole set of data or measurements can be collected, together with the information from the throttle valves10, i.e. the location and size of the obstructions13. The computing unit12will make a mathematical model on the basis of all this information. This mathematical model is preferably a black-box model or a data-driven model. The model typically contains a number of parameters or coefficients, also called ‘weights’, which are estimated. The black-box model, for example, takes the form of a matrix or a non-linear mathematical vector function or the like. The mathematical model is based on a number of assumptions. In this case, it is assumed that there are no leaks in the gas network1. The training phase16should preferably be carried out during the operation or operational phase of the gas network1. The mathematical model is used in an operational phase17to detect, locate and quantify obstructions13in the gas network1. Although not common, it cannot be excluded that during the operational phase the adjustable throttle valves10are controlled in a predetermined order to locate obstructions13. In this phase17, the following steps are performed:reading out the first group of sensors9a,9b,9c,9d;based on the readout measurements of sensors9a,9b,9c,9d, calculating or determining the value of the second group of sensors9a,9b,9c,9d, using the mathematical model, also known as ‘predicted target’;comparing the calculated or determined values of the second group of sensors9a,9b,9c,9dwith the read values of the second group of sensors9a,9b,9c,9d, and determining the difference between them;determining whether there is an obstruction13present in the gas network1on the basis of the aforementioned difference and any of its derivatives;generating an alarm if an obstruction13is detected. In order to determine an obstruction13in the gas network1, in the penultimate step it will be examined whether the aforementioned difference exceeds a certain threshold value. This indicates an obstruction13in the gas network1. This threshold can be set or selected in advance. When an obstruction13is detected, an alarm will be generated. In this case, this is done using monitor14, which displays the alarm. The user of the gas network1will notice this alarm and be able to take the appropriate steps. These steps of the operational phase17are preferably repeated sequentially at a certain time interval. This means that during the entire operational period of the gas network1, obstructions12can be detected and not just once during or shortly after the start up of the gas network1. The aforementioned time interval can be selected and set depending on the gas network1. It cannot be excluded that the time interval may vary over time. In a preferred variant of the invention, at certain moments, the operational phase17will be temporarily interrupted or stopped, after which the training phase16will resume to redefine the mathematical model between the measurements of different sensors9a,9b,9c,9d, before the operational phase17is resumed. ‘At certain moments’ should herein be interpreted as moments that are preset, for example once a week, per month or per year, or as moments that can be chosen by the user. This will update the mathematical model to take into account any time-varying behavior of the system. These include, for example, obstructions12in the network4which, by replacing the relevant parts or valves, will be repaired to existing small obstructions12in the base-line situation, which will become larger over time and must be taken into account, or adjustments or expansions of the network4which will change the aforementioned base-line situation of the gas network1. Although in the example ofFIG.1it is a gas network1under pressure, it can also be a gas network1under vacuum. Source side2then comprises a number of sources of vacuum, i.e. vacuum pumps or similar. In this case, the consumers7have been replaced by applications that require vacuum. Furthermore, the method is the same as disclosed above. This invention is by no means limited to the embodiments by way of example and shown in the figures, but such a method and gas network as claimed in the invention can be carried out in different variants without going beyond the scope of the invention. | 14,657 |
11859773 | DETAILED DESCRIPTION InFIG.5, a light bulb apparatus includes a bulb shell881, a light source module882, a driver883, a first cap body885, a wireless module884and a second cap body886. The light source module882includes a plurality of LED modules. For example, the LED modules are disposed on a light source plate. In some other embodiments, the LED modules may be embedded in elongated filaments, rigid or flexible. In some other embodiments, the LED modules may be accompanied with a light guide or a lens for changing the light paths. In some embodiments, the LED modules may include LED chips of multiple colors or multiple color temperatures for mixing needed parameters. The first cap body885is connected to the bulb shell881. The first cap body885has a surrounding wall. The surrounding wall includes metal material. Heat of the light source module and the driver is transmitted to the surrounding wall. For example, the first cap body is a tube housing with a surrounding wall. The tube housing is made by molding a plastic insulation layer outside an aluminum body. Such tube housing is helpful on heat dissipation. The light source module may be connected to the tube housing directly or indirectly for transmitting to the tube housing. In addition, the tube housing may enclose partially or completely the driver. Heat of the driver that contains multiple electronic components may be transmitted to the tube housing, too. The wireless module884is electrically connected to the driver883. The second cap body886is connected to the first cap body885and an Edison cap. The Edison cap has two electrodes887,888for receiving an external power source from an Edison socket. For example, the lateral screw wall is used for receiving electricity as a first electrode and the bottom piece is used for receiving electricity as a second electrode. The second cap body is made of plastic material. The wireless module is located at least partially in the second cap body. Unlike being disposed and surrounded by the first cap body, which has metal material, the wireless module is operated in a better environment that no shielding cover affecting signal receiving and transmitting. In addition, to keep the wireless module a distance from the driver helps make the wireless module more stable. In addition to place a wireless module, other electronic devices that are more sensitive may be added or replace the wireless module mentioned above in other embodiments. InFIG.5, the light bulb apparatus may be inserted to a socket base889. The socket base889has two strings890. A magnet unit891is attached at an end of the string890. A hook892may also disposed. Please refer toFIG.1. InFIG.1, a light source3is enclosed by a bulb shell. There is a first cap body2providing a container space4for storing a driver. There is a second cap body1surrounding a battery and a wireless module. There is an Edison cap with two electrodes5,6for connecting to a socket base or a common Edison socket that connects to an indoor power source. Please refer toFIG.2. InFIG.2, the light bulb embodiment has a light source plate7with LED modules3. There is a driver plate4connected to the light source plate7. The driver plate4is enclosed by a surrounding wall of a first cap body2. There is a battery8installed and surrounded partially by a second cap body1. The second cap body has connecting columns11,111to connect to the light source plate3. The connecting columns11,111are extended upwardly to connect the light source plate3, thus clipping the first cap body2therebetween. The water proof ring9helps enhance water proof. There is a positioning structure12for connecting components. There is a screw structure13to be added to an Edison socket that has two electrodes5,6. The light bulb apparatus may be inserted to a bulb socket10. There are two strings102connected to the bulb socket10for attaching the light bulb apparatus to another position102. There is a magnet unit104for attaching two strings together. In addition, a hook103may also be disposed. InFIG.3, The second cap body1has a gas exit14for heat dissipation. The connecting column11is used for connecting other components and provide structure support. There is a positioning structure12for ensuring to align between components. InFIG.4, there is an elastic bar101for contacting two electrodes of an Edison cap in a base socket10. In some embodiments, the first cap body has a plastic surface wrapping an aluminum piece. In some embodiments, the second cap body has a connecting column extended upwardly to connect to a light source plate of the light source module and is fixed to the first cap body between the lights source module. In such design, the connecting column is used as a connector for connecting the light source module and the second cap body while clipping the first cap body between the light source module and the second cap body. Such design makes assembling of such light bulb apparatus more easily and thus decrease overall cost. InFIG.5, an antenna894is placed on the light source plate and electrically connected to the wireless module via the connecting column. Since the light source plate is usually facing to an external space so that light may be escaped to outside, the light source plate is a good place for placing wireless antenna. The wireless module in the second cap body or the driver may connect to the antenna on the light source plate for receiving a better signal quality. In some wireless design, more than one antenna may be used for enhancing signal quality. Therefore, a first antenna may be disposed with the wireless module and a second antenna may be disposed on the light source plate. In some embodiments, the light bulb apparatus may also include a battery container for containing a battery at least partially stored in the second cap body. In some embodiments, the wireless module receives a wakeup command from an external device and controls the battery for supplying power to the light source module. In some embodiments, the light source module is operated with a lower power than being operated connected to an external power source when the battery supplies power to the light source module. In some embodiments, the second cap body has an opening for installing the battery to the battery container. For example, the second cap body may have a detachable cover so that the battery may be installed and then put back the detachable cover to the second cap body. In some embodiments, there is a secondary power socket for detachably connecting to a direct current power source. For example, an USB socket may be disposed on the second cap body or the first cap body for receiving a DC 5V power source for the light bulb apparatus to operate in another mode. In some embodiments, the second cap body has a bracket for holding an external battery for supplying power to the light source module. As mentioned above, the light bulb may be connected to an external power source. It is common and inexpensive to acquire a USB power module today. Such USB power module may be connected to the light bulb apparatus for providing another working mode conveniently. In some embodiments, there is a bulb socket with an Edison socket inside for connecting to the Edison cap. For example, the bulb socket is made as a part of the light bulb apparatus kit. Specifically, the bulb socket is detachably removed from the light bulb apparatus so that the bulb apparatus is connected to a normal Edison socket. When the bulb socket is used, the light bulb apparatus may be operated in a second operation mode. More details of such design are mentioned below. In some embodiments, there is an elastic bar for electrically both the two electrodes of the Edison cap. The driver has an impedance detector. When the two electrodes are found electrically connected, the lights source module switches to receive power from an internal battery. For example, the elastic bar contacts both the two electrodes of the Edison cap, making the impedance between the two electrodes of the Edison cap different from daily use. In such case, the driver determines the abnormal situation and cuts off the path of the Edison cap. Instead, the battery path is activated for getting current from the battery. In some embodiments, the bulb socket has two strings, at least one string has a magnet end for attaching to an external magnet piece. This is particularly helpful when carrying the light bulb apparatus moving around for working. In some embodiments, at least one string has an end hook for hooking to an external base. In some embodiments, the bulb socket has a switch for enabling supplying power from an internal battery. In some embodiments, the second cap body is detachable from the first cap body, the first cap body has a second Edison cap for connecting to an external power source. In some embodiments, the second cap body has an extending electrode for attaching a function module, the function module receives power from the driver. In some embodiments, the driver supplies power to the wireless module in the second cap body. In such case, the driver supplies power both to the light source module and the to the wireless module. In some embodiments, the wireless module has a power driver independently from the driver. In such case, a separate power unit is used for the wireless module so as to separate the influence between the driver and the wireless module. As mentioned above, the wireless module may be replaced other dedicated sensitive electronic devices. Such design makes the electronic devices more stable. In some embodiments, the first cap body handles heat dissipation of the light source module and the driver and the second cap body handles heat dissipation of the wireless module. For example, the components in the first cap body and the second cap body are separated trying not to letting heat of one portion to affect the other portion. Two portions have independent heat dissipation structures so as to prevent the heat of the driver or the light source module affecting the operation of the wireless module. The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the techniques and their practical applications. Others skilled in the art are thereby enabled to best utilize the techniques and various embodiments with various modifications as are suited to the particular use contemplated. Although the disclosure and examples have been fully described with reference to the accompanying drawings, it is to be noted that various changes and modifications will become apparent to those skilled in the art. Such changes and modifications are to be understood as being included within the scope of the disclosure and examples as defined by the claims. | 11,156 |
11859774 | All the figures are schematic, not necessarily to scale, and generally only show parts which are necessary in order to elucidate the embodiments, wherein other parts may be omitted or merely suggested. Like reference numerals refer to like elements throughout the description. DETAILED DESCRIPTION The present aspects will now be described more fully hereinafter with reference to the accompanying drawing, in which currently preferred embodiments are shown. The invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness, and fully convey the scope of the present aspects to the skilled person. FIG.1illustrate an incandescent lamp known in the prior art. The lamp comprises a glass bulb1enclosing a low pressure inert gas2such as argon, nitrogen, krypton or xenon, and a tungsten filament3arranged on a glass stem7by means of electrically insulated support wires6. The tungsten filament3is electrically connected to a contact wire4that goes out of the stem7, through a cap or sleeve9and to an electrical terminal or contact11. The filament3is also connected to another contact wire5that goes into the stem7and to the cap9. The cap9and the contact11are electrically insulated from each other by means of an electrical insulation10, such as vitrite. FIGS.2a-dillustrate lighting devices200according to some embodiments of the present invention. In line with the present embodiment, the lighting device comprises an at least partly light transmitting envelope110and a solid state light source120. The envelope110may also be referred to as a bulb110and may be arranged to at least partly enclose the solid state light source120. The bulb110according to the present embodiment provides optical effects such as collimation, and may improve the light output of the bulb110to be more uniform. The light source120may be formed as a LED chimney120which is a set of LED modules wrapped around a central cylinder, or cylindrical holding member122having an axial extension along an optical axis O of the lighting device. Such light source120may leave a black spot at the top of the chimney120, or the top of the bulb110. Further, an optical structure150may be formed on a portion of an outer surface of the envelope110. The optical structure150may e.g. be formed during manufacturing of the envelope110, such as during a blow molding process of the envelope110. The optical structure150may e.g. be formed by a surface structure arranged on an inner surface portion of a mold (not shown inFIG.2a) used in the blow molding process. Such optical structure150may alleviate at least some of the issues of light distribution from the bulb. According to some embodiments, such as shown inFIG.2a, the optical structure150may comprise grooves in a bottom part of the bulb housing, i.e. the portion of the housing closest to a socket160of the lighting device100. The grooves151may e.g. be micro- or nano-grooves151and may be lengthwise oriented from south to north (should the lighting device100be standing in a vertical direction, i.e. the optical axis O being aligned with a vertical direction), i.e. along the optical axis O, or the optical path of the lighting device100, and in a direction away from the socket160. Micro-grooves should be understood as grooves having an average depth in the range of 1-1000 μm, whereas nano-grooves refer to grooves having an average depth of less than 1 μm. The grooves151may e.g. be arranged on a lower or bottom half of the envelope110. Turning now toFIG.2b, which shows a cross-sectional top view of the lighting device ofFIG.2a, an example of micro-prismatic grooves151is shown. Micro-prismatic grooves may e.g. be provided with a peak152with a top angle α of approximately 90° and a feature size or valley153depth of 10-100 micrometers, such as 25-100 micrometers. Such micro-prismatic grooves151may act efficiently as total internal reflection mirrors adapted to reflect impinging light (represented by arrows inFIG.2b). This may provide a collimating reflector without the use of light reflecting metal coatings. Turning back toFIG.2a, such collimating effect can be achieved with the envelope110and the optical structure150according to the present embodiment. Light emitted by the LEDs120may be reflected at the optical structure150, redirected upwards, in a direction away from the socket160, and emitted from the lighting device200through the upper or north portion of the at least partly light transmitting envelope110. Light emitted from mainly side-emitting light sources120may therefore be redirected so as to provide a mainly top-emitting lighting device200. It will however be appreciated that the optical structure150may be configured such that at least some light exits the envelope110through the optical structure150. The amount of light exiting through the optical structure150may e.g. depend on the angle of incidence, wherein total internal reflection e.g. may occur for light impinging at an angle of incidence exceeding a critical angle of the optical structure150. Additionally, external focusing lens170is provided which is arranged to be external to (and separate from) the bulb110and to project an image of the logo154on e.g. a wall or surface. FIG.2cis a cross-section of a similar lighting device as that described with reference toFIGS.2aandb, wherein the optical structure150comprises a nano-structure which may be arranged to reflect and/or to diffuse light emitted by the light source120. The nano-structure150may e.g. have an average feature size of less than 1 micrometer. FIG.2dshows a lighting device200similarly configured as the lighting device described with reference toFIGS.2aandb. However, the optical structure150, which may comprise grooves or micro-grooves, may be arranged in the top or north part of the bulb housing, oriented from east to west so as to form concentric circles or a spiral having a centre coinciding with the optical axis O of the lighting device200. The micro-prismatic grooves151may e.g. be provided with a peak or sharp corner having a top angle α of approximately 90° and a feature size or valley depth of 10-100 micrometers, thereby allowing light emitted by the light source120to be reflected and the resulting light beam to be reshaped or redirected. The embodiments described with reference toFIGS.2a-dthereby allow for beam shaping, wherein grooves151, such as e.g. micro-grooves, in the top or bottom part of the bulb housing110may be arranged to redirect the emitted light. An emission pattern of a LED source, directed north, can e.g. be steered to go partially south, thereby being more compliant with requirements relating to energy saving. At least some problems associated with beam shaping of light from an incandescent replacement LED-bulb can hence be addressed. Effects associated with the beam shaping can for instance include collimation effects, lensing effects (Fresnel) or scattering. InFIG.2e, two examples of such emission patterns are illustrated. The emission pattern of the light source120is represented by arrows inscribed in an area10defined by a solid line. The arrows indicate the different directions in which light is emitted from the light source120, in this example along the optical axis O, i.e. directed north, and in directions ranging between the optical axis and a lateral axis L being orthogonal to the optical axis. The length of the arrows, or the distance from the enclosing line and origo, indicates the relative amount of light emitted in that direction. The longer arrow, the more light may be emitted in that direction. The dotted line20illustrates the emission pattern of a lighting device according toFIGS.2aandb, wherein the optical structure150may be arranged in the bottom part of the bulb110. As shown inFIG.2e, the emission pattern may be redirected upwards such that a lighting device having a top-lighting character may be provided. Further, the dashed line30illustrates the emission pattern of a lighting device according toFIG.2dwherein the optical structure150may be arranged in the top part of the bulb110so as to increase the amount of light being emitted in lateral and downward directions. FIG.3illustrates a lighting device300according to an embodiment, which may be similarly configured as the lighting devices described with reference toFIGS.2a-d. The present embodiment however differs in that the optical structure150may be introduced to stamp a visual pattern, such as a trademark154on the outer surface of the bulb110. The light scattering properties can be made different for the logo154and the rest of the bulb110surface. This makes the logo154visible in the OFF-state of the lighting device300, thereby allowing for a potential buyer or user to inspect the logo154under e.g. ambient light to verify that the lighting device300is a genuine product and not a counterfeit one. However, in the ON-state the light emitted from the lighting device300may dazzle the eye of the observing buyer or user. In such case, the logo154may be made visible with the aid of an external focusing lens170, which is arranged to be external to (and separate from) the bulb110and to project an image of the logo154on e.g. a wall or surface. The observer may then inspect the projected logo154to verify authenticity of the product. FIG.4a-cshow a lighting device400according to an embodiment similar to the embodiments as described in connection withFIGS.2and3. According to this embodiment, the optical structure150comprises concentric diffraction gratings or rings155that e.g. may be embossed in the bulb110and designed in such a way that a colored spot appears in the far field or at a specific distance of e.g. 20-30 cm. The grating pitch may depend on the angle of incidence of the LED light.FIG.4bshows a cross sectional portion of the envelope110, wherein light may be emitted from the light source120and diffracted by the grating rings155arranged at the surface of the envelope and at different incident angles as seen from the light source120. In this example, an outer one of the grating rings155may be configured to diffract light such that a blue spot may be generated in the focal point fBof the outer grating ring. Further, a green spot may be generated in the focal point fGof a middle grating ring, and a red spot in the focal point fRof an inner grating ring. Each colored spots may e.g. appear at different distances from the lighting device400. FIG.4cshows an example wherein the diffractive grating may be configured to generate a green colored spot in the far field, whereby the grating pitch of three concentric grating rings arranged in a plane orthogonal to the optical axis O may be chosen as 635 nm/855 nm/1610 nm for the grating rings that are at an angle of incidence of 60°/40°/20°, respectively. As shown by the arrows inFIG.4c, the green light may be diffracted by each one of the grating rings and exit the envelope110in a direction parallel to the optical axis, wherein the remaining light continues in another direction. It will however be appreciated that the optical structure150or grating may be adapted to generate further colors, such as blue and green, as indicated inFIG.4c. FIGS.5aandbillustrate a lighting device500according to an embodiment similarly configured as the embodiments described with reference toFIGS.2-4. According to the present embodiment, the optical structure150comprises decorative patterns, such as patches of Fresnel lenses or other structures which may create a pattern in far field. The size, orientation and position of the patches or regions provided with the optical structure may be adapted depending on the desired result or optical effect. As shown by the cross section ofFIG.5b, the optical structure150may also be configured to focus light at a certain point or distance from the lighting device500. FIGS.6a-cillustrate a blow molding process according to an embodiment of the present invention. The mold130has a surface structure132arranged on an inner surface portion of the mold130. The mold130comprises two parts137,139that can be joined during the blow molding process and disjoined so as to allow for the blow molded envelope110to be removed from the mold. InFIG.6a, an at least partly light transmitting plastic material140, which may be arranged on a blowing rod135, has been introduced in the mold130. InFIG.6b, the plastic material140has been expanded by e.g. air, supplied by the blowing rod135, such that the plastic material140forms a thin plastic layer that may be pressed against the inner surface of the mold130and hence against the surface structure132. The surface structure132, which may comprise both extrusions and indentations, hence forms an imprint or embossing in an outer surface of the plastic layer, thereby transferring the surface structure132of the mold140into an optical structure150at the resulting envelope110. As shown inFIG.6c, the mold130may be disjoined, the blowing rod135retracted and the blow molded envelope110removed. FIG.7schematically illustrates a method according to an embodiment of the present invention. The method comprises:arranging710a plastic material140in a mold130having a surface structure132arranged on an inner surface portion of the mold130;blow molding720the plastic material140so as to form the envelope110, the surface structure being at least partly transferred to the plastic material140to form an optical structure150on a portion of an outer surface of the envelope110;removing730the envelope110from the mold130;arranging740the envelope110to at least partly enclose a solid state light source120; and optionallyarranging a light refracting lens750in an optical path of the lighting device100to focus a visual pattern in the far field, wherein the visual pattern may be formed of light being diffracted by the optical structure150. Thus, the present invention provides a lighting device, which may comprise an at least partly light transmitting envelope and a solid state light source. The envelope may be blow molded and provided with an optical structure that may be transferred to a surface of the envelope from a mold used during a blow molding process. The optical structure may e.g. be a diffractive or refractive optical structure and designed for providing optical effects such as collimation, scattering, lensing, various watermarking or trademarking optical effects, and far field and near field effects. The person skilled in the art realizes that the present invention by no means is limited to the embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims. By means of the above-described lighting device, the envelope, even if referred to as a bulb, may be formed into almost any form capable of transmitting light and at least partly enclose a light source. Further, the blow molding technique could also be used according to some embodiments of the invention to provide a tube for tube lighting (TL), or any other type of luminaire requiring a shaped envelope or bulb. Additionally, the mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope. | 15,463 |
11859775 | As illustrated in the figures, the sizes of elements and regions may be exaggerated for illustrative purposes and, thus, are provided to illustrate the general structures of the embodiments. Like reference numerals refer to like elements throughout. DETAILED DESCRIPTION Exemplifying embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which currently preferred embodiments are shown. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness, and fully convey the scope of the invention to the skilled person. With reference toFIG.1, a LED filament arrangement100, in accordance with some embodiments, will be described. The LED filament arrangement100comprises an elongated, flexible LED filament110. The LED filament arrangement100further comprises three bending units120. Each bending unit comprises a body, in which a channel121is defined or formed. Within the channel of each bending unit, a portion of the LED filament110is arranged. The channels121of the bending units120are curved, such that bends are induced in the LED filament110. In the specific embodiment shown inFIG.1, the bending units120are arranged such that the LED filament110forms a zig-zag shape (i.e. a shape having abrupt alternate left and right turns, or up and down turns or the like). In the present embodiment, portions of the LED filament110which are outside, and between, the bending units120are substantially straight. Further, in the present embodiment, the bending units120are at least partially light-transmissive. Specifically, the bending units120are transparent, meaning that the portions of the LED filament110which are arranged within (inside) the channels121of the bending units120are visible through the bending units120. As the bending units120are transparent, light emitted by the portions of the LED filament110which are arranged within the bending units120may be emitted through the bending units120. With reference toFIG.2, a LED filament arrangement200, in accordance with some embodiments, will be described. The LED filament arrangement200illustrated inFIG.2comprises a LED filament210, which may be equivalent to the LED filament110as described with reference toFIG.1. The LED filament arrangement200further comprises five bending units220. As described above with reference toFIG.1, the bending units each comprise a channel in which a portion of the LED filament220is arranged. However, as the bending units220of the present embodiment are light-blocking, these channels are not visible inFIG.2. Further, the curvature of the channels and the arrangement of the bending units induce an S-like curvature of the LED filament210, with a bending unit220arranged at the outmost point of each turn of the S-curve. With reference toFIGS.3aand3b, a bending unit320, in accordance with some embodiments, will be described.FIG.3ais an isometric view of the bending unit320.FIG.3bis a cross-sectional view of the bending unit320taken along the line A-A′, which is normal to the local extension of the channel. The bending unit320comprises a body322, in which a channel321is formed. In the present embodiment, the body322is light-transmissive. It will be appreciated that, in other embodiments, the body may be at least partially light-blocking. Further, the bending unit320(specifically the body322) may comprise a material with a thermal conductivity of at least 200 Wm−1K−1. For example, the bending unit320may comprise any high thermal conductive materials such as aluminum, iron, steel or copper. The bending unit320has a surface323which defines a wall of the channel321. The surface323may be highly reflective, for example it may have a reflectivity of at least 85%. The surface323may have an even higher reflectivity, for example the reflectivity may be 90%, 92% or higher. The surface323may further comprise a coating layer. The coating layer may comprise a metal, such as silver or aluminum. The coating layer may also comprise a polymer, such as silicone, and light scattering particles, such as barium sulfate (BaSO4), aluminum(III) oxide (Al2O3), or titanium dioxide (TiO2). The bending unit320of the present embodiment has a bent/curved tubular shape. As may be seen inFIG.3b, the cross section of the bending unit320has a substantially circular outer perimeter. Further, the surface323defining the wall of the channel is also substantially circular, in the cross-sectional view. It is appreciated that the channel and the body of the bending unit may have differently shaped cross sections in other embodiments. Specifically, the channel may be shaped to accommodate a type of LED filament with which it is intended to be used. With reference toFIGS.4aand4b, a LED filament arrangement400, in accordance with some embodiments, will be described.FIG.4ais an isometric view of the LED filament arrangement400.FIG.4bis a cross-sectional view taken along the line B-B′ which is normal to the local extension of the bending unit420and the LED filament410. The LED filament410may be equivalent to any of the LED filaments described with reference to the preceding figures. The bending unit420may be equivalent to any of the previously mentioned bending units described with reference toFIGS.1-3, except that it comprises a slit424. The slit424provides an opening between the outside of the bending unit420and the channel, extending along the elongation of the bending unit420. The slit424is adapted to allow for insertion of the LED filament410into the channel. Specifically, in the present embodiment, the slit424is adapted to allow for sideways insertion of the LED filament410into the channel. To insert the LED filament410sideways into the channel, the LED filament410may be aligned parallel with the slit424. (Light) force may be applied to either the LED filament or the bending unit (or both) to press them together, and thus insert the LED filament410into the slit424. The bending unit420may thus have a certain flexibility/elasticity, which may allow the bending unit420to be slightly deformed during the insertion, and then return back to its original shape. In other embodiments, the LED filament may be thread into the channel of the bending unit by inserting one end of the LED filament into one end of the channel and threading it through the channel until the portion in which the bend is to be induced is within the channel. With reference toFIG.5, a bending unit520, in accordance with some embodiments, will be described.FIG.5is a cross-sectional view of a bending unit, similar to those shown inFIGS.3band4b. The bending unit520may be equivalent to the bending unit420described with reference toFIG.4, except that the surface523defining a wall of the channel comprises a plurality of recesses525. The recesses525may extend along the entire length of the channel. Alternatively, the recesses525may only extend along some portions of the channel. It will be appreciated that bending units without a slit, such as those depicted in for exampleFIGS.1,2,3aand3b, may comprise recesses as described herein with reference toFIG.5. Further, different embodiments may comprise fewer or more recesses along the inner surface523(i.e. the surface defining the wall of the channel). With reference toFIG.6, a LED filament arrangement600, in accordance with some embodiments, will be described.FIG.6ais an isometric view of the LED filament arrangement600.FIG.6bis a cross-sectional view taken along the line C-C′, similar to the cross-sectional views ofFIGS.3b,4band5. The LED filament arrangement600comprises a bending unit620, which may be equivalent to bending units120or220described above with reference toFIGS.1and2. The LED filament arrangement600further comprises a LED filament610. The LED filament610comprises a flexible carrier611on which a plurality of LEDs612is arranged. The LEDs612are arranged in a single row on a first surface613of the carrier611. Especially, the LEDs612are arranged along a direction of elongation (i.e. along the elongation) of the LED filament. An encapsulant614covers (encapsulates) the carrier611and the LEDs612. Specifically, both the first surface613and a surface opposite to the first surface of the carrier611are covered by the encapsulant614, giving the LED filament610a round shape (i.e. a round cross section as shown inFIG.6b). The carrier611may be at least partially light-transmissive, such as translucent or transparent. The LEDs612are configured to emit light, which may be referred to as LED light. They may, for example, be configured to emit blue light (blue LEDs) or ultraviolet light (UV LEDs). Alternatively, red-green-blue (RGB) LEDs, which combine red, green and blue light to emit combined light, may be used. Especially in embodiments employing blue or UV LEDs, the encapsulant614may comprise a wavelength converting (luminescent) material. Such material may absorb light in a certain range of wavelengths and re-emit the light at a second, different, range of wavelengths, which may be referred to as converted light. The process of absorbing and re-emitting light at a different wavelength may be referred to as converting the wavelength of the light. Light emitted by a LED filament may be referred to as LED filament light. The LED filament light may comprise LED light and/or converted light. A portion of the LED filament610is arranged within the channel of the bending unit620. The portion of the LED filament610which is covered by (i.e. arranged within) the bending unit620comprises four LEDs, in the present embodiment. This is however only an example and the bending unit may surround more or less than four LEDs. AlthoughFIG.6ashows ten LEDs612arranged in a single row on the carrier611, in other embodiments, the LED filament may comprise fewer or more LEDs, which may be arranged in one or more rows, or in other configurations, on one or more sides of the carrier. It will be appreciated that, in general, a LED filament may provide LED filament light and comprise a plurality of light emitting diodes (LEDs) arranged in a linear array. Preferably, the LED filament may have a length L and a width W, wherein L>5 W. The LED filament may be arranged in a straight configuration or in a non-straight configuration such as for example a curved configuration, a 2D/3D spiral or a helix. Preferably, the LEDs are arranged on an elongated carrier like for instance a substrate, that may be flexible (e.g. made of a polymer or metal e.g. a film or foil). The bending units described in the present disclosure may aid in arranging the LED filament in such configurations, by inducing bends in the LED filament. In case the carrier comprises a first major surface and an opposite second major surface, the LEDs may be arranged on at least one of these surfaces. The carrier may be reflective or light-transmissive, such as translucent and preferably transparent. The LED filament may comprise an encapsulant at least partly covering at least part of the plurality of LEDs. The encapsulant may also at least partly cover at least one of the first major or second major surface. The encapsulant may be a polymer material which may be flexible such as for example a silicone. Further, the LEDs may be arranged for emitting LED light e.g. of different colors or spectrums. The encapsulant may comprise a luminescent material that is configured to at least partly convert LED light into converted light. The luminescent material may be a phosphor such as an inorganic phosphor and/or quantum dots or rods. The LED filament may comprise multiple sub-filaments. With reference toFIG.7a LED filament arrangement700, in accordance with some embodiments, will be described. The LED filament arrangement700comprises a LED filament710which may be equivalent to the LED filament610described with reference toFIG.6. The LED filament arrangement700further comprises a plurality of bending units720. More specifically the LED filament arrangement700comprises seven bending units720. The bending units720may be equivalent to any bending units described above with reference toFIGS.1-6. In the present embodiment, the portions of the LED filament710which are not covered by (i.e. arranged within the channels of) the bending units720are of similar length, and with little or no curvature (i.e. substantially straight). Further, the bending units720are arranged with alternating orientation, such that the LED filament710forms a zig-zag shape. Moreover, the two end points of the LED filament710are arranged next to each other, such that the zig-zag shaped arrangement700forms a crown-like shape. Such arrangements, in which the bends have a sharper corner appearance, may be created with the use of bending units with improved reliability over similar arrangements without bending units. With reference toFIG.8, a lighting device830, in accordance with some embodiments, will be described. The lighting device830comprises a LED filament arrangement800. In the present embodiment, the LED filament arrangement800may be equivalent to the LED filament arrangement700described with reference toFIG.7. However, LED filament arrangements of other shapes, such as shown in the other embodiments, may also be used. The lighting device830further comprises an at least partially light-transmissive envelope831which envelops the LED filament arrangement800. Specifically, the envelope831is transparent. The envelope831is mounted on a base832. The base832is adapted to be connected with a socket of a luminaire. The illustrated embodiment is adapted to be connected with a socket of Edison type. However, other embodiments may be adapted to other types of socket. In order to arrange the LED filament arrangement800within the envelope831(or bulb), the arrangement800is connected with holding means833, which also connect to the base832. Further, electrical contacts834are provided for connecting the endpoints of the LED filament810with the base832in order to provide power to the LED filament810. The person skilled in the art realizes that the present invention by no means is limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims. Although features and elements are described above in particular combinations, each feature or element can be used alone without other features and elements or in various combinations with or without other features and elements. Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed invention, from a study of the drawings, the disclosure and the appended claims. In the claims, the word “comprising” does not exclude other elements, and the indefinite article “a” or “an” does not exclude a plurality. The mere fact that certain features are recited in mutually different dependent claims does not indicate that a combination of these features cannot be used to advantage. | 15,174 |
11859776 | In the figures,100, circuit board;110, light-emitting unit;120, first wiring part;130, second wiring part;210, fixing plate;211, wiring terminal;212, threading hole;220, elastic sheet;230, clip;300, housing;310, receiving cavity;311, limiting stand;320, wiring port;330, first shell;331, protruding portion;332, positioning hole;340, second shell;341, recessed portion;342, positioning pin;350, unlocking groove;360, locking groove;361, snap-on recess;362, one-way slope;370, positioning block;400, wiring block;410, connecting block;411, snap-on protrusion;420, positioning groove;430, line distribution hole. DETAILED DESCRIPTION OF THE INVENTION The following are specific embodiments of the present invention and further describe the technical solutions of the present invention in conjunction with the accompanying drawings, but the present invention is not limited to these embodiments. It should be noted that all directional indications (such as up, down, left, right, front and back) in the embodiments of the present invention are only used to explain a relative positional relationship, motion, etc. between the various components in a specific attitude (as shown in the accompanying drawings). If the specific attitude changes, the directional indications will also change accordingly. In addition, descriptions such as “first”, “second”, “one”, etc. in the present invention are only used for description purposes, and should not be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, features defined by the term “first” or “second” may include at least one of the features, either explicitly or implicitly. In the description of the present invention, “a plurality of” means at least two, such as two, three, etc., unless otherwise expressly and specifically defined. In the present invention, unless otherwise expressly specified and defined, the terms “connected”, “fixed” and the like should be understood in a broad sense. For example, the connection may be either a fixed connection or a detachable connection, or in one piece; it may be a mechanical connection, or it may be an electrical connection; it may be a direct connection or indirect connection through an intermediate medium, and may be an internal communication of two components or an interaction relationship between two components, unless otherwise expressly defined. For those skilled in the art, the specific meanings of the above terms in the present disclosure could be understood according to the specific conditions. In addition, the technical solutions of the various embodiments of the present invention can be combined with each other, but must be based on the implementation by those of ordinary skill in the art. When the combinations of technical solutions contradict each other or cannot be implemented, it should be considered that such combination of technical solutions does not exist and does not fall within the scope of the present invention. The specific embodiments described herein are only examples to illustrate the spirit of the present invention. Those skilled in the art to which the present invention belongs can make various modifications or additions to the specific embodiments described or use similar alternatives, without departing from the spirit of the present invention or going beyond the scope defined in the appended claims. As shown inFIG.1toFIG.16, a light bulb includes: a circuit board100and a fixing member. The circuit board100is provided with a light-emitting unit110, two first wiring parts120and at least two second wiring parts130. One of the first wiring parts120and one of the second wiring parts130are both connected to a positive terminal of the light-emitting unit110, and the other first wiring part120and the other second wiring part130are both connected to a negative terminal of the light-emitting unit110. Specifically, the two first wiring parts120are respectively configured to be electrically connected to the positive and negative poles of a power supply or with the two second wiring parts130of other light bulbs. At least two second wiring parts130are provided. As other implementations, two or four or six second wiring parts130may also be provided. The second wiring parts130are identical in shape and structure with the first wiring parts120. Specifically, as shown inFIG.4, the circuit board100may be provided with two first wiring parts120and two second wiring parts130; or as shown inFIG.8, the circuit board100may be provided with two first wiring parts120and four second wiring parts130; or more second wiring parts130may be provided. The fixing member is connected to the circuit board100. The fixing member is capable of fixing wires to the first wiring parts120and the second wiring parts130. In this embodiment, when the two first wiring parts120are powered on and the two second wiring parts130form a loop together with an external circuit, the light-emitting unit110and the external circuit are connected in parallel. Wires can be fixed to the first wiring parts120and the second wiring parts130by the fixing member, without additional welding and fixing, and the wires can be connected and fixed according to requirements. So it is very flexible to use. As shown inFIGS.4,5,6and7, on the basis of the above embodiment, the fixing member is configured as a fixing plate210. The fixing plate210is detachably connected to the circuit board100. The fixing plate210is provided with wiring terminals211and the number of wiring terminals211is the same as the sum of the number of first wiring parts120and the number of second wiring parts130. The wiring terminals211are in one-to-one correspondence with the first wiring parts120and the second wiring parts130. When the fixing plate210is connected to the circuit board100, the wiring terminals211can crimp the wires on the first wiring parts120and the second wiring parts130. In this embodiment, by arranging the entire fixing plate210close to the circuit board100, the wires can be crimped on the first wiring parts120and the second wiring parts130by corresponding wiring terminals211at one time. As shown inFIGS.4,5,6and7, on the basis of the above embodiment, both the first wiring parts120and the second wiring parts130are configured as guide holes, and the wiring terminals211are slidably connected to the guide holes. In this embodiment, the circuit board100can crimp the wires passing through the guide holes to the first wiring parts120and the second wiring parts130, so that the wires can be fixed to the first wiring parts120and the second wiring parts130by sliding along the wiring terminals211through the guide holes. As shown inFIGS.4,7, and8, on the basis of the above embodiment, each wiring terminal211is provided with a threading hole212. The wiring terminals211are arranged on a front side of the fixing plate210, and the wires can extend from a back side of the fixing plate210through the threading holes212to the front side of the fixing plate210. In this embodiment, the wires can extend from the back side of the fixing plate210through the threading holes212to the front side of the fixing plate210, so that the wires originally located under the fixing plate210can be led to the position above the fixing plate210through the threading holes212. As shown inFIG.9, on the basis of the above embodiment, the fixing member is configured as elastic sheets220, ends of the elastic sheets220are fixedly connected to the circuit board100, and the number of elastic sheets220is the same as the sum of the number of first wiring parts120and the number of second wiring parts130. The elastic sheets220are in one-to-one correspondence with the first wiring parts120and the second wiring parts130. The elastic sheets220can crimp the wires on the first wiring parts120and the second wiring parts130. In this embodiment, one end of the elastic sheet220is fixedly connected to the circuit board100, and the other end of the elastic sheet220can move on the circuit board100. When the wires are inserted into gap between the elastic sheets220and the first wiring parts120or the second wiring parts130, the elastic sheets220can crimp the wires on the first wiring parts120or the second wiring parts130. As shown inFIG.10, on the basis of the above embodiment, the fixing member is configured as a clip230, and the clip230is detachably connected to the circuit board100. When the clip230is connected to the circuit board100, the clip230can crimp the wires on the first wiring parts120and/or the second wiring parts130. In this embodiment, the clip230is provided with a slot, and the clip230is inserted into the circuit board100through the slot. When the clip230is used to clamp the wires at the first wiring parts120or the second wiring parts130, the wires are crimped on the first wiring parts120or the second wiring parts130. As shown inFIGS.3,11and12, on the basis of the above embodiment, a housing300is further included. The housing300has a receiving cavity310and a wiring port320. The wiring port320is connected to the receiving cavity310. Both the circuit board100and the fixing member are both arranged in the receiving cavity310. The light emitted by the light-emitting element passes through the housing300. In this embodiment, the housing300can cover the circuit board100and the fixing member, and the light emitted by the light-emitting element can pass through the housing300. As shown inFIGS.11and12, on the basis of the above embodiment, the housing300includes a first shell330and a second shell340, and the first shell330is detachably connected to the second shell340and is assembled with the second shell340to form the housing300. In this embodiment, the first shell330and the second shell340are both semi-closed shell structures, the first shell330is detachably connected to the second shell340and is assembled with the second shell340to form the housing300. The receiving cavity310is formed in the housing300. As shown inFIGS.11and12, on the basis of the above embodiment, the first shell330is provided with a protruding portion331, and the second shell340is provided with a recessed portion341adapted to the protruding portion331. The first shell330and the second shell340are engaged with the recessed portion341through the protruding portion331. In the present embodiment, an inner edge of the first shell330protrudes outward to form the protruding portion331, an inner edge of the second shell340is recessed inward to form the recessed portion341, and the first shell330and the second shell340are engaged with the recessed portion341through the protruding portion331. As shown inFIGS.11and12, on the basis of the above embodiment, the first shell330is further provided with a positioning hole332, and the second shell340is further provided with a positioning pin342adapted to the positioning hole332, and through the positioning hole332, the first shell330can guide the positioning pin342of the second shell340to move. In this embodiment, through the positioning hole332, the first shell330can guide the positioning pin342of the second shell340to move. Based on a better positioning effect, two positioning holes332and two positioning pins342can be provided. The two positioning holes332and the two positioning pins342that are arranged correspondingly can limit the rotation of the first shell330relative to the second shell340. As shown inFIGS.11and12, on the basis of the above embodiment, the receiving cavity310is provided with a limiting stand311, and the circuit board100and the fixing member are limited in the limiting stand311and are exposed out of the light-emitting unit110. In this embodiment, the limiting stand311is actually a plate-like structure formed by the inner wall of the housing300protruding inward. The circuit board100and the fixing member are limited in the limiting stand311and are exposed out of the light-emitting unit110. As shown inFIGS.15and16, on the basis of the above embodiment, a wiring block400is further included. The wiring block400is detachably connected to the housing300. When the wiring block400is connected to the housing300, the wiring port320is covered. In this embodiment, the wiring block400is detachably connected to the housing300. When the wiring block400is connected to the housing300, the wiring port320is covered, thereby preventing the wire from falling out of the wiring port320. As shown inFIGS.13,15and16, on the basis of the above embodiment, the end of the housing300, which is of a cylindrical structure, is provided with unlocking grooves350in its axial direction and locking grooves360in its circumferential direction. The unlocking groove350and the locking groove360communicate with each other. The wiring block400is provided with connecting blocks410. The connecting blocks410can move axially along the unlocking grooves350at the end of the housing300and can move circumferentially along the locking grooves360at the end of the housing300. When located in the locking grooves360, the connecting blocks410are limited by the locking grooves360to move axially at the end of the housing300. Specifically, the unlocking grooves350formed in the axial direction of the end of the housing300are connected to the locking grooves360formed in the circumferential direction of the end of the housing300to form L-shaped groove structures. In this embodiment, when located in the locking grooves360, the connecting blocks410are limited by the locking grooves360to move axially at the end of the housing300, so the connecting blocks410are first slid to the unlocking grooves350and then to the locking grooves360. In this way, the wiring stand400can be prevented from falling off from the housing300automatically. As shown inFIGS.13,15and16, on the basis of the above embodiment, each locking groove360is provided with a snap-on recess361, and each connecting block410is provided with a snap-on protrusion411. When the connecting blocks410move along the locking grooves360and the snap-on protrusions411are aligned with the snap-on recesses361, the connecting blocks410are engaged with the snap-on recesses361of the locking grooves360through the snap-on protrusions411. In this embodiment, when the connecting blocks410move along the locking grooves360and the snap-on protrusions411are aligned with the snap-on recesses361, the connecting blocks410are engaged with the snap-on recesses361of the locking grooves360through the snap-on protrusions411, thereby preventing the connecting blocks410from sliding arbitrarily in the locking grooves360. Preferably, two unlocking grooves350, two locking grooves360and two connecting blocks410are provided. The two unlocking grooves350are arranged symmetrically, the two locking grooves360are arranged symmetrically, and the two connecting blocks410are arranged symmetrically. As shown inFIGS.14,15and16, on the basis of the above embodiment, the wiring block400is provided with positioning grooves420. The side wall of each locking groove360is provided with a one-way slope362. One connecting block410can move from the unlocking groove350to the adjacent locking groove360through the one-way slope362. In this embodiment, one connecting block410can move from the unlocking groove350to the adjacent locking groove360through the one-way slope362, so even if the user rotates the connecting block in a wrong direction, the connecting block410can still fall into the adjacent unlocking groove350rather than being blocked from rotating, and the wiring block400can be used more flexibly. As shown inFIGS.1,2and3, on the basis of the above embodiment, the wiring block400is provided with positioning grooves420, and the housing300is provided with positioning blocks370. When the connecting block410move along the locking grooves360and the positioning blocks370are aligned with the positioning grooves420, the housing300can be engaged with the positioning grooves420of the wiring block400through the positioning blocks370. In this embodiment, when the connecting blocks410move along the locking grooves360and the positioning blocks370are aligned with the positioning grooves420, the housing300can be engaged with the positioning grooves420of the wiring block400through the positioning blocks370, so that the housing300can better fix the wiring block400. Preferably, two positioning grooves420and two positioning blocks370are provided. The two positioning grooves420are arranged symmetrically, and the two positioning blocks370are arranged symmetrically. In fact, the two positioning grooves420evenly divide the wiring block400into two elastic blocks that can be stretched outward. Therefore, when the positioning blocks370are not in the positioning grooves420, the positioning blocks370push and stretch the two elastic blocks outward. When the positioning blocks370are in the positioning grooves420, the elastic blocks are automatically reset to complete the locking. As shown inFIGS.1,2and3, on the basis of the above embodiment, the wiring block400is provided with a line distribution hole430. In this embodiment, the line distribution hole430allows customers to distinguish the wires that need to be connected. Generally speaking, an even number of second wiring parts130are provided, and the number of line distribution holes430can be set to be half of the sum of the number of wiring parts120and the number of second wiring parts130. As shown inFIGS.1to16, further provided is a light strip, including the light bulb and further including a power supply, wherein at least one light bulb is provided, the light bulbs are electrically connected in sequence, the two first wiring parts120of one of the light bulbs are connected to positive and negative poles of the power supply, and the two first wiring parts120of the next light bulb are respectively electrically connected to the two second wiring parts130of the former light bulb. In this embodiment, users can connect the light bulbs in sequence as needed to form a complete light strip, and the light bulbs can be disassembled and replaced at any time. The light strip can be lengthened by connecting the bulbs in sequence through wires. | 18,241 |
11859777 | DETAILED DESCRIPTION Please refer toFIG.6, a light bulb apparatus includes a glass housing601, a sleeve housing602, a light source plate603, a sleeve connector604and an Edison cap605. The Edison cap605has various standards and is used in daily life to screw a light bulb to an Edison socket to receive power supply. The glass housing601defines a tubular part6012and a trumpet part6011. The trumpet part6011has an enlarging profile extended from a top end of the tubular part6012. The tubular part6012has a tube shape, leaving an inner space empty for inserting a portion of the sleeve housing602. The sleeve housing602includes a neck part6021and a protruding part6022. The neck part6021is enclosed by the tubular part6012of the glass housing601. The protruding part6022is exposed outside tubular part6012of the glass housing601. The light source plate603is fixed to the sleeve housing602, e.g. on top of the sleeve housing602. The glass housing601is made of glass material. The sleeve housing602may be made of plastic, metal material or complex material mixed with multiple materials. The sleeve connector604wraps an exterior surface6023of the protruding part6022. The Edison cap605is attached to the sleeve connector604. The Edison cap605has two electrodes6051,6052connecting to two ends of an electrical wire via an Edison socket. The two electrodes6051,6052are respectively connected to a driver606. The driver606includes a driver plate6061and a driver circuit6062. The light bulb apparatus has a glass appearing while being easy to be assembled. In some embodiments, the sleeve housing602has a sleeve trumpet6024extended from the neck part6021toward the trumpet part6011of the glass housing601. The sleeve trumpet6024prevents the sleeve housing602moving downwardly when the sleeve trumpet6024engages the trumpet part6011of the glass housing601. Specifically, the sleeve trumpet has a larger diameter than the diameter of the tubular part6012of the glass housing601and thus stops the sleeve housing602to keep moving downwardly when the sleeve trumpet6024engages the trumpet part6011. On the other end of the sleeve housing602, the protruding part6022is further fixed with a sleeve connector604and thus the sleeve housing602is kept at its position relative to the glass housing easily and conveniently. InFIG.7, the sleeve trumpet611has a reflective layer612in an inner surface613for reflecting a light614of the light source plate615. InFIG.8, the sleeve connector620has a screw groove621on an exterior surface622of the sleeve connector620for fixing the Edison cap623by rotation. InFIG.6, the sleeve connector604may be fixed to the Edison cap605with a rivet6057. InFIG.8, the sleeve connector620has a screw groove624on an interior surface of the sleeve connector620for fixing the protruding part625by rotation. InFIG.2, the glass housing has a concave stop structure12for preventing the sleeve housing2moving downwardly when the neck part of the sleeve housing2engages the concave stop structure12. InFIG.4, the sleeve housing has a gap opening221for adjustment during thermal expansion and contraction. Specifically, the glass housing and the sleeve housing have different thermal expansion ratios. Thus, the gap opening221provides an elastic space preventing damage of the components during thermal expansion and contraction. InFIG.6, a driver606is disposed inside the sleeve housing602. In some embodiments, the driver606has a driver plate6061mounted with driver circuits6062. The driver plate6061is inserted to the sleeve housing602along a sliding track6063of the sleeve housing602. InFIG.6, a lens607is standing upon the light source plate603. In some embodiments, there are multiple concentric circles6071,6072with different height levels disposed on a top surface of the lens607. Such lens607may be a condensing lens or a diffusion lens depending on design requirement. In some embodiments, a light passing cover608covers the lens607. In some embodiments, a driver component6071is placed on the light source plate603outside covering of the lens607. Such design prevents the driver component6071making shadow or affecting light output of the light source plate603, when LED modules6031are placed at center area of the light source plate603covered by the lens607. InFIG.7, a glue layer617is disposed between the glass housing618and the sleeve housing611. In some embodiments, the glue layer is heat dissipation glue for performing heat dissipation. InFIG.7, the sleeve connector6191is manually rotatable with respect to the sleeve housing for changing a setting of LED modules on the light source plate615. For example, the sleeve connector6191is exposed and placed below the glass housing but before the Edison cap. The sleeve connector6191is designed to be rotatable with respect to the glass housing and triggers a mechanic switch connected to a driver to change a setting of the LED modules, e.g. to change to different color temperatures. In some embodiments, there is a manual switch6192for changing a setting of LED modules on the light source plate615. In some embodiments, an ultra-violet light source616and a motion sensor617is disposed on the light source plate615. When the motion sensor indicates no person is nearby, the ultra-violet light source emits ultra-violet light to perform sterilization. In some embodiments, the ultra-violet light is turn off after a predetermined time period, e.g. to turn off sterilization after 30 minutes. Please refer toFIG.1, which shows a light bulb apparatus embodiment. InFIG.1, the light bulb apparatus has a Edison cap4and a glass housing1. The Edison cap has an electrode8at its bottom. Please refer toFIG.2, which shows a cross-sectional view of the example inFIG.1. InFIG.2, a light source plate6is placed on a sleeve housing2. The sleeve housing2is enclosed by the glass housing1by inserting into a container hole13. There is a concave stop structure12. There is a driver7for rectifying input power and generates a driving current. There is a sleeve connector21connected to the protruding part211of the sleeve housing2. There is an escape hole. The Edison cap4has a screw head6and a bottom electrode8. An exterior surface of the sleeve connector has screw grooves3. FIG.3shows an exploded view of the example inFIG.1. The glass housing has a container hole13, a concave stop structure12, and an escape hole11. The sleeve housing2has a sleeve trumpet22and a protruding part21. There is a screw groove211for installing the sleeve connector3. The sleeve connector3has a screw groove31. There is a connecting hole32. Rivets5are used for fixing components. The Edison cap4has an inner screw groove41and a bottom electrode8. Please refer toFIG.4, which illustrates an example of the sleeve housing2. There are a protruding part21, a gap opening221for preventing damages during thermal expansion and retraction, a sliding track23for inserting a driver plate as mentioned above, and a sleeve trumpet22. Please refer toFIG.5. InFIG.5, a driver7is illustrated to have a driver plate71to be inserted into the sleeve housing inFIG.4. The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the techniques and their practical applications. Others skilled in the art are thereby enabled to best utilize the techniques and various embodiments with various modifications as are suited to the particular use contemplated. Although the disclosure and examples have been fully described with reference to the accompanying drawings, it is to be noted that various changes and modifications will become apparent to those skilled in the art. Such changes and modifications are to be understood as being included within the scope of the disclosure and examples as defined by the claims. | 8,133 |
11859778 | DETAILED DESCRIPTION People who spend a significant portion of time indoors during the day can be deprived of exposure to natural sunlight that provides circadian regulation to humans. Although artificial lighting systems exist for providing circadian entrainment, the spectra provided by these conventional systems—typically ceiling lights—often are deficient in the melanopic region (blue, particularly 480 nm to 500 nm). Also, ceiling lights primarily illuminate horizontal surfaces (i.e., tabletops), and do not provide sufficient light in the vertical plane which is beneficial for circadian entrainment. Indirect lighting can be used to reflect light off of walls toward a user's eyes, but indirect lighting is only effective when walls are close enough to one another to sufficiently reflect the light to the user. Thus, indirect lighting has less effect in open plan offices or large spaces. Other options to solve the spectral problem include either providing cold white light or spectrally optimized light. Yet, customizing the spectra does not ensure that the light is effectively reaching the user's eyes. Increasing the brightness of lighting significantly, such as through use of light therapy boxes, can provide a sufficient daytime light cue. However, high brightness is very intrusive and cannot be used comfortably for extended periods of time, such as over an entire workday. Accordingly, it may be desirable to have more individualized exposure than a full environment. Furthermore, a more individualized exposure may be more energy efficient in some applications. In the present disclosure, lighting apparatuses are disclosed that deliver high melanopic flux in a manner such that the emitted light is efficiently received by a recipient's eyes, while being aesthetically pleasing and without causing visual fatigue. Embodiments of lighting devices utilize two distinct colors of light placed separate from one another, with a diffuser creating a mixture of the colors in between the two separate regions. This color separation in combination with a mixture (e.g., a gradient) in between creates a unique effect that makes colors appear warmer and thus more acceptable for the end user, consequently providing a high melanopic flux per visual stimulus (melanopic to photopic ratio, “M/P ratio”). Furthermore, the light emitted spatially upward from the lighting apparatus—that is, above a horizon region relative to the user's face—is of a colder color temperature than the light emitted spatially downward. The colder color temperature light has capacity for much higher M/P ratio, which provides optimal stimulation of melanopsin-related photoreceptors in the lower hemisphere of the retina (e.g., by direct illumination or by light bouncing off a ceiling or wall). FIG.1shows a perspective view of an example embodiment of a lighting apparatus100in which color-separated light is emitted, providing biological lighting directed toward the face of the user. The lighting apparatus100has a first region110that emits bluish melanopic light, a second region120that emits warm light, and a third region130between the first and second regions in which the bluish light and warm light are mixed. The first region110is above the third region130(relative to the ground), and the second region120is below the third region130. Thus, the lighting apparatus100emits bluish light in an upper first region and warm light in a lower second region, where the first and second regions are separated from each other by a third region. Both colors are emitted toward the user, with the blue light being positioned in the upper region of the lamp to simulate blue sky of natural lighting. The lighting provides a comfortable brightness level and an aesthetically pleasing spectrum to the user. In the embodiment ofFIG.1, the lighting device100is a table lamp with the third region130designed to be aligned with the user's face to deliver light directly toward a user's eyes. However, in other embodiments this third “horizon” region does not need to be aligned with the user's face. For example, embodiments may be configured as a ceiling fixture where the color separation lighting effect is achieved indirectly by reflecting off the walls of a room. Conventionally, emitting light at the face of the user is not desirable, as it will cause glare. In particular, blue light tends to cause more glare than other colors. However, the color separation utilized in the present embodiments provides a surprising aesthetic acceptability by users and also visually replicates outdoor natural lighting (e.g., blue sky and warmer light toward the horizon). The spectral power distributions of the present lighting devices also provide ultra-high amounts of melanopic light (e.g., M/P ratio>1 or >1.2 or >1.3). The lighting devices of the present disclosure deliver a high amount of vertical illuminance to the viewer's eyes, either directly or indirectly, thus providing a significant physiological impact. At the same time, the color separated light creates a unique effect where the overall perceived color temperature from the lighting apparatus is aesthetically acceptable even though the biological lighting directed at the viewer's face is colder in color temperature. Delivery of a high amount of biological light toward a user's eyes is counter-intuitive to conventional practices where colder colors are typically less acceptable aesthetically, and conventional lighting fixtures are often designed to direct light downward, avoiding light in the eyes in order to prevent glare. Insights behind the color separation concepts of the present embodiments, and the wavelengths and colors used to produce the desired physiological and visual effects, shall now be described. In this disclosure, “lighting apparatus” shall refer to lighting devices such as, not but limited to, lamps (e.g., task lamps, table lamps, decorative lamps), ceiling-mounted fixtures, devices emitting light from a the entire surface of vertical panel (e.g., a wall) or other types of lighting fixtures. A “light engine” refers to a lighting source capable of producing one or more spectral power distributions, such as a light emitting diode (LED) or an LED board with one or more LEDs. The term “LED boards” may also be referred to in this disclosure as a circuit board or a chip or simply a light emitting diode (LED), and can contain one or more individual LEDs. A person who will be receiving light from a lighting apparatus shall be referred to as a user, end user, viewer, occupant, or observer. Characteristics of light emitted from a particular region of a light apparatus shall be referred to as, for example, a correlated color temperature (CCT) or light spectrum, while the characteristics of total light emitted from the full lighting apparatus shall be referred to as “overall” or “integrated,” such as an integrated CCT or integrated spectrum. These overall or integrated characteristics represent the total light combined from all the sources of the lighting apparatus, as received by a user at the user's location. The user's location is the position of the user relative to the lighting apparatus, in which the light is received by the user's eyes when the light is in its intended installation orientation. For example, at the user's location the lighting apparatus may be near or above the user's eye level, or near or above the user's primary viewing area (area that the user is intending to look at). In another example, the mixed-light gradient region may be approximately at eye level with user (i.e., observer), or near or above eye level, or near or above the user's primary viewing area. The user's location relative to the lighting apparatus will depend on the type of fixture and the use-case for the lighting fixture (e.g., task lamp on a desk, table lamp, ceiling-mounted fixture, wall-mounted fixture, nightstand lamp, or other). Color Perception and Biological Light As mentioned above, ipRGCs mediate physiological effects of light beyond just vision. However, these physiological responses require greater amounts of light than what is required by vision. A melanopic to photopic (M/P) ratio refers to the melanopic flux of light relative to the photopic visual stimulus. Thus, it would be beneficial to balance these physiological effects with the visual effects by creating a M/P ratio greater than 1. Known physiological effects mediated by ipRGCs include melatonin suppression, acute alertness, circadian alignment, body temperature, cognition and mood. Each ipRGC subtype utilizes a different proportion of cone contributions and melanopsin expression. These cone contributions can be combined with melanopsin to skew the peak sensitivity to be slightly different than 490 nm. For example, melatonin suppression has been shown to have a peak sensitivity near 465 nm, suggesting the blue cone with in vivo peak sensitivity between 430 and 450 nm has skewed the peak sensitivity of this ipRGC subtype. On the other hand, circadian alignment has been shown to have a peak sensitivity closer to 490 nm, suggesting that melanopsin is the main contributor. Each of these sensitivities may be altered with duration and intensity of light exposure. However, all known sensitivities occur in the range between 450-500 nm, known as blue light. Thus, it would be very beneficial to create a light source that contains all wavelengths from 450-500 nm rather than pinpoint any single physiological effect. However, very blue-enriched light sources such as ones with all wavelengths from 450-500 nm, resulting in cooler (higher) color temperatures, are generally not well received by people. This appears to be especially true for LED light sources. For example, the office lighting standard historically has been 4100 K for fluorescent lighting but is being replaced by 3500 K or 3000 K for LEDs (i.e., warmer color temperature LEDs than were used for fluorescent lights). In fact, in recent polling of designers, architects and engineers, the favorite color temperature preference is 3500 K followed by 3000 K and 4000 K. Moreover, a polling of which color temperatures are forbidden in designs were almost unanimously 5000 K and 6500 K. For example,FIG.2shows results of a study based on 200 participants that was done in relation to the present disclosure.FIG.2is a chart of color acceptability versus color temperature, where acceptability was rated based on the percentage of participants who chose a color temperature as their favorite subtracted by the percentage of participants who would never use a certain color temperature. Participants were allowed to have only a single answer for favorite but could have several answers for unacceptable color temperatures. The graph ofFIG.2shows that 3500 K was the highest acceptable light source and 6500 K was the least acceptable light source. Similarly, a study was conducted on the productivity of workers under cold versus warm color temperatures. The results of the study showed higher productivity under cold color temperatures. These results were shared with the participants of the study. Despite the participants discovering that their productivity increased under blue-enriched light sources, the majority still chose to work under non-enriched light sources as these lights created a much more comfortable environment. Thus, the results indicate that it is imperative to provide the most melanopic content for each color temperature in order to achieve maximum benefit without compromising user preference on the perceived color. In order to achieve the best melanopic content per perceived blue color, the interaction between melanopsin and color vision was considered in the lighting devices of the present disclosure. Color vision is perceived by three color cones—red, green and blue. Color matching functions in graph300ofFIG.3Aare known functions that are used to convert any spectral power distribution into a point (i.e., a color) on the CIE 1931 color space diagram350ofFIG.3B.FIG.3Ashows color matching functions X (curve310), Y (curve320), and Z (curve330) that are used to convert any spectral power distribution into an (x,y) color point on the color space diagram350shown inFIG.3B. InFIG.3A, melanopsin weighting function340is also plotted. The left-hand y-axis scale is for the curves310,320and330, showing units relative to the Y-curve320. The right-hand scale is for the melanopsin curve. Y (curve320) also serves as the luminous efficiency function, which is analogous to brightness. The black body locus that defines white light is shown as curve360inFIG.3B, where the x-axis inFIG.3Bis X-chromaticity values and the y-axis is Y-chromaticity values. Using a dot product of any spectra, the tristimulus values X, Y, and Z for a spectral power distribution (SPD) can be determined. This is then converted to (x,y) on the CIE 1931 color space (diagram350) via the following equations: x=XX+Y+Z(Eq.1)y=YX+Y+Z(Eq.2) In terms of color seen by a viewer, having more Y will make the color appear more green but also add more lumens. Having more X will make the color appear more red, and having more Z will make the color appear more blue. FIG.4shows a traditional white light LED spectrum400overlaid on the color matching functions fromFIG.3A. The spectrum400generally has a narrow peak at 450 nm followed by a trough in the 480-500 nm region and a broad mound with a lot of energy around 550 nm. The peak at 450 nm is a blue LED “pump” aligned with the peak Z (i.e., blue sensitivity) that is used to excite a broad phosphor or phosphors. The phosphor has the majority of its weight around peak Y (of curve320), as this will yield the most amount of lumens. In other words, because of the narrow peak at 450 nm and trough in the 480-500 nm range, a traditional white light LED has a low amount of blue light for any given color temperature and is unable to deliver significant melanopic light. In contrast, the lighting apparatuses of the present disclosure aim to maximize the melanopic component for any given color temperature. The physical structure of conventional white light LEDs can also impair the ability to deliver melanopic light effectively. A phosphor white LED that produces the spectrum400is constructed by coating a blue LED with a phosphor. The thickness of the phosphor coating can vary between LEDs, and the thickness can also vary across the surface of an individual LED. When the phosphor thickness within an individual blue die is not uniform, the color of light can vary at different angles of the emitted light. This effect, known as “color over angle,” is another challenge of producing consistent colors from LEDs and can also impair the ability to deliver melanopic light effectively. Visually, this color over angle effect causes gradients of color across a diffuser, and has been determined to be unacceptable by the industry. Thus, the lighting industry has largely solved this color over angle issue, eliminating any gradients of color across diffusers. To efficiently deliver significant amounts of biological (e.g., melanopic 480-500 nm) light, the present disclosure uniquely recognizes the effect of different wavelengths of blue light on the color produced.FIG.5demonstrates how a blue light is used to shift a color point. Various amber phosphors with different wavelengths of blue LEDs are depicted by sub-graphs A-J, and the color points of each of these phosphor-LED combinations are then plotted on graph500in the CIE 1931 color space. First, sub-graph A is the spectrum of an amber phosphor without any blue LED, which results in color point A on graph500. In sub-graph B the same amber phosphor as in sub-graph A is used, but with a 410 nm blue LED to shift the color point. The resulting color point is shown as point B in the CIE 1931 color space (graph500), where the x-axis is X-chromaticity values and the y-axis is Y-chromaticity values. Thus, an amber phosphor color point is shifted with an LED with peak emission at 410 nm such that the peak-to-peak ratio is 1:1 (amber peak to blue peak), and the resulting color is shifted (point B relative to point A) towards the black body locus (BBL) that defines white light. FIG.5also illustrates further color point shifts caused by blue LED wavelengths of 420 nm to 490 nm in 10 nm increments combined with the same amber phosphor as in sub-graph A. Sub-graph C and color point C represent the amber phosphor combined with a 420 nm blue LED. Sub-graph D and color point D are for the amber with a 430 nm blue LED, sub-graph E and color point E are for the amber with a 440 nm blue LED, sub-graph F and color point F are for the amber with a 450 nm blue LED, sub-graph G and color point G are for the amber with a 460 nm blue LED, sub-graph H and color point H are for the amber with a 470 nm blue LED, sub-graph I and color point I are for the amber with a 480 nm blue LED, and sub-graph J and color point J are for the amber with a 490 nm blue LED. By shifting from 410 nm to 420 nm (point B to point C) of same peak intensity, twice the color shift (distance away from the BBL) is achieved. Going from 420 nm to 430 nm (point C to point D) achieves another similarly sized step in color shift. The step size of the shift becomes smaller going to 440 nm (point E), and step size of the shift resulting from 450 nm (point F) is not much different than 440 nm (point E). An interesting phenomenon was observed at 460 nm (point G), where the shift starts to make a U-turn and heads back towards the black body locus. Point H corresponding to 470 nm shifts closer to the BBL than 460 nm (point G). Point I corresponding to 480 nm has less of color shift relative to the BBL than 470 nm (point H), and point J corresponding to 490 nm has a smaller shift relative to the BBL than 480 nm (point I). In fact, 490 nm (point J) and 410 nm (point B) have similar magnitudes of color shifts. The interaction of this color shift with melanopic content was quantified in terms of color shift and M/P ratio as shown inFIGS.6A-6B. Graph600ofFIG.6Ashows the color shift distance610and the M/P ratio620as a function of blue peak wavelength. Graph650ofFIG.6Bshows the M/P ratio divided by (x,y) distance from the phosphor point (“M/XY shift”), showing the interaction in terms of melanopic content per color shift. As can be seen inFIG.6B, a peak emission at 490 nm will achieve the highest amount of melanopic flux per visual color shift. Moreover, from this data, it was deduced that a nighttime-friendly spectrum should contain a blue pump with peak emission from 410 nm to 450 nm, ideally at 430 nm (where the least melanopic content per color shift occurs). However, the most energy efficiency will occur with 450 nm. Consequently, it was determined that for nighttime scenarios, lighting devices of the present disclosure should employ a warm color temperature of CCT from 1800 K to 2500 K (for the integrated spectrum from the entire lighting apparatus) with blue pump peak emission between 430 nm and 450 nm. Of equal importance to providing the highest amount of stimulation at a given color temperature is the ability to skew that color temperature preference to compensate for colder color temperatures of the biologically stimulating light. Embodiments achieve visually desirable color temperatures using a visual phenomenon known as color constancy, which is known to visual psychophysiologists but has not been used in the lighting industry. Color constancy accounts for the fact that a macular pigment exists in the most central field of view. The believed purpose of the pigment is to protect the fovea from damage from blue light by attenuating these blue wavelengths. Furthermore, the central field of view has a significantly lower amount short wavelength (blue) cones relative to photoreceptors outside this portion of the retina. For these reasons, human color vision is insensitive to blue light in the center field of view. Thus, human color vision uses this color constancy technique to use information from the surrounding environment to determine colors in the central field of view. This is done by taking surrounding color information or information about the light source and subtracting it from a centrally viewed object in order to uncover the true color of said object. A known example demonstrating color constancy was a photograph of a dress that appeared to be black and blue to some people and white and gold to others. The reason why this dress was perceived differently was based on the observer's assumptions of the light source. Those who assumed the light source to be daylight subtracted that bluish light information and perceived the dress to be yellow and gold. Those who assumed the light source to be warmer incandescent subtracted that yellowish information and perceived the dress to be blue and black. In another example of color constancy, but more relevant to lighting perception, a sun in a blue sky appears yellow, similar to indoor color temperatures preferred by humans, while a moon appears a cooler white in a dark sky. Yet, the solar disk during midday actually has a CCT of 5000 K and the moon in the middle of the sky has a CCT of 4000 K. That is, the sun has a cooler CCT than the moon, yet a human's perception is the opposite. Another factor that complicates lighting perception is that outdoor lighting is not homogeneous like indoor lighting. Outdoor lighting contains gradients of light that make sunlight feel much warmer by contrast. While daylight is nominally 6500 K, there are few objects in the sky that are actually 6500 K. The combination of sunlight and daylight is comprised of a solar disk of about 5000 K, a colder sky of 8000 K to 20,000 K, and a gradient of light in between, which combine to create an integrated total color of about 6500 K. Embodiments of the present disclosure beneficially utilize this insight by creating a light of otherwise unappealing color temperature (e.g., near 5000 K) in the direction of the intended viewing angle of the end user and contrasting that with much cooler color temperatures, such as 8,000 K to 20,000 K emitted in a direction separated from (e.g., above) the intended viewing angle. This contrast is not a stark difference of two discretely separate colors but rather is designed to create a gradient of colors between white light and much colder bluish colored light. The result is that, unexpectedly, the 5000 K light source appears much more acceptable than data would predict. Furthermore, with a gradient created from the cooler and warmer light sources, an integrated color temperature at the face of an observer of about 5500 K to 8000 K can be achieved. Thus, by placing two distinct colors of light separate from one another with a gradient in between, colors appear warmer and thus more acceptable for the end user, thereby providing the highest melanopic flux per visual stimulus (melanopic to photopic ratio). Standard LEDs are unable to deliver light with high M/P ratios while also producing visually acceptable light.FIGS.7A-7Cdemonstrate how producing colder color temperatures with high amounts of melanopic light as in the present embodiments is counterintuitive using conventional methods.FIG.7Ais a graph700of theoretical maximum M/P spectrums that can be produced for different color temperatures. That is, the spectra are the highest possible M/P ratio that can be produced with the narrow melanopic peak at 490 nm shown in graph700for each CCT. Curve701is for a CCT of 2700 K, curve702is for a CCT of 3000 K, curve703is for a CCT of 3500 K, curve704is for a CCT of 4000 K, curve705is for a CCT of 4500 K, curve706is for a CCT of 5000 K, curve707is for a CCT of 5700 K, and curve708is for a CCT of 6500 K. Each curve has a peak between 480 nm to 490 nm to produce melanopic light. As can be seen from graph700, the phosphor peak is centered around approximately 600 nm rather than 550 nm (seeFIG.4), and as CCT increases, the intensity of the 480 nm to 490 nm peak relative to the phosphor becomes significantly disproportionate. These types of spectra inFIG.7Aare foreign enough from conventional spectra to skew color rendering to undesirable levels.FIG.7Bis a graph730of M/P ratio (curve731) and color rendering index “CRT” (curve732) as a function of CCT, where it can be seen that as M/P ratio increases with CCT, the CRT decreases to unacceptable levels (higher CRT is generally desired).FIG.7Cis a graph760of theoretical maximum M/P versus standard LED M/P, where curve761represents a standard LED M/P ratio, curve762represents M/P ratios that have acceptable CRIs (at least 80), and curve763represents the theoretical maximum M/P. As can be seen, M/P ratios that can be produced by standard LEDs are <1. Higher M/P ratios, such as greater than 1 in curve763, result in unacceptable CRIs (being above curve762). Thus,FIGS.7A-7Cillustrate how conventional LEDs are unable to provide high melanopic ratios with aesthetically pleasing colors. Spatial Effects Spatial effects are also carefully considered in the lighting devices of the present disclosure. Historically, horizontal light levels have been the metric by which the lighting industry evaluates electric light and human performance. This horizontal illuminance is illustrated inFIG.8A, where conventionally the lighting industry has focused on horizontal tasks and light that hits the horizontal work surface. Consequently, light fixtures have been largely designed to be the most effective at delivering horizontal light levels, but not as effective at providing vertical light levels. Typically it is found that general lighting provides1vertical lux for every 2 to 3 horizontal lux. Thus it would be a waste of energy to use traditional lighting for physiological effects of light. For example, point A inFIG.8Aindicates a photo sensor that is pointed upward, representing the conventional metric of designing light810to provide horizontal illuminance at the desk's surface approximately 2.5 ft above the finished floor. Architectural task lights have also focused on delivering light to the horizontal task plane and minimizing vertical light output for efficiency and visual comfort. In contrast, embodiments of the present disclosure represent a paradigm shift by focusing on vertical illuminance.FIG.8Billustrates vertical illuminance, which evaluates light emitted on a vertical surface such as a user's face while seated. For example, point B indicates a photo sensor pointed horizontally relative to ground, where the light820is designed to provide vertical illuminance at the eye level of a seated person (e.g., approximately 4 ft above the finished floor) with the sensor oriented in the primary “forward” direction that a person would be looking while sitting at their desk. The present embodiments recognize the importance of light that reaches a person's eyes as playing a significant role in healthy circadian rhythms, and uniquely utilizes this understanding in creating a light fixture that focuses on vertical illuminance rather than horizontal illuminance. Additionally, the present embodiments recognize that spatial distribution of light plays a significant role in the impact of light on the eye's photoreceptors. That is, light coming from above the horizon (and being received in a downward direction by the eye) has a much stronger impact on some melanopsin related photoreceptors than light coming from below the horizon (being received in an upward direction). The lighting devices of the present disclosure target and optimize biological effects via spatial distribution and/or spatial modulation of illumination systems. These spatial effects are combined with color constancy to produce high melanopic flux in a visually acceptable manner. By either placing two different sources of light separate from one another or by using an object to separate the two light sources, a horizon effect in the mixture (e.g., gradient) region between the two regions of light emitted from the two light sources is created that enhances the perception of light color to the end user. This horizon effect is achieved by an optical diffusing element creating the gradient mixing. The first light spectrum is emitted above the second light spectrum, relative to the ground, in the lighting device's intended installation orientation, with the horizon region between the first and second spectrums. FIG.9is a schematic900illustrating spatial aspects of the color separation concepts of the present disclosure. Lighting apparatus910is shown relative to an observer905, where the lighting apparatus projects a sky color920(bluish color) spatially upward and projects a sun color930(warmer color) spatially downward. The two colors are mixed in a gradient region940between the upward and downward regions to create direct illumination toward the observer905. Color constancy950drives the deeper blue color in the upward direction, while the integration of the colors drives the observer's perceived preferred color choice960in the downward direction. The lighting apparatus is installed relative to the observer905such that the primary viewing area (intended view970of the observer) is adjacent or below the gradient region940of the lighting apparatus910. In some embodiments, the mixed-light gradient region940may be approximately eye level with observer905. In a non-limiting example, the lighting apparatus910may be a task lamp installed (i.e., placed) on the user's desk, where the user's primary viewing area is toward a computer screen adjacent to the lamp. In another example, the lighting apparatus910may be a ceiling-mounted pendant fixture where the gradient region is near or above the observer's head (i.e., primary viewing area is adjacent or below the lighting apparatus910).FIG.9also shows the color-separated light920,930and940being projected toward a wall980, where the light can be reflected off the wall980and then received by the observer905. The reflected light results in the same color-separated perception effect as when the light is directly received by the observer. Glare Although vertical illuminance is beneficial for a user receiving biological light, vertical illuminance (i.e., delivering light horizontally toward a user's face) is conventionally less desirable because of discomfort due to glare. FIG.10is a graph1000of glare response versus wavelength, using data recreated from Stringham and Snodderly (“Enhancing Performance While Avoiding Contribution of Macular Pigment,”Investigative Ophthalmology&Visual Science, September 2013, Vol. 54, No. 9, p. 6298-6306). The different lines refer to subjects with different macular pigment optical densities (MPOD), where curve1010is for MPOD=0.10, curve1020is for MPOD=0.22, curve1030is for MPOD=0.39, curve1040is for MPOD=0.52, curve1050is for MPOD=0.64, and curve1060is for MPOD=0.71. From the graph1000, it can be seen that glare sensitivity decreases as wavelength increases. In other words, this known study suggests that cooler white light sources cause more glare than warmer light sources. In one typical example, high-intensity discharge headlamps are very blue in color and very glary. In another common example, cool white streetlights are substantially more glary than warmer ones. Thus, glare response appears to have a spectral component that suggests that the macular pigment protects from glare. FIG.11is a graph1100of melanopic-to-glare ratio (“M/Gf”) versus wavelength, created in relation to this disclosure by dividing the melanopic weighting function by the glare data ofFIG.10. Curve1120is calculated from the MPOD=0.10 curve ofFIG.10, curve1130is for MPOD=0.22, curve1140is for MPOD=0.39, curve1150is for MPOD=0.52, curve1160is for MPOD=0.64, and curve1170is for MPOD=0.71. It can be seen inFIG.11that there is a peak at 460 nm with a skew towards 500 nm. This suggests that to achieve the most melanopic content for the glare response, an emitted light spectrum should be designed to have a peak at 460 nm with a skew towards 500 nm. FIG.12shows an example spectrum1210of a lighting apparatus in accordance with some embodiments. The lighting apparatus is a task lamp with an upper region (“twilight”) having a CCT of 17,000 K. The full task lamp has an integrated spectrum1220and an average CCT of about 7,000K (i.e., overall spectrum and overall CCT resulting from all the light emitted from the task lamp combined together). These spectra1210and1220are overlaid on the melanopic-to-glare ratio graph ofFIG.11. The similarity in shapes of the spectra1210and1220to the Stringham and Snodderly data illustrate that the present embodiments have an optimal melanopic content for the glare response. Thus, the present embodiments achieve very high melanopic ratio while minimizing glare, providing comfortable light to a user despite being directed at their eyes. In other words, the lighting profile (spectrum1220) ofFIG.12achieves high melanopic content (480-490 nm) while reducing the amount of glare. Embodiments of Lighting Devices Various embodiments shall now be described for lighting apparatuses having color separation to enable efficient delivery of melanopic light to a user. The color temperatures and ranges shall be described primarily in regard toFIG.13but shall apply to the other embodiments described throughout this disclosure. The figures illustrate different arrangements of light engines and diffusers that enable various types of lighting apparatuses and various form factors to be implemented. In this disclosure, an installation orientation of a lighting apparatus refers to the intended orientation and placement of the lighting apparatus relative to a viewer when in in use. For example, the installation orientation of a table lamp or task lamp may be an upright position, with the lighting apparatus near or above a viewer's eye level. The installation orientation of a horizontal ceiling fixture (e.g., a pendant fixture) may be the longitudinal axis of the fixture being approximately parallel to the ground and above the eye level of a viewer. In the descriptions of the embodiments, “L1” shall refer to the bluish light (“first light spectrum”) emitted from the upper region (“first region”) of a lighting apparatus; “L2” shall refer to the warm light (“second light spectrum”) emitted from the lower region (“second region”), and “L3” shall refer to the mixture of the first light spectrum and second light spectrum that is emitted from a third region in between the first and second regions. To simplify the figures, the label L1 may also be used to indicate the region where light spectrum L1 is emitted, L2 may be used to indicate the region where light spectrum L2 is emitted, and L3 may be used to indicate the region where light spectrum L3 is emitted. Note that in the various embodiments, the light emitted from a light source may be slightly altered as it exits the lighting apparatus but shall be represented with one label for clarity in this disclosure. For example, light spectrum L1 that is emitted outside the diffuser of the lighting apparatus (i.e., fixture) may have a slightly warmer color temperature than the initial light spectrum L1 that is generated inside the fixture, since light spectrum L1 outside the fixture will be combined with reflected L2 light. In another example, light spectrum L2 that is emitted outside the lighting apparatus may be colder than the initial light spectrum L2 produced inside the fixture, since reflected L1 light will contribute to L2 outside the fixture. FIG.13shows a vertical cross-section schematic of a lighting apparatus1300configured as a vertical cylindrical lamp (similar to the lamp ofFIG.1) according to some embodiments. The color separation effect is achieved in this embodiment by having two light engines (e.g., LED boards) positioned apart from and facing each other, where a first light engine1310produces a first light spectrum L1 in region1315, and second light engine1320emits a first light spectrum L2 in region1325. Both the first light engine1310and the second light engine1320are encased by an enclosure, which in this embodiment includes an optical diffuser1340and the substrates1312and1322on which the light engines1310and1320, respectively, are mounted. In other embodiments, the enclosure may consist solely of the optical diffuser or may include other components such as structural framing or additional light-transmitting panels in addition to the optical diffuser. The optical diffuser may also be referred to in this disclosure as an “optical diffusing element” or “diffuser.” In an example installed orientation as a task lamp (e.g., sitting on a user's desk or tabletop), the optical diffuser1340is approximately parallel to the user's face (i.e., vertical), providing the majority of the light onto the user's face (i.e., providing vertical illuminance). First light spectrum L1 and second light spectrum L2 are directed toward each other, grazing an inside surface of the diffuser1340to form a mixture L3 of the first light spectrum L1 and the second light spectrum L2. That is, the two spectrums of light are placed at a distance from one another, pointing in opposite directions and facing one another allowing a diffuser1340to create a gradient mixing. In the first region1315of the enclosure, adjacent to first light engine1310, the first light spectrum L1 is primarily emitted out of diffuser1340. In the second region1325of the enclosure, adjacent to second light engine1320, the second light spectrum L2 is primarily emitted from diffuser1340. In other words, light L1 emitted from the upper region1315of the lighting apparatus1300is primarily from the first light engine1310, while light L2 emitted from the lower region1325of the lighting apparatus1300is primarily from the second light engine1320. In a third region1335of the enclosure, between the first region1315and the second region1325, the mixture L3 of L1 and L2 is emitted from diffuser1340. Thus, first light spectrum L1 is spatially separated from second light spectrum L2, where L3 is a gradient from L1 to L2. The third region L3 creates an effect similar to a horizon line. The optical diffuser1340covers the regions1315,1325and1335. Each light engine1310and1320may contain various LEDs to emit a particular light spectrum. In the embodiment ofFIG.13, first light engine1310is configured to emit a cool white color, such as a correlated color temperature of >7000 K or >7500 K or >15,000K, while second light engine1320is configured to emit a warmer white color, such as a CCT less than (i.e., warmer than) 6500 K or <5000 K, such as approximately 4000 K. In one particular embodiment, the first light spectrum L1 has a CCT of approximately 17,000 K which simulates a natural blue sky, and the second light spectrum L2 has a CCT of approximately 4000 K. Other combinations of colors for light emitted from the upper (cooler color) and lower (warmer color) LED circuits are possible, such as the upper (first) light engine1310emitting a purple color (e.g., “twilight”) and the bottom (second) light engine1320emitting an orange color. In one embodiment where L1 has a spectrum with a CCT that is approximately 17,000 K and L2 has a spectrum with a CCT that is approximately 4000 K, L3 has a CCT that is a gradient between 4000K and 17,000K, with an average CCT of approximately 7000 K from the combination of L1 and L2. In some embodiments, a difference in CCT of the spectra emitted by L1 and L2 is at least 1000 K, such as greater than 5000 K difference or greater than 10,000 K difference, such as approximately 13,000 K difference (e.g., L1=4000 K, L2=17,000 K) or such as approximately 15,000 K difference (e.g., L1=5000 K, L2=20,000 K). The vertical distance between LED boards (1310and1320) can vary, as long as a color separation is created between L1 and L2. The color separation of the present lighting devices allows for biological light to be delivered to a user's eyes in a highly effective manner and with individualized dosing and control for each user, even in an open plan office (i.e., high room cavity ratio) where traditional lighting cannot be nearly as individualized. In one example, the present lighting devices may be used for workers in a night shift (e.g., nurses in a hospital), where melanopic light is provided by a lighting apparatus to the user at their workstation without affecting the overall lighting of the room or facility. In the embodiment ofFIG.13, the two light engines1310and1320are positioned opposite each other and facing one another in the lighting apparatus1300. In such embodiments where the LED boards face each other (i.e., are directed toward each other), the boards may have a minimum distance apart of, for example, at least 6 inches, such as 12 inches or 18 inches. Other configurations of the boards relative to each other are possible, such as the boards being slightly angled instead of directly facing each other or facing outward toward the diffuser surface. In embodiments where L1 and L2 both face outward, the boards may be adjacent to each other or may be separated by a distance between them; additionally, L1 and L2 may be located on the same board with two separate circuits. Also, although the two light engines1310and1320inFIG.13are shown to be at the ends of the lighting apparatus1300, in other embodiments they may be positioned near the ends or away from the ends while still being separated from each other. In the embodiment ofFIG.13, the shape of diffuser1340is cylindrical, and the LED boards are circular circuit boards to match the ends of the cylinder. However, other shapes for the lamp and components are possible. For example, the lighting apparatus1300can be a vertical prism (e.g., triangular, rectangular or hexagonal) with flat surfaces for the diffuser1340, or a flat panel that is edge-illuminated (i.e., where the LEDs emit light into the edges of the panel and the panel serves as a light guide). In some embodiments, a majority of the diffuser surface may be vertical without needing the entire surface to be vertical. The diffuser1340may be made from various translucent materials, such as but not limited to plastics (e.g., polyethylene, polycarbonate, acrylics, polyvinyl chloride), fabrics, papers, and glass (e.g., frosted glass). Plastics include films and stretchable forms such as BARRISOL®. The diffuser1340may be smooth or may be textured on the interior and/or exterior surfaces of the lighting apparatus1300and may also include coatings. In some embodiments the diffuser1340may be a single, completely continuous piece. In other embodiments, a plurality of diffuser pieces may be joined together to achieve a seemingly continuous diffuser and thus achieve the same visual effect of gradient mixing. Construction of a continuous diffuser could include ornamental or structural pieces intended to support the fixture, or to hide seams, shadowing effects or other optical artifacts, while still appearing continuous to the end user. In various embodiments, the present lighting devices include a first light engine that produces a first light spectrum having a first correlated color temperature greater than or equal to 7000 K and a second light engine that produces a second light spectrum with a second CCT less than or equal to 6500 K. An enclosure is around the first light engine and the second light engine, the enclosure having an optical diffuser. The optical diffuser is positioned over a first region, a second region and a third region of the enclosure. The first region and the second region are separated by the third region. The first light spectrum is primarily emitted from the first region of the enclosure; the second light spectrum is primarily emitted from the second region of the enclosure; and a mixture of the first light spectrum and the second light spectrum is emitted from the third region of the enclosure. In some embodiments, a first light engine may produce a first light spectrum having a first CCT greater than or equal to 3500 K. A second light engine produces a second light spectrum having a second CCT less than or equal to 6500 K, where the second CCT is less than the first CCT and the difference between the first CCT and the second CCT is at least 1000 K, such as at least 10,000 K. In some embodiments, as illustrated byFIG.14, a first light engine may produce a first light spectrum having a first color in a first area bounded by a first set of chromaticity coordinates (x,y) of (0.11, 0.1), (0.16, 0.004), (0.255, 0.33), (0.32, 0.325) in a CIE 1931 color space diagram using 10-degree color matching functions (i.e., the CIE 1964 10-degree Standard Observer, which may also be referred to as the 1964 10° Supplementary Standard Observer or the 10-degree observer), while a second light engine produces a second light spectrum having a second color in a second area bounded by a second set of chromaticity coordinates of (0.55, 0.44), (0.691, 0.311), (0.417, 0.45), (0.35, 0.35) in the CIE 1931 color space diagram using 10-degree color matching functions. In various embodiments, the present lamps, such as task lamps, include a first light engine (e.g., LED) that emits a first light spectrum with a correlated color temperature greater than 7500 K and a second light engine (e.g., LED) that emits a second light spectrum with a CCT less than 6500 K. A diffuser encases the first light spectrum emitted from the first LED and the second light spectrum emitted from the second LED, where the diffuser is configured to be approximately parallel to a user's face. An upper region of the lamp emits primarily the first light spectrum, the upper region being color separated from a lower region of the lamp that emits primarily the second light spectrum. In various embodiments, task lamps may include a first LED in an upper region of the task lamp, the first LED emitting a first light spectrum with a CCT greater than 7000 K; a second LED in a lower region of the task lamp, the second LED emitting a second light spectrum with a CCT less than 6500 K; and a diffuser. The diffuser encases the first light spectrum emitted from the first LED and the second light spectrum emitted from the second LED, where the diffuser is configured to be approximately parallel to a user's face. The first light spectrum is emitted primarily from the upper region of the task lamp and is color separated from the second light spectrum that is emitted primarily from the lower region of the task lamp. FIG.15Ais a perspective view of a horizontal cylindrical lighting apparatus1500used as a ceiling fixture, whileFIG.15Bis a cross-sectional view across the diameter of the lighting apparatus. In this embodiment, the effect of creating a horizon is achieved by placing a first light engine1510and a second light engine1520centrally within the lighting apparatus1500and directed away from one another, utilizing a diffuser1540to create the gradient mixing. The diffuser1540forms the enclosure of the lighting apparatus along with end caps1560. First light engine1510(emitting first light spectrum L1) and second light engine1520(emitting second light spectrum L2) may have the CCT or color region ranges as described above in relation toFIG.13. First light engine1510is placed centrally in the lighting fixture1500and directed upward, where the translucent diffuser1540causes light L1 to be partially transmitted out of (arrow1513) and partially reflected back into (arrow1514) the lighting apparatus1500. Similarly, second light engine1520is placed centrally in the lighting fixture and directed downward (e.g., back-to-back with first light engine1510), where the translucent diffuser1540causes the light L2 to be partially transmitted out of (arrow1523) and partially reflected back into (arrow1524) the lighting apparatus1500. The reflection from the diffuser1540may be due to the nature of the diffuser material itself (e.g., translucency of material) and/or due to enhancements to promote reflectivity such as a reflective coating or texturing on an interior surface of the optical diffuser. As a result of this arrangement of L1 and L2 being emitted outward and opposite each other and being partially reflected back within the diffuser, L1, which is emitted from the top of the lighting apparatus, is color-separated from L2 which is emitted from the bottom of the lighting apparatus. L1 and L2 are mixed in the region between, from the light reflected within the diffuser, creating a gradient from the first CCT of the first light engine to the second CCT of the second light engine. In the illustration shown, the gradient progressing from L1 to L2 includes color temperatures L3a, L3b and L3c. In an example embodiment where L1 has a CCT of 14,000 K and L2 has a CCT 4000 K, L3a may be 8000 K, L3b may be 6500 K, and L3c may be 5000 K. Note that the spatial color gradient L3 (i.e., L3a, L3b and L3c) in the emitted light may apply to all embodiments in the present disclosure, even though not illustrated in other figures. FIG.16is a cross-sectional view of an embodiment of a lighting apparatus1600in which two light sources—first light engine1610and second light engine1620—are coplanar on a substrate1612. A reflective element1650is utilized to separate the first light spectrum L1 (produced by first light engine1610) and second light spectrum L2 (produced by second light engine1620) from one another. Substrate1612is located on the bottom of the lighting apparatus1600and forms, along with diffuser1640, an enclosure around the first light engine1610and the second light engine1620. Diffuser1640is over the regions L1, L2 and L3 where light is emitted from the lighting apparatus. Both L1 and L2 are directed upward in the installation orientation of the lighting apparatus. In one embodiment, the lighting apparatus1600may be a spherical fixture with first light engine1610in the center of substrate1612and second light engine1620being a ring of LEDs surrounding the first LED board1610. In another embodiment, the lighting apparatus1600may be a longitudinal lighting fixture with first light engine1610being a row of LEDs along a central axis of the substrate1612, and second light engine1620being additional LEDs on either side of the central row (first light engine1610). Reflector1650may be, for example, a cone-shaped or trough-shaped reflective material such as a metal or a plastic coated with reflective material. The reflector1650maintains color separation between L1 and L2, while the diffuser1640causes gradient mixing of L1 and L2 due to reflection from the inside surface of the diffuser (dashed arrows). The color temperatures and wavelength ranges for L1 and L2 may be the same as described in the previous embodiments. In one embodiment, the lighting apparatus1600may be the light emitting portion of an Edison style A-lamp. FIG.17is a cross-sectional view of another embodiment of a lighting apparatus1700in which light output from first light engine1710and second light engine1720are separated by a physical barrier. The lighting apparatus1700may be, for example, a horizontal cylinder similar toFIG.15Awhen the lighting apparatus1700is in its intended installed orientation. In this embodiment, first light engine1710is mounted on one side of substrate1712, and second light engine1720is mounted on the opposite surface of substrate1712. Substrate1712is mounted in the interior (e.g., the center) of the lighting apparatus, with its edges extending to the diffuser1740to form a physical barrier between L1 and L2. Similar toFIG.15B, some of the light from L1 and L2 bounces off the interior of the diffuser1740, as indicated by the dashed arrows. Through-holes1760near the edges of the substrate1712enable the reflected light L1 and L2 to blend together, creating a mixed light L3 from L1 and L2. FIGS.18A-18Cshow an embodiment of lighting apparatuses1800and1801in the form of a light bulb, which enable standard lighting fixtures to be converted to emit color-separated melanopic light.FIG.18Ais a perspective view;FIG.18Bis a cross-sectional view of the light bulb ofFIG.18Ain an upward installation orientation, such as in a table lamp; andFIG.18Cis a cross-sectional view of a light bulb1801in a downward installation orientation, such as in a ceiling fixture. Similar to the previous embodiments, the light bulbs ofFIGS.18A-18Chave a first light engine1810, a second light engine1820and an optical diffuser1840. InFIGS.18A-18B, first light engine1810is in the center of the base of the bulb1800, and second light engine1820surrounds first light engine1810. A reflective element1850in the shape of a flared cylinder separates the light output L1 (from first light engine1810) and L2 (from second light engine1820). The reflective element1850has a hole1860that allows the light L1 and L2 to mix, forming mixed light profile L3. In the upward orientation ofFIG.18B, L1 is emitted upwards relative to the ground, with L2 below L1, and L3 in between L1 and L2. In the downward orientation ofFIG.18C, the first light engine1810is in the periphery of the bulb's base, with second light engine1820in the center of the base so that L1 is still emitted upward relative to the ground and L2 is emitted downward. FIG.19shows yet another embodiment of a lighting apparatus1900configured as a task lamp with more than two light engines to enable various light spectrums to be emitted. In this embodiment, there are five light sources arranged along a vertical tower1970, with optical diffuser1940surrounding the tower. A first light engine1910may be, for example, an 8000 K to 20,000K uplight (i.e., upward-directed light) that emits a first light spectrum L1. An auxiliary first light engine1916below first light engine1910may also be an 8000 K to 20,000 K uplight, emitting light L1b that is similar or slightly warmer than L1. A second light engine1920in a lower portion of tower1970, and an auxiliary second light engine1926above second light engine1920, may both be 3500 K to 5000 K downlights (i.e., downward-directed lights), where second light engine1920emits light L2 that may be the same as or slightly warmer than light L2b from auxiliary second light engine1926. The bottom light engine1980may be, for example, a dedicated downlight emitting a nighttime-focused light spectrum LN that has a CCT of approximately 2200 K with red added (e.g., greater than approximately 700 nm). Diffuser1940causes gradient mixing between successive light outputs, such as L3 being a mixture of L1b and L2b. The addition of auxiliary first light engine1916, auxiliary second light engine1926and bottom light engine1980to first light engine1910and second light engine1920can enable light profiles to be customized even further, such as for producing scenes simulating natural lighting over the course of a day. In some embodiments, a controller may be connected to the lighting apparatus1900(or any of the lighting apparatuses in this disclosure) to implement dimming profiles according to a time of day, where the dimming profiles (which shall be described in more detail later) may include a sunrise scene, a daytime scene, daytime cloudy scene, a sunset scene, and a nighttime scene. FIG.20shows a further embodiment of a lighting apparatus2000that uses light guides to create the color separation effect. Lighting apparatus2000includes first light engines2010and second light engines2020mounted on and facing upward from substrate2012. Optical diffuser2040surrounds the regions in which light is emitted from the light engines and forms an enclosure along with substrate2012for the lighting apparatus2000. A light guide is vertically oriented on top of each light engine, with each light guide having a reflector or mirror “M” at its tip to direct the light produced from each of the light engines. In some embodiments, the reflector M may be an element other than a mirror, such as semi-reflective material or textured material that scatters or redirects light. The light guides having different heights to direct light output to different regions of the lighting apparatus. Light guide2018for first light engines2010have the longest length, such that light L1 is produced from an upper, first region of the lighting apparatus2000. Light guides2028for second light engines2020have a shorter length than light guides2018, such that light L2 is produced in a second region below the first region L1. As light L1 and L2 bounce of the interior of the optical diffuser2040, mixed light profile L3 is created in a third region between the first region L1 and second region L2. Lighting apparatus2000may optionally include a third light engine2080which may be used to create additional lighting profiles, such as for dimming profiles over the course of a day. Third light engine2080may be, for example, a nighttime-focused light spectrum LN having a CCT of approximately 2200 K with red added (e.g., visible red, such as 620 nm to 630 nm, or such as approximately 625 nm), where LN is emitted in a downward direction via light guide2088. FIG.21shows an example schematic of a printed circuit LED board2100for lighting apparatuses of the present disclosure. The LED board2100can be used as a light engine for producing either the upper light spectrum (L1) or lower light spectrum (L2), with certain LEDs on the board being utilized depending on which position it is mounted into within the lighting device. The embodimentFIG.21contains arrays of three independently controllable LED circuits. A first circuit2110contains melanopic LEDs (“BIOS Supp”) and 3500 K white LEDs (e.g., Nichia 757) used for either an L1 or L2 light spectrum. A second circuit2120contains either 2200 K LEDs if it is used on an L2 LED board or a 17,000K “Twilight” LED if it is used on an L1 LED board. A third circuit2130contains either a Phosphor Converted Amber (“PCA”) LED if it is used on an L2 LED board or a 405 nm LED if it is used on an L1 LED board. A controller2140may be in communication with the circuits2110,2120and2130, such as through connector2150, to control the lighting output from the LEDs and to implement various dimming profiles. In further embodiments, additional LED populations may included, such as an LED with a CCT higher than 20,000K, for the upward portion of the multi-zone lamp ofFIG.19. Each of these circuits2110,2120and2130can be combined in various proportions to produce a desired color temperature for the light emitted from the board2100. For example, combinations of the LEDs can be activated to produce CCTs of less than 6500 K or less than 5000 K, such as 4000 K or 3500 K for the lower region (L2) of a lighting apparatus. For the upper region of the lighting apparatus, combinations of the LEDs can be activated to produce CCTs of greater than 7000 K, for example greater than 10,000 K, such as 17,000 K. The various types of LEDs may be arranged on the board to produce a uniform light distribution. For example, in a cylindrical lighting apparatus the different types of LEDs may be arranged in concentric rings, with one color of LED in an outer ring, a second color in a central ring, and another color in the center. For a lighting apparatus having flat surfaces (e.g. a rectangular prism), different color LEDs may be arranged in linear arrays or may be interspersed with each other such as in an alternating manner. In various embodiments of the lighting apparatuses disclosed herein, the first region is vertically above the second region, relative to the ground, in an installation orientation of the lighting apparatus. In some embodiments, a primary viewing area of a viewer is adjacent or below the third region in an installation orientation of the lighting apparatus. In some embodiments, in an installation orientation of the lighting apparatus, the first light spectrum is emitted upward relative to the ground, the mixture is emitted in a horizontal direction, and the second light spectrum is emitted downward relative the ground. In various embodiments of the lighting apparatuses disclosed herein, the first light engine emits a first blue emission peak in a first wavelength range of 450 nm to 480 nm, and the second light engine emits a second blue emission peak in a second wavelength range of 480 nm to 500 nm. In some embodiments, a total melanopic to photopic ratio (M/P ratio) emitted by the lighting apparatus is greater than 1.0 or more, such as greater than 1.3, as received by a user at the user's location. In some embodiments, the first CCT is at least 17,000 K and the second CCT is 4000 K to 5000 K. In some embodiments, the first CCT is at least 17,000 K and the first light spectrum has a melanopic to photopic ratio (M/P ratio) greater than or equal to 1.7. In some embodiments, the mixture emitted from the third region has a third CCT profile comprising a gradient from the first CCT to the second CCT. In some embodiments, a first light emitting diode (LED) of the first light engine and a second LED of the second light engine face each other and are near opposite ends of the lighting apparatus. In some embodiments, the optical diffuser is a continuous piece covering the first region, the second region and the third region. In some embodiments, the optical diffuser comprises a translucent material, and at least one of the first light spectrum and the second light spectrum partially reflects off an interior surface of the optical diffuser. Spectral Profiles and Dimming Profiles The LEDs utilized in the present lighting devices may emit various wavelengths of biological light. In one example, the BIOS Supp LED (FIG.21) may emit a spectrum as shown inFIG.22, where biological light spectrum2200includes wavelength peaks at 490 nm (melanopic light, curve2210) and 660 nm (sub-dermal stimulation, curve2220). In some embodiments, one or more of the LEDs in the light apparatus may emit ultraviolet light, such as 370 nm to 410 nm, or near 380 nm. It has been recently been found in the scientific literature that the photoreceptor OPN5 (also known as neuropsin), which has a peak absorption at 380 nm, plays a role in photoentrainment. OPN5 has also been shown to accelerate circadian shifting to a new time zone, further indicating the importance of not only a visually purple twilight, but one that also contains wavelengths near 380 nm to 420 nm. In some embodiments, dimming profiles of the present disclosure can include modulating the OPN5/OPN4 ratio as well as creating a purple color. The OPN5/OPN4 ratio is a ratio of an OPN5 lux to a melanopic lux, where OPN4 lux is for melanopic light (480 nm to 500 nm, such as approximately 490 nm) that targets the photoreceptor OPN4, and OPN 5 lux is for violet light (380 nm to 410 nm, such as approximately 380 nm) that targets the photoreceptor OPN5. In some embodiments, the M/P ratio of light emitted from the upper region of the lamp is greater than 1.3, such as greater than 1.5. In one example, the M/P ratio for 17,000 K light emitted from the upper region is 1.7. In some embodiments, the M/P ratio of the total light emitted from the full light apparatus (i.e., light from both the upper and lower regions combined) is greater than 1.3. For example, a light apparatus emitting 7000 K may have an M/P ratio of 1.35. These high M/P ratios are critical to provide high enough melanopic lux, while still keeping glare down. In some embodiments, the luminance emitted by the lamp is at most 3000 candelas/m2, such as less than 2000 cd/m2, such as approximately 1000 cd/m2. Spectral modulation of the present color separation lighting devices may be beneficial for different population types where ipRGC subtypes may mediate undesired physiological effects. For example, people with migraine headaches, photophobia or bipolar disorder may have an increased sensitivity to blue wavelengths in the range from 450-500 nm. Thus it is beneficial to have the capability—as can be performed with the lighting apparatuses of the present disclosure—to limit some of certain types of blue light, such as including 465 nm but removing 490 nm, or vice versa. In some embodiments, the light apparatus may include dimming profiles to change the spectral output of the upper and/or lower LED boards. For example, melanopic and/or other biological light wavelengths and intensities may be varied in the light device according to the time of day. Embodiments may include a controller that implements dimming profiles and features as described in U.S. Pat. No. 10,420,184 entitled “Bio-Dimming Lighting System,” which is hereby incorporated by reference. The dimming profiles can be pre-programmed, user-defined, or scheduled based on chronotype or individual sleep/wake preferences. In some embodiments, the dimming profiles and/or lighting spectra may be customized based on a group of lights and users in a particular area, such as a group of desks within a region of an open plan office. In such embodiments, the lighting profiles may be based on an average (or other calculation) of preferences of the users in the group, where the lighting devices may include electronic connections (e.g., physical or wireless) to update preferences and lighting profiles to each other. In some embodiments, the amount of color separation—that is, the difference in CCT between L1 and L2—may be changed based on the ambient weather conditions. For example, on an overcast day the amount of color separation may be reduced from what would be used for a sunny day. In some embodiments, the lighting levels emitted from the lamps of the present disclosure may take into consideration the amount of light from the surroundings, such as other light sources (e.g., ceiling or nearby lamps), light from computer monitors, and the natural environmental (e.g., sunlight changing due to time of day and/or weather). The lighting levels could be measured, for example, using light sensors in the vicinity of the lamps and may include hard-wired or wireless connections (e.g., Bluetooth®) to communicate the lighting measurements to the lamp. Some embodiments, such as the multi-light source apparatus shown inFIG.19described previously, may include enhanced light characteristics projected in three different directions—an uplight (L1), side light (L1b and L2b), and down light (L2). In such embodiments, the side light is white light broken down into two subsets. These subsets enable more red and yellow to be combined within the downward portion in sunrise and sunset modes. One additional benefit of this approach is that a true downlight only portion can be created after a sunset scene has been executed, but before a sunrise scene in effort to put less light into the eyes of the end user. Studies have shown that the dynamic change of light is imperative for maintaining alertness and attention, similar to what occurs naturally outside with cloud coverage. Some embodiments can implement color separation but can also modulate the color separation to be removed along with reducing intensity over time, similar to cloud cover. This simulation of a daytime cloudy scene can be performed either randomly or in conjunction with information about the weather outside. This information about cloud coverage can be obtained, for example, via an internet connection or via a sensor placed outdoors. Evidence points to the fact that the suprachiasmatic nucleus (SCN), which contains the master circadian clock, has capacity for color representation. These data suggest that this color representation is specifically looking for color transitions to more blue or purple and yellow or red colors. This data suggests that twilight, which contains even higher contrasted color separation, may contain key biological information to the SCN that encoded information about the beginning and end of the day period. This may be of particular importance for seasonal encoding and circadian amplitude, as the SCN has the capacity to entrain to long and short days. These twilight type responses have been demonstrated in crepuscular creatures. Consequently, some embodiments of the present disclosure may beneficially be configured as a color separated lighting device to modulate the spectrum of the bluish color representing sky (first region) toward an even bluer or purplish color (e.g., wavelength having a peak in the 370 nm to 410 nm range, such as 380 nm), while the white light below the horizon (second region) can modulate to a more yellow or red color, creating a higher color contrast while simultaneously modulating intensity. Thus, embodiments may include coordinating spatial variations and time variations of emitted spectrums with each other to beneficially regulate human circadian behavior with the natural day or to a desired daily schedule (e.g., night shift schedule). Information supplied to the present lighting devices regarding when to begin the day and end the day may be based on solar data, such as an astronomical clock, or may come as a result of social requirements, habitual or preferred sleep and wake time, or may be a hybrid of all of these. An astronomical clock example would execute a sunrise when a natural sunrise occurs, if the lighting device is on, and execute a sunset when a natural sunset occurs, if the lighting device is on. A social requirement example would be an office work schedule from 9 AM to 6 PM, which would instruct a lighting device such that a sunrise occurs each day around 9 AM, and a sunset occurs each day around 6 PM. A hybrid example would be a scenario in which office work hours may be 9 AM to 6 PM in a region with a large geographical latitude. This means that during the summer, the natural daytime hours would start before 9 AM and end after 6 PM. In this case, a sunrise and sunset would not occur during the work hours. In the winter a natural sunrise would occur before 9 AM, and a natural sunset would occur before 6 PM. In this wintertime case, the controller would implement a dimming profile in which the lighting device would execute no sunrise at 9 AM, but would execute a sunset at 6 PM, thus only extending the daylength, but never shortening the daylength. This may prove useful as data suggest that humans have better memory consolidation during long days compared to short days. The data on social requirements may be derived, for example, via a local occupancy sensor, or based on BLUETOOTH® connectivity timing, or can be manually inputted via an end user. If multiple end users connect to the device in a shared space setting, the controller for the lighting apparatus may pool all individual data and obtain average or median daylengths. Additionally, if a lighting device is located in the home, some embodiments may include the ability to either execute a sunrise when the natural sunrise occurs or to create a natural sunrise at preferred wakeup time. Conversely, the lighting device can execute a sunset when the natural sun sets or during a time period (e.g., 2-3 hours) prior to preferred bedtime. In other embodiments, the lighting apparatus may know that user owns multiple lighting devices, such as at work and at home, and interact with the other lighting devices based on an understanding that the opportunity to provide biological signals may extend beyond the intended application. For example, a lighting device at the user's workplace may want (e.g., through learning by the controller) to execute a sunset at a habitual end of worktime of the user. However, if the lighting device knows the end user has an additional lighting device at home, it may then choose to not execute sunset at the workplace, allowing the end user to get exposure to that sunset when they get home. In all cases, after the natural sunset occurs, the controller of the lighting device at the location of the end user may cause the first LED spectrum (L1) located above the horizon to be either purple or completely dark, while the second LED spectrum (L2) is converted to a nighttime friendly light of between 1800 K to 2500 K with peak blue emission from 430 nm to 450 nm. In some embodiments, lighting apparatuses include a controller in communication with the first light engine and the second light engine. The controller implements a dimming profile according to a time of day, where the dimming profile comprises a sunrise scene, a daytime scene, daytime cloudy scene, a sunset scene, and a nighttime scene; or the dimming profile includes at least one of these scenes. In some embodiments, the lighting apparatus is configured to produce a sunrise scene, where during the sunrise scene an overall light output (i.e., integrated or total or combined light) from the lighting apparatus increases in intensity over time, and an OPN5/OPN4 ratio of the overall light output as received by a user at the user's location is inversely proportional to the intensity. In some embodiments, the lighting apparatus is configured to produce a sunset scene, where during the sunset scene an overall light output from the lighting apparatus decreases in intensity over time and an OPN5/OPN4 ratio of the overall light output as received by a user at the user's location is inversely proportional to the intensity. In some embodiments, the lighting apparatus is configured to produce a nighttime scene, where during the nighttime scene an integrated spectrum from the lighting apparatus as received by a user at the user's location has a nighttime CCT of 1800 K to 2500 K with nighttime blue emission peak between 430 nm to 450 nm. In some embodiments, the lighting apparatus is configured to produce a daytime scene, where during the daytime scene the first CCT of the first light engine is greater than 6500 K with first blue emission peak between 450 nm to 480 nm, and the second CCT of the second light engine is less than 6500 K. In some embodiments, an integrated spectrum from the lighting apparatus during the daytime scene has an M/P ratio greater than 1, as received by a user at the user's location. In some embodiments, an integrated spectrum from the lighting apparatus during the daytime scene, as received by a user at the user's location, has a daytime CCT of greater than 5000 K. In some embodiments, the lighting apparatus is configured to produce a daytime cloudy scene, where during the daytime cloudy scene first CCT and the second CCT are both between 4000 K to 6500 K. User Response Testing The vertical illuminance produced by the color separation lamps of the present disclosure provide functional benefits of not only circadian strength but also visual acuity, and furthermore provide unexpected aesthetic acceptability by users. These benefits and user acceptances shall be described in terms of pupillometry test results, glare response, and preference testing that were performed in relation to this disclosure. FIGS.23-25shall be used to describe pupillometry testing. It is known that pupil size drives visual acuity, where smaller pupils lead to higher visual acuity. An additional property of smaller pupil size is an understanding that non-visual responses driven by ipRGCs, includes circadian entrainment and pupil size. Thus, pupil size is understood as a correlate to circadian strength, where a stronger circadian strength leads to smaller pupil size.FIGS.23A-23Ddescribe example lighting scenarios in an office or workspace which can affect pupil size. In these schematics, drawn in vertical cross-section, the variables in the office are a general light, a computer monitor and a task lamp. The general light is typically a ceiling light, while the task lamp and computer monitor are on a desk or table and are near the level of the user's face. InFIG.23Aonly the computer is on; inFIG.23Bboth the computer and general light are on; inFIG.23Cthe computer, task lamp and general light are on; and inFIG.23Dthe computer and task lamp are on. FIG.24shows a graph2400of average pupil size versus visual lux for the scenarios ofFIGS.23A-23D. The downward slope of the line2405from the “computer only” scenario2410to the “computer+task lamp” scenario2420to the “computer+general light+task lamp” scenario2440suggests that task lamps impact pupil size. That is, adding light from a task lamp decreases pupil size, which consequently can improve visual acuity. Thus, the present task lamps can provide both circadian entrainment as well as assist in visual acuity during use. The outlying point representing “computer+general light” scenario2430suggests that general illumination does not significantly impact pupil size. FIG.25is a graph2500of average pupil size versus melanopic lux measured at the eye for the scenarios ofFIGS.23A-23D. A linear trend is seen related to the task lamp, with melanopic lux increasing (moving upward along the line2505from point 2520) with addition of the task lamp (point 2520) and with addition of the general light in combination with the task lamp (point 2540). That is, more melanopic lux was received as pupil size decreased, showing that the task lamp results in more effective circadian benefit and visual acuity. Preference testing was also performed in relation to this disclosure, comparing two identical tasks lamps (similar to that shown inFIG.13)—one task lamp emitting light only with a CCT of 4000 K and the other emitting color-separated light with CCTs of 4000 K and 17,000 K. Graphs showing user preference as a function of melanopic lux are shown inFIGS.26A-26C, comparing the 4000 K versus the color-separated lamp.FIG.26Ais a scenario with two of the tested task lamps on and the ambient light off;FIG.26Bis a scenario with two of the tested task lamps on and the ambient light on; andFIG.26Cis a scenario with one test task lamp on and the ambient light on. For each graph, estimated trendlines are plotted for the color separated task lamp (line C) and the 4000 K task lamp (line T). It can be seen that the color separated task lamp received higher preference scores than the 4000 K task lamp; that is, the overall preference from test subjects was for the bluer light sources. The graphs, particularlyFIG.26C, also show that there was a sharper decline in preference as brightness increased for the white light (4000 K lamp) compared to the color separated light. These preference testing graphs show the surprising results that although the present task lamps have more blue content (which traditionally results in more glare), they were aesthetically more acceptable by users. FIGS.27A-27Care graphs that are similar toFIGS.26A-26Cbut show preferences as a function of photopic lux. The lines labeled “C” representing color-separated data are higher than the lines labeled “T” representing 4000 K light, showing again that users preferred the color-separated light. The graphs ofFIGS.27A-27Calso demonstrate that the color-separated light had visual brightness levels similar to the 4000 K light, indicating that the increased comfort is not due to a higher M/P ratio of the color-separated light compared to the 4000 K light but rather was due to the color separation of the light. Reference has been made to embodiments of the disclosed invention. Each example has been provided by way of explanation of the present technology, not as a limitation of the present technology. In fact, while the specification has been described in detail with respect to specific embodiments of the invention, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily conceive of alterations to, variations of, and equivalents to these embodiments. For instance, features illustrated or described as part of one embodiment may be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present subject matter covers all such modifications and variations within the scope of the appended claims and their equivalents. These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the scope of the present invention, which is more particularly set forth in the appended claims. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention. | 80,458 |
11859779 | BEST MODE Hereinafter, with reference to the accompanying drawings will be described in detail preferred embodiments that may be easily carried out by the person of ordinary skill in the art. However, it should be understood that the configurations shown in the embodiments and drawings described in this specification are only preferred embodiments of the invention, and that there may be various equivalents and modifications that can replace them at the time of application. In the detailed description of the operating principle for the preferred embodiment of the invention, when it is determined that a detailed description of related known functions or configurations may unnecessarily obscure the subject matter of the invention, the detailed description will be omitted. Terms to be described later are terms defined in consideration of functions in the invention, and the meaning of each term should be interpreted based on the contents throughout the present specification. The same reference numerals are used for parts having similar functions and functions throughout the drawings. The lighting device according to the invention may be applied to various lamp devices that require lighting, such as vehicle lamps, household lighting devices, and industrial lighting devices. For example, when applied to vehicle lamps, it is applicable to head lamps, car width lights, side mirror lights, fog lights, tail lamps, brake lights, daytime running lights, vehicle interior lights, door scars, rear combination lamps, backup lamps, etc. The lighting device of the invention may be applied to indoor and outdoor advertising devices, display devices, and various electric vehicle fields. In addition, it may be applied to all lighting-related fields or advertising-related fields that are currently developed and commercialized or may be implemented according to future technological development. Hereinafter, the embodiments will be apparent through the description of the accompanying drawings and embodiments. In the description of the embodiments, each layer (film), region, pattern or structure is formed “on” or “under” of the substrate, each layer (film), region, pad or patterns. In the case described as, “on” and “under” include both “directly” or “indirectly” formed through another layer. In addition, the criteria for the top or bottom of each layer will be described based on the drawings. <Lighting Module> As shown inFIGS.1to7, a lighting module200according to an embodiment of the invention is a device that includes a plurality of light emitting devices100and emits light emitted from the light emitting devices100as line-shaped surface light. The lighting module200may have a side, an exit surface, or a transparent surface having a line width around the plurality of light emitting devices100. The lighting module200may be provided with an exit surface having a predetermined width or a transparent surface on one surface of the plurality of light emitting devices100. The lighting module200may include a first surface S1facing one surface of the light emitting device100, a second surface S2opposite to the first surface S1, and third and fourth surfaces S3and S4extending in a second direction from both ends of the first surface S1and the second surface S2. The first and second surfaces S1and S2may face each other. At least a portion of the third and fourth surfaces S3and S4may face each other. As another example, as shown inFIG.21, the third and fourth surfaces S3and S4may not face each other. The minimum distance between the first and second surfaces S1and S2may be smaller than the minimum distance between the third and fourth surfaces S3and S4. The first surface S1and the second surface S2may have a long length in one direction or the first direction X. The one direction or the first direction X may be a straight line or may include a curve as shown inFIG.21. The third surface S3and the fourth surface S4may be perpendicular to the first direction X, or may be perpendicular to the first or second surfaces S1and S2. The first surface S1may face the emission surface111of the light emitting device100or may be a surface exposed in the second direction from the first ends of the third surface S3and the fourth surface S4. The second surface S2may be a surface that faces the non-emission surface of the plurality of light emitting devices100or is exposed in the second direction from the second ends of the third surface S3and the fourth surface S4. The third and fourth surfaces S3and S4may be different from the first and second surfaces S1and S2. In the lighting module200, a plurality of light emitting devices100may be arranged in a first direction or along a region between the first surface S1and the second surface S2. The plurality of light emitting devices100may be arranged in one row. The virtual line connecting the light emitting devices100arranged in one row may be a straight line or may include a curved line having a curvature. As another example, the plurality of light emitting devices may be arranged in two rows, and the light emitting devices in the second row are disposed between the first surface S1and the second surface S2in a column direction (e.g., a Y direction). They may be disposed so as not to overlap each other. The plurality of light emitting devices100arranged in the first direction X may face the first surface S1or the exit surface, respectively. Each of the emission surfaces111of the plurality of light emitting devices100may face the first surface S1. The light emitted from the light emitting device100may be emitted through the first surface S1, and some light passes may be emitted through at least one of the second surface S2, the third surface S3, and the fourth surface S4. As shown inFIGS.2to5, the lighting module200may have a length X1in the first direction X longer than a width Y1in the second direction Y. The length X1in the first direction may vary depending on the number of arrangements of the light emitting devices100, and may be, for example, 30 mm or more. The width Y1in the second direction may be 13 mm or more or 16 mm or more. The width Y1in the second direction Y of the lighting module200may provide a region in which the emitted light of the light emitting device100is diffused and a region protecting the rear of the light emitting device100. As shown inFIG.2, a distance D1between the light emitting device100and the first surface S1and a distance D5between the light emitting device100and the second surface S2based on the light emitting device100may be different from each other. The distance D5between the light emitting device100and the second surface S2may be 2 mm or more, for example, may be in the range of 2 mm to 20 mm. When the distance D5between the light emitting device100and the second surface S2is smaller than the above range, the region where moisture may penetrate or form a circuit pattern may be reduced, and when larger than the above range, a size of the lighting module200may be increased. In the lighting module200, the first surface S1, the second surface S2, the third surface S3, and the fourth surface S4may be provided as surfaces perpendicular to the third direction Z. The third direction Z may be a direction orthogonal to the first and second directions X and Y. The first surface S1, the second surface S2, the third surface S3, and the fourth surface S4may have the same thickness or the same height in the third direction Z. The lighting module200includes a substrate210, a resin layer220on the substrate210, and a first reflective member240on the resin layer220. The first to fourth surfaces S1, S2, S3, and S4may be side surfaces of the resin layer220. The resin layer220includes the first surface S1, the second surface S2, the third surface S3, and the fourth surface S4. The resin layer220may be disposed to surround the device disposed on the substrate210, for example, one or a plurality of light emitting devices100. At least three or more of the plurality of light emitting devices100may be arranged in the first direction, and may be disposed in the resin layer220. The plurality of light emitting devices100may be disposed between the substrate210and the first reflective member240. The resin layer220may be made of a light-transmitting material such as silicone or epoxy. The resin layer220may include a glass material as another material. The lighting module200may include a second reflective member230between the resin layer220and the substrate210. The second reflective member230may not be formed, and a reflective member may be attached to the upper surface of the substrate210to serve as the second reflective member230. The substrate210includes a printed circuit board (PCB), for example, a resin-based printed circuit board (PCB), a metal core PCB, a flexible PCB, and a ceramic PCB, or a FR-4 substrate. The substrate210may be a flexible or non-flexible substrate. A circuit pattern may be disposed on the substrate210. The circuit pattern of the substrate210may include a plurality of pads in a region corresponding to the light emitting device100. Among the regions of the substrate210, a rear region with respect to the light emitting device100is a region opposite to a region from which light is emitted, and circuit patterns for connecting the light emitting devices100may be disposed. The width of the rear region may vary according to the number of the light emitting devices100or a connection method of the light emitting devices100. The width of the rear region is the distance D5between the light emitting device100and the second surface S2, and may be 2 mm or more. Accordingly, a circuit pattern for connecting the plurality of light emitting devices100and suppressing moisture penetration from the rear of the light emitting device100may be formed. The plurality of light emitting devices100may have a bonding portion disposed thereunder and may be electrically connected to the pad of the substrate210. The plurality of light emitting devices100may be connected in series by a circuit pattern of the substrate210. As another example, the plurality of light emitting devices100may be connected in parallel by a circuit pattern of the substrate210, or two or more groups connected in series may be connected in parallel. The light emitting device100may include a device including a light emitting chip or a package in which an LED chip is packaged. The light emitting chip may emit at least one of blue, red, green, and ultraviolet (UV) light. The light emitting device100may emit at least one of white, blue, red, and green. The light emitting device100may emit light in a lateral direction, and a bottom portion may be disposed on the substrate210. The light emitting device100may be a side view type. As another example, the light emitting device100may be an LED chip, and one surface of the LED chip may be opened and a reflective member may be disposed on the other surface. The emission surface111of the light emitting device100may be disposed on a surface adjacent to the substrate210, for example, on a side adjacent to the upper surface of the substrate210. The emission surface111is disposed on a side surface between the bottom and the upper surfaces of the light emitting device100, and emits light in the second direction Y. The emission surface111of the light emitting device100may be adjacent to the second reflective member230and may be a surface perpendicular to the upper surface of the substrate210and the upper surface of the second reflective member230. The thickness of the light emitting device100may be smaller than the length of the light emitting device100in the first direction X. The thickness of the light emitting device100may be 3 mm or less, for example, 2 mm or less. The thickness of the light emitting device100may be in the range of 1 mm to 2 mm, for example, in the range of 1.2 mm to 1.8 mm.4and5, the pitch G1between the light emitting devices100may be 10 mm or more, for example, 10 mm to 30 mm. In addition, the distance G2between the outermost light emitting device100and the third or fourth sides S3and S4of the resin layer220may be smaller than the pitch G1, and may be 10 mm or less. The length of the light emitting device100in the first direction X (L1inFIG.7) may be greater than the thickness of the light emitting device100, for example, 1.5 times or more of the thickness of the light emitting device100. Since the light emitting device100has a thin thickness and a long length in the first direction X, the light emission angle in the first direction X which is a left-right direction with respect to the center of the light emitting device100may be provided widely. Here, the light emission angle in the first direction X of the light emitting device100may be greater than the light emission angle in the third direction Z, which is an up-down direction. The light emission angle of the light emitting device100in the second direction Y may be in the range of 110 degrees to 160 degrees. Here, as shown inFIG.3, the thickness Za of the substrate210may be smaller than the thickness of the light emitting device100. The thickness of the light emitting device100may be more than twice the thickness Za of the substrate210, for example, may be in the range of 2 times to 4 times. Since the thickness Za of the substrate210is thin, the lighting module200may be provided as a flexible plate. The resin layer220may be disposed on the substrate210. The second reflective member230may be disposed between the resin layer220and the substrate210. The resin layer220may cover the light emitting device100, and the first reflective member240may cover an upper surface of the resin layer220. The resin layer220may be in contact with the upper surface and side surfaces of the light emitting device100. The resin layer220may be in contact with the upper surface of the second reflective member230. A portion of the resin layer220may be in contact with the substrate210through the opening232of the second reflective member230. The resin layer220may be in contact with the emission surface of the light emitting device100. The first surface S1, the second surface S2, the third surface S3, and the fourth surface S4of the resin layer220are side surfaces between the first and second reflective members240and230. The first surface S1, the second surface S2, the third surface S3, and the fourth surface S4may be peripheral surfaces of the light emitting device100or surfaces corresponding to the side surfaces of the light emitting device100. The upper surface area of the resin layer220may be the same as the upper surface area of the substrate210, the upper surface area of the second reflective member230, or the upper surface area of the first reflective member240. The length of the resin layer220in the first direction may be the same as the length of the substrate210, the length of the second reflective member230, or the length of the first reflective member240. The maximum width Y1of the resin layer220in the second direction may be the same as the maximum width of the substrate210, the maximum width of the second reflective member230or the maximum width of the first reflective member240. The resin layer220may be disposed between the first and second reflective members240and230. The upper surface of the second reflective member230and the lower surface of the first reflective member240may be disposed to face each other on the lower surface and the upper surface of the resin layer220. The upper surface of the first reflective member230and the lower surface of the second reflective member230may have the same area. Accordingly, the resin layer220may diffuse the light emitted from the light emitting device100and the light reflected by the first and second reflective members240and230to guide them in the lateral direction. The resin layer220may be formed to a thickness Zb that is thicker than that of the light emitting device100. Accordingly, the resin layer220may protect the upper portion of the light emitting device100and prevent moisture penetration. Since the substrate210is disposed on the lower portion of the light emitting device100and the resin layer220is disposed on the upper portion of the light emitting device100, the light emitting device100may be protected. Accordingly, the interval between the upper surface of the resin layer220and the light emitting device100may be 0.6 mm or less, for example, in the range of 0.5 mm to 0.6 mm. An upper portion of the resin layer220may be disposed to have the same thickness as the gap to protect an upper portion of the light emitting device100. The thickness Zb of the resin layer220is the distance between the first and second reflective members240and230, and the distance (e.g., Zb) between the first and second reflective members240and230may be smaller than a distance between the first surface S1and the second surface S2. For example, the distance between the first surface S1and the second surface S2may include a maximum distance or a minimum distance. The distance or interval between the second reflective member230and the first reflective member240may be smaller than the distance or interval between the first surface S1and the second surface S2of the resin layer220. By disposing the distance between the first and second reflective members240and230to be smaller than the width Y1or the minimum width in the second direction of the lighting module200, a surface light in the form of a line is provided and the luminous intensity is improved and a hot spot may be prevented. In addition, it is possible to provide a lighting module flexible in the third direction. The thickness Zb of the resin layer220may be less than or equal to twice the thickness of the light emitting device100, for example, more than 1 to 2 times or less. The thickness Zb of the resin layer220may be, for example, in the range of 1.5 mm to 1.9 mm or in the range of 1.6 mm to 1.8 mm. The thickness Zb of the resin layer220may be 0.8 times or less of the thickness Z1of the lighting module200, for example, in a range of 0.4 times to 0.8 times the thickness Z1of the lighting module200. Since the resin layer220is disposed with a difference of 1.2 mm or less from the thickness Z1of the lighting module200, it is possible to prevent a decrease in light efficiency in the lighting module200and to strengthen the ductility characteristics. The resin layer220may include a resin material such as silicone, silicone molding compound (SMC), epoxy, or epoxy molding compound (EMC). The resin layer220may include a UV (ultra violet) curable resin or a thermosetting resin material, for example, may selectively include PC, OPS, PMMA, PVC, and the like. The resin layer220may include a phosphor. The phosphor may include at least one of a yellow phosphor, a green phosphor, a blue phosphor, and a red phosphor. A light extraction structure such as a concave-convex structure may be disposed on the first surface S1of the resin layer220, but the invention is not limited thereto. On the first surface S1, a first region horizontally overlapping with the light emitting device100and a second region horizontally overlapping with a region between the light emitting devices may be disposed on the same plane. As another example, the second region may be concave in a second surface direction than the first region, or the first region may protrude more convex than the second region. The second reflective member230may reflect the light emitted from the light emitting device100. The second reflective member230may be formed on the upper surface of the substrate210. The second reflective member230may be formed as an upper layer of the substrate210or as a separate layer. The second reflective member230may be adhered to the upper surface of the substrate210with an adhesive. The resin layer220may be adhered to the upper surface of the second reflective member230. The second reflective member230has a plurality of openings232in a region corresponding to the lower surface of the light emitting device100, and the light emitting device100may be connected to the substrate210through the openings232. A portion of the resin layer220may be in contact with the substrate210through the opening232. The opening232may be a region in which the light emitting device100may be bonded to the substrate210. The second reflective member230may be formed in a single-layer or multi-layer structure. The second reflective member230may include a material that reflects light, for example, a metal or a non-metal material. When the second reflective member230is a metal, it may include a metal layer such as stainless steel, aluminum (Al), or silver (Ag), and in the case of a non-metallic material, it may include a white resin material or a plastic material. The second reflective member230may include a white resin material or a polyester (PET) material. The second reflective member230may include at least one of a low reflection film, a high reflection film, a diffuse reflection film, and a regular reflection film. The second reflective member230may be provided as, for example, a regular reflection film for reflecting the incident light to the first surface S1. One end of the second reflective member230may be disposed on the same plane as the first surface S1. The other end of the second reflective member230may be disposed on the same plane as the second surface S2. As another example, one end and the other end of the second reflective member230may be spaced apart from the first surface S1and the second surface S2and may be in contact with the resin layer220. That is, the outside of the second reflective member230may be covered with the resin layer220to prevent moisture from penetrating. The thickness Zc of the second reflective member230may be smaller than the thickness Za of the substrate210. The thickness Zc of the second reflective member230may be 0.5 times or more of the thickness Za of the substrate210to reduce transmission loss of incident light. The thickness Zc of the second reflective member230may be in the range of 0.2 mm to 0.4 mm, and when it is smaller than the above range, light transmission loss may occur, and when it is thicker than the above range, the thickness Z1of the lighting module200may increase. The first reflective member240may be disposed on the resin layer220. The first reflective member240may be adhered to the upper surface of the resin layer220. The first reflective member240may be disposed on the entire upper surface of the resin layer220to reduce light loss. The first reflective member240may be made of the same material as the second reflective member230. In order to reflect light and reduce transmission loss of light, the first reflective member240may be made of a material having a higher light reflectance than that of the second reflective member230or may have a thicker thickness. The first reflective member240may have the same thickness or a thicker thickness as the second reflective member230. For example, the first and second reflective members240and230may be provided with the same material and the same thickness. The first reflective member230may be spaced apart from the edge of the substrate210, and a portion of the resin layer220may be in contact with an edge-side upper surface of the substrate210. When the resin layer220is in contact with the edge of the substrate210, moisture penetration may be suppressed. The thickness Zd of the first reflective member240may be smaller than the thickness Za of the substrate210. The thickness Zd of the first reflective member240is disposed to be 0.5 times or more of the thickness Za of the substrate210, thereby reducing transmission loss of incident light. The thickness Zd of the first reflective member240may be in the range of 0.2 mm to 0.4 mm, and when it is smaller than the range, light transmission loss may occur, and when it is thicker than the above range, the thickness Z1of the lighting module200may increase. The first reflective member240may be formed in a single-layer or multi-layer structure. The first reflective member240may include a material that reflects light, for example, a metal or a non-metal material. When the first reflective member240is a metal, it may include a metal layer such as stainless steel, aluminum (Al), or silver (Ag), and in the case of a non-metallic material, it may include a white resin material or a plastic material. The first reflective member240may include a white resin material or a polyester (PET) material. The first reflective member240may include at least one of a low reflection film, a high reflection film, a diffuse reflection film, and a regular reflection film. The first reflective member240may be provided as a regular reflective film so that, for example, incident light travels in the direction of the first surface S1. The exit surface of the resin layer220may be treated as a haze surface, so that light may be diffused. The haze surface may be treated as a surface rougher than the inner surface of the resin layer220to diffuse the emitted light. The lighting module200according to an embodiment of the invention may provide the thickness Z1in the third direction in the form of a line to provide a surface light source in the form of a line having ductility. The thickness Z1of the lighting module200may be 3 mm or less. That is, the lighting module200may be provided as a line-shaped surface light source of 3 mm or less. As another example, the lighting module200may be larger than 3 mm and may be arranged to be 6 mm or less. In this case, the thickness of the lighting module200is increased, but the thickness of the resin layer220is increased to increase the line width and to increase the light distribution region. Referring toFIG.3, looking at the thickness of each component in the lighting module200, the thickness of the substrate210is Za, the thickness of the resin layer220is Zb, and the thickness of the second reflective member230is Zc, and the thickness of the first reflective member240is Zd, there may have a relationship of Zb>Za>Zd≥Zc. An interval between the lower surface of the substrate210and the upper surface of the first reflective member240is the thickness Z1of the lighting module200. The thickness Zb may be a ratio of 0.4 to 0.8 of Z1, the thickness Za may have a ratio of 0.14 to 0.18 of Z1, and the thickness Zd or Zc may have a ratio of 0.08 to 0.12 of Z1. The Zb may have a ratio of 3.5 to 4 of Za. The Zb may have a ratio of 5.8 to 6.4 of Zc or Zd. By disposing the thickness Zb of the resin layer220thicker than the thickness Za of the substrate210, the light emitting device100may be protected and light is diffused to guide it, and the ductility may be strengthened. In addition, since a line-shaped exit surface having a thickness Zb or a height of the resin layer220is provided, a line exit surface may be provided. Referring toFIGS.2and7, in the first embodiment of the invention, the resin layer220includes a hole R0therein. The hole R0may penetrate the resin layer220from the upper surface of the resin layer220toward the substrate210or may be recessed through the resin layer220. One or a plurality of the holes R0may be disposed. The hole R0may be disposed between each of the light emitting devices100and the first surface S1. At least a portion of the hole R0may horizontally overlap the emission surface111of the light emitting device100. The hole R0may diffuse the light emitted from the light emitting device100. A material filling the hole R0may be different from the refractive index of the resin layer220. The material filling the hole R0may have a refractive index lower than that of the material of the resin layer220. A gas may be disposed in the hole R0, and may include, for example, air or at least one of oxygen, nitrogen, hydrogen, argon, and carbon dioxide gas. The hole R0may be in a vacuum state. As another example, the hole R0may be filled with a material having a higher refractive index than that of the resin layer220. The material having a high refractive index may include a metal oxide or a metal nitride. The hole R0and each light emitting device100may overlap in a direction from the first surface S1toward the light emitting device100. An area of each of the holes R0may be greater than an area of each emission surface of the light emitting device100. That is, a hole R0having a larger area than the front area of each light emitting device100may be provided in front of each light emitting device100. A maximum length B1of the hole R0in the first direction X may be greater than a length L1of each light emitting device100in the first direction. The maximum length B1of the hole R0in the first direction may be greater than the length of the emission surface111of each light emitting device100in the first direction. Accordingly, the hole R0may cover the emission-side region of the light emitting device100in the first direction, and may diffuse incident light having a predetermined orientation angle distribution. The length B1may be 1 mm or more greater than the length L1of the light emitting device100or 115% or more compared to the length L1. The maximum width B2of the hole R0in the second direction may be equal to or greater than the width L2of the light emitting device100. The maximum width B2in the second direction of the hole R0may be 1 mm or more, for example, 1 mm to 4 mm. When the maximum width B2in the second direction of the hole R0is smaller than the above range, processing is difficult and when larger than the above range, the improvement rate of light uniformity may be insignificant. The hole R0may be disposed in a region of 5% or more, for example, 5% to 60% of the distance D1between the light emitting device100and the first surface S1. The minimum distance D2between the first surface S1of the resin layer220and the hole R0may be smaller than the minimum distance D1between the light emitting device100and the first surface S1of the resin layer220. The minimum distance D2between the first surface S1of the resin layer220and the hole R0may be equal to or greater than the minimum distance D3between the hole R0and the light emitting device100. That is, the hole R0may be disposed closer to the light emitting device100than the first surface S1of the resin layer220. The minimum distance D1between the light emitting device100and the first surface S1of the resin layer220may be 4 mm or more, for example, 4 mm to 10 mm, or 4 mm to 20 mm. As the minimum distance D2is arranged in a range of 10% to 60% of the distance D1, the incident lights may be refracted by the hole R0and then diffused. The minimum distance D3between the hole R0and the light emitting device100may be 2 mm or more, for example, 2 mm to 4 mm. When the minimum distance D3is smaller than the above range, the distribution of the beam angle of the light emitting device100may be affected, and light extraction efficiency may be reduced. The minimum distance D3may be a minimum distance in consideration of an error between a mounting process of the light emitting device100and a fixing pin (see,291ofFIG.23) inserted when the hole R0is formed. The distance G4between the light emitting devices100may be 5 mm or more, for example, between 5 mm and 18 mm. When the distance G4is too narrow, the number of light emitting devices100may be increased, and when the distance G4is too large, dark portions may be generated between the light emitting devices100. The distance G4may vary according to the distribution of the orientation angle of the light emitting device100. The hole R0may be disposed on a one-to-one basis with the light emitting device100, thereby reducing a hot spot on a central region of the light emitting device100. When a plurality of holes R0are disposed, the distance G3between the holes R0may be smaller than the distance G4between the light emitting devices100. The distance G3may be 100% or more of the distance G4, for example, in the range of 100% to 200%. When the distance G3is smaller than the distance G4, the difference in luminous intensity between the region passing through the hole R0and its periphery may increase. Here, adjacent holes R0may be connected to each other. As shown inFIG.3, the height of the hole R0is the same as the thickness Zb of the resin layer220, or is in the range of 50% to 100% or 80% to 100% of the thickness Zb of the resin layer220. A lower surface of the first reflective member240may be disposed on the upper surface of the hole R0. On the lower surface of the hole R0, an upper surface of the second reflective member230may be disposed, an upper surface of the substrate210may be disposed, or a portion of the resin layer220may be disposed. The hole R0may be formed by disposing a fixing pin in the resin layer220and removing the fixing pin after the resin layer220is cured. Here, when the fixing pin is first disposed in the process of forming the hole R0and then the resin layer220is dispensed and cured, the resin may not be disposed on the bottom of the fixing pin. As another example, when the resin layer220is dispensed and the fixing pin is inserted before curing, a portion of the resin may be present at the bottom of the fixing pin. Accordingly, the height of the hole R0may be equal to the thickness Zb of the resin layer220or in the range of 50% to 100% or 80% to 100% of the thickness Zb of the resin layer200. The top view shape of the hole R0may include a polygonal shape or a shape having a curved surface. The polygonal shape may be a triangular, quadrangular, or pentagonal shape or more. The hole R0may include a first surface portion Ra facing the light emitting device100, and a second surface portion Rb and a third surface portion Rc facing the first surface S1. The first surface portion Ra may be a region to which the light is incident. The second surface portion Rb and the third surface portion Rc may be surfaces for emitting light traveling through the first surface portion Ra or another surface portion. The first surface portion Ra may have a height of the hole R0and a maximum length in the first direction X of the hole R0. The second surface portion Rb and the third surface portion Rc may be disposed to be inclined from both ends of the first surface portion Ra. The distance between the second surface portion Rb and the third surface portion Rc may be the largest in the first surface portion Ra, and the smallest point at a point closest to the first surface S1. The second surface portion Rb and the third surface portion Rc may provide vertices at intersections with each other. The interior angle C1of the vertex Rp may be 120 degrees or less, for example, in the range of 60 degrees to 120 degrees. That is, the interior angle C1of the vertex Rp is the angle between the second surface portion Rb and the third surface portion Rc or the interior angle of the emission region, and may be in the range of 60 degrees or more or 60 degrees to 120 degrees. Here, (A) ofFIG.20is a case in which the interior angle C1of the emission region of the hole R0is 60 degrees, (B) is 90 degrees, (C) is 120 degrees, and (D) may be provided at 150 degrees. Here, when the interior angle C1of the emission region of the hole R0is changed, the position and length of the first surface portion Ra are fixed and measured. The luminance graph according to the interior angle of the hole R0may be provided as shown inFIG.26. As shown in Table 1, when the interior angle C1is 60 degrees to 120 degrees, the light uniformity may be 84% or more, and when the interior angle C1is 150 degrees, it may be about 80%. TABLE 1Interior angle (degree)6090120150Uniformity (%)85.4%85.1%84.8%79.7%Luminance (nit)6477672068817015 Accordingly, by selecting the interior angle C1of the emission region of the hole R0in the range of 60 degrees to 120 degrees, the uniformity of light emitted through the second and third surface portions Rb and Rc of the hole R0may be improved. In the first embodiment, the resin layer220is adjacent to the first surface S1and has a plurality of holes R0arranged along the first surface S1, and each of the plurality of holes R0may be disposed between each of the light emitting devices100and the first surface S1, respectively. Accordingly, since the light emitted through the light emitting device100is diffused by the hole R0, the uniformity of the light emitted through the first surface S1may be improved. Also, hot spots may be eliminated. In addition, in order to improve light uniformity on the first surface S1, a convex lens may not be formed. In addition, since the distance between the first surface S1and the light emitting device100may be reduced, it is possible to suppress an increase in the width of the module.FIGS.8to12are examples in which the hole of the lighting module according to the first embodiment is modified. For convenience of description, the configuration of the first embodiment will be selectively included, and the modified holes will be described. Referring toFIG.8, the hole R0may include a first surface portion Ra, a second surface portion Rb, and a third surface portion Rc, and a fourth surface portion Rd facing the first surface portion Ra. The fourth surface portion Rd may be connected between the second surface portion Rb and the third surface portion Rc, and may have a length B3smaller than the length B1of the first surface portion Ra. The fourth surface portion Rd may have a shape in which the vertex ofFIG.7is removed. The fourth surface portion Rd may transmit light incident through the first surface portion Ra to a minimum. A convex pattern may be formed on the first surface S1facing the fourth surface portion Rd, but the invention is not limited thereto. Referring toFIG.9, the hole R0includes a first surface portion Ra, a second surface portion Rb, and a third surface portion Rc, and the second surface portion Rb and the third surface portion Rc may include a concave-convex pattern Rr1. The concave-convex pattern Rr1may be provided in a triangular prism shape, and may diffuse incident light. Lights incident by the concavo-convex pattern Rr1may be diffused through various paths, and light uniformity may be further improved. Referring toFIG.10, the fourth surface portion Rd of the hole R0may include a plurality of concavo-convex patterns Rr2. Since the fourth surface portion Rd has a plurality of concavo-convex patterns Rr2, a hot spot caused by light emitted through the fourth surface portion Rd of the hole R0may be suppressed. Referring toFIG.11, the hole R0includes a first surface portion Ra, second and third surface portions Rb and Rc, and may include a recess portion Re concave in the direction of the light emitting device in a region between the second surface portion Rb and the third surface portion Rc, and the recess portion Re may face the light emitting device100. A first vertex portion Rp1may be connected between the recess portion Re and the second surface portion Rb, and a second vertex portion Rp2may be connected between the recess portion Re and the third surface portion Rc. The depth B5of the recess portion Re may be 10% or more of the width B2of the hole R0, for example, in a range of 10% to 50%. A lower point of the recess portion Re may be disposed closer to the first surface portion Ra than the first and second vertex portions Rp1and Rp2. The center of the recess Re may be disposed in the same region as the center of the light emitting device100. The recess portion Re adjusts the degree of diffusion of the incident light according to the depth B5, thereby suppressing a hot spot in the center of the light emitting device100. Referring toFIG.12, the hole R01may include a first surface portion Ra1convex in the direction of the first surface S1of the resin layer220, and a curved second surface portion Rb1facing the first surface portion Ra1. The interval between the first surface portion Ra1and the second surface portion Rb1may be constant or may be wider toward the center of the hole R01. The outer surface Rk1between the first surface portion Ra1and the second surface portion Rb1may be a horizontal surface or an inclined surface. The first surface portion Ra1may refract incident light, and the second surface portion Rb2may refract the refracted light again. The hole R01may diffuse the light incident by the first surface portion Ra1and the second surface portion Rb1. FIG.13is a modified example of the hole. The hole R02may include a first hole portion R21having a long length in one direction and a second hole portion R22protruding from the first hole portion R21in the direction of the first surface S1of the resin layer220. The first hole portion R21may include a first surface portion Ra2facing the plurality of light emitting devices100, and the second surface portion Rb2opposite to the first surface portion Ra2may be an exit surface. The second hole portion R22includes an exit surface portion Rc having third and fourth inclined surface portions Rc1and Rc2, and the third and fourth surface portions Rc1and Rc2may be horizontally overlapped with each of the light emitting devices100. The third and fourth surface portions Rc1and Rc2form vertices in a region adjacent to the first surface S1, and the interior angle of the vertices may be 120 degrees or less, for example, 60 to 120 degrees. The second hole portion RR2may guide incident light and spread it laterally. FIGS.14to19are examples of plan views showing a hole of a lighting module according to a second embodiment. The configuration of the lighting module can be selectively applied to the configuration of the first embodiment, and the changed part will be described. Referring toFIGS.14and15, the resin layer220includes a plurality of holes R1therein, and the plurality of holes R1may each correspond to the light emitting device100. The plurality of holes R1may be respectively disposed between the light emitting device100and the first surface S1of the resin layer220. The hole R1may have a bar shape or a rectangular shape having an elongated shape in one direction. A first direction length B1of the hole R1may be longer than a first direction length L1of the light emitting device100. The plurality of holes R1may be spaced apart from each other. The first direction length B1of the hole R1may be longer than the first direction length L1of the light emitting device100by 1 mm or more. The width B2in the second direction of the hole R1may be 1 mm or more, for example, 1 mm to 3 mm. A distance D3between the hole R1and the light emitting device100may be closer than a distance D2between the hole R1and the first surface S1. The hole R1may include a first surface portion R11facing the light emitting device100and a second surface portion R12facing the first surface S1. An outer surface Rs1is disposed at both ends between the first and second surface portions R11and R12, and the outer surface Rs1may extend perpendicular to at least one or both of the first surface portion R11and the second surface portion R12. Accordingly, the light incident on the hole R1may be diffused, and the diffused light may be output as line surface light. As shown inFIG.16, a single hole R2may be disposed to have a length to cover the plurality of light emitting devices100. The hole R2may have a bar shape or a rectangular shape. The length of the hole R2in the first direction may be 80% or more of the maximum length of the resin layer220in the first direction. A length of the hole R2in the first direction may be greater than a length connecting the outermost ends of the plurality of light emitting devices100. Accordingly, the hole R2may be disposed between each of the light emitting devices100and the first surface S1and may be disposed to correspond to the region between the light emitting devices100. Accordingly, since the hole R2covers the emission side of the light emitting device100and the outer region thereof, it is possible to diffuse the incident light and prevent a hot spot on the first surface S1. The hole R2may be provided in a sine wave shape or may include convex portions each convex in the direction of the light emitting device100and/or concave portions convex in the direction of the first surface S1. The bar-shaped hole R2may reduce the straightness of the incident light. As shown inFIG.17, the resin layer220may include a first hole R1adjacent to the light emitting device100and a second hole R2adjacent to the first surface S1of the resin layer220. At least one of the first hole R1and the second hole R2may be single or plural. The plurality of holes R1and R2may be arranged in at least two rows between the light emitting device100and the first surface S1of the resin layer220. A plurality of the first holes R1may be arranged in the first direction and may face each of the plurality of light emitting devices100. The first holes R1may be disposed between the light emitting device100and the second holes R2, respectively. A single second hole R2may be disposed in the first direction and may be disposed between the first hole R1and the first surface S1of the resin layer220, respectively. The length of the longer hole among the first and second holes R1and R2may be twice or more than five times the length of the shorter hole. A long hole R2among the first and second holes R1and R2may be spaced apart from the third and fourth side surfaces S3and S4. The distance D6between the first and second holes R1and R2may be at least 1 mm apart, and may be equal to or smaller than the distance D3between the first hole R1and the light emitting device100. At least a portion of the first and second holes R1and R2may be connected to each other, which may vary depending on the shape of the fixing pin. The lengths of the first holes R1in the first direction X may be the same or shorter than the lengths of the second holes R3. Conversely, the positions of the first hole R1and the second hole R2may be changed from each other. The first and second holes R1and R2are arranged in a double structure and overlap the light emitting device100in a horizontal direction, thereby reducing a hot spot in the center of the light emitting device. As shown inFIG.18, the resin layer220may include a first hole R1adjacent to the light emitting device100and a second hole R3adjacent to the first surface S1of the resin layer220. The first hole R1and the second hole R3may be plural. The plurality of first holes R1may be arranged in the first direction X and face each light emitting device100. The first hole R1may be disposed between the light emitting device100and the second hole R3, respectively. A plurality of the second holes R3may be arranged in the first direction X and may be disposed between the first hole R1and the first surface S1of the resin layer220. The lengths B11and B1of the first and second holes R1and R3in the first direction are equal to each other, or the length B11of the second hole R3may be shorter than the length B1of the first hole R1. Alternatively, the positions of the first hole R1and the second hole R3may be changed from each other. The first and second holes R1and R3are disposed in a double structure and overlap the light emitting device100in a horizontal direction, thereby reducing a hot spot in the center of the light emitting device. As shown inFIG.19, the plurality of holes R2aand R2bhave a long length in the first direction, the plurality of holes R2aand R2bmay overlap in the second direction, and may include regions do not overlap in the first direction. The plurality of holes R2aand R2bmay be disposed parallel to each other. A first hole R2aadjacent to the light emitting device100among the plurality of holes R2aand R2bmay be parallel to a straight line connecting the light emitting devices100. A second hole R2badjacent to the first surface S1among the plurality of holes R2aand R2bmay be parallel to the first surface S1. Each of the plurality of holes R2aand R2bmay be spaced apart from the third and fourth side surfaces S3and S4. The plurality of holes R2aand R2bmay be disposed closer to the third and fourth side surfaces S3and S4than the outermost light emitting device100. Accordingly, light incident from the entire light emitting device100may be diffused. As shown in FI.21, the lighting module201may be provided in a curved shape based on a horizontal straight line X0. When applied to a vehicle ramp, it may be combined into a curved ramp shape extending to the rear (or front) and sides of the vehicle. In the lighting module201, the angle between the virtual straight line X2connecting both ends of the first surface S1in the straight line X0may be an angle C2in the range of 10 degrees to 60 degrees, and a virtual straight line X3extending in a tangential direction from the first surface S1disposed at one end of the lighting module201may have an angle C3in the range of 5 degrees to 30 degrees. A virtual line connecting the adjacent light emitting devices100in the lighting module201may include a straight line, an oblique line, or a curved line. The virtual line connecting the plurality of holes R0may include a straight line, an oblique line, or a curved line. Here, a portion of the line connecting the light emitting devices100may be disposed closer to the first surface direction than a virtual straight line connecting the other end from one end of the first surface S1of the lighting module201. As shown inFIG.22, in the lighting module, a third reflective member245may be disposed on the rear or second side S2of the resin layer. The third reflective member245may be a metal or a non-metal material among the materials of the reflective member disclosed above. The third reflective member245extends from the side surface of the substrate210to the side surface of the first reflective member240or may be disposed on the side surface of the resin layer220at the side height of the resin layer220. The third reflective member245may re-reflect the light reflected from the hole R0or the first surface S1. FIG.23(A)-(C) are views illustrating a manufacturing process of a lighting module according to an embodiment. As shown in (A) ofFIG.23, the fixing pin291may penetrate through the resin layer220and contact the second reflective member230or the substrate210. In this case, the fixing pin291may be disposed before the resin layer220is formed, and after the resin layer220is dispensed and cured, it may be separated as shown in (B). As another example, after dispensing the resin layer220, the fixing pins291are positioned, and when the resin layer220is cured, the fixing pins may be separated as shown in (B). As shown in (C) ofFIG.23, when the hole R0is formed in the region where the fixing pin is removed, the first reflective member240is formed on the resin layer220. The first reflective member240may be disposed on the resin layer220and the hole R0. At least one position of the hole R0may be disposed between the light emitting device100and the first surface S1. FIG.24is a luminous intensity distribution of the lighting module according to the first embodiment of the invention, andFIG.25is a graph showing the luminous intensity distribution of the lighting module according to the second embodiment. As shown inFIG.24, the light intensity distribution by the triangular hole may provide a light uniformity of 80% or more, for example, 85% or more. As shown inFIG.25, it can be seen that the light intensity distribution by the line-shaped or bar-shaped hole has a light uniformity of 50% or more.FIG.26is a view showing the luminous intensity distribution at 60 degrees, 90 degrees, 120 degrees and 150 degrees of the interior angle C1along (A)-(D) of each lighting module ofFIG.20. It may be seen that the range of the interior angle of 60 degrees to 120 degrees has a uniform distribution of about 85%, and in the case of 150 degrees, it may be seen that it has a uniform distribution of about 80%. FIG.27is an example of a module in which a light emitting device is disposed on a circuit board in a lighting module according to an embodiment of the invention, andFIG.28is a view of the module viewed from the other side ofFIGS.27and28, the light emitting device100includes a body10having a cavity20, a plurality of lead frames30and40in the cavity20, and one or a plurality of light emitting chips71disposed on at least one of the plurality of lead frames30and40. The light emitting device100is an example of the light emitting device disclosed in the above embodiment, and may be implemented as a side emission type package. The light emitting device100may have a length (or a length of a long side) in the first direction X that is three times or more, for example, four times or more, than a width in the second direction Y. The length of the second direction Y may be 2.5 mm or more, for example, in the range of 2.7 mm to 6 mm, or in the range of 2.5 mm to 3.2 mm. The light emitting device100may reduce the number of the light emitting devices100in the first direction X by providing a longer length in the first direction X. The light emitting device100may provide a relatively thin thickness, thereby reducing the thickness of the lighting device having the light emitting device100. The thickness of the light emitting device100may be in the range of 2 mm or less, for example, 1.5 mm or less, or 0.6 mm to 1 mm. The body10has the cavity20and the length in the first direction X may be three times or more compared to the thickness of the body10, so as to widen the beam angle of the light in the first direction X. At least one or a plurality of lead frames30and40are disposed on the body10. At least one or a plurality of lead frames30and40are disposed on the bottom of the cavity20. A first lead frame30and a second lead frame40are coupled to the body10, for example. The body10may be formed of an insulating material. The body10may be formed of a reflective material. The body10may be formed of a material having a reflectance higher than a transmittance for a wavelength emitted from the light emitting chip, for example, a material having a reflectance of 70% or more. When the reflectance is 70% or more, the body10may be defined as a non-transmissive material or a reflective material. The body10may be formed of a resin-based insulating material, for example, a resin material such as Polyphthalamide (PPA). The body10may be formed of a silicone-based, epoxy-based, or thermosetting resin including a plastic material, or a material having high heat resistance and high light resistance. The body10may include a reflective material, for example, a resin material to which a metal oxide is added, and the metal oxide may include at least one of TiO2, SiO2, and Al2O3. The body10may effectively reflect incident light. As another example, the body10may be formed of a translucent resin material or a resin material having a phosphor for converting the wavelength of incident light. The first side portion15of the body10may be a surface on which the cavity20is disposed, or a surface on which light is emitted. The second side portion of the body10may be the opposite side of the first side portion15or the second side. The first lead frame30may include a first lead portion31disposed on the bottom of the cavity20, and a first bonding portion32disposed in a first outer region of the third side portion11of the body10, and a first heat dissipation portion33disposed on the third side surface portion13of the body10. The first bonding portion32is bent from the first lead portion31in the body10and protrudes to the third side portion11, and the first heat dissipation portion33may be bent from the first bonding portion32. The first outer region of the third side surface portion11may be an area adjacent to the third side surface portion13of the body10. The second lead frame40may include a second lead portion41disposed on the bottom of the cavity20and a second bonding portion42disposed in a second outer region of the third side portion11of the body10, and a second heat dissipation portion43disposed on the fourth side surface portion14of the body10. The second bonding portion42may be bent from the second lead portion41in the body10, and the second heat dissipation portion43may be bent from the second bonding portion42. The second outer region of the third side surface portion11may be a region adjacent to the fourth side surface portion14of the body10. The interval portion17between the first and second lead portions31and41may be formed of a material of the body10, and may be on the same horizontal plane as the bottom of the cavity20or may protrude, but not limited thereto. As another example, two or more lead frames may be disposed in the body10, for example, three lead frames are disposed, one of which may be a heat dissipation frame or a frame of positive polarity, and the other two may have different negative polarities. Here, the light emitting chip71may be disposed on the first lead portion31of the first lead frame30, for example, and may be connected to the first lead part31by the wires72and73, or may be connected to the first lead portion31with an adhesive and connected to the second lead portion41with a wire. The light emitting chip71may be a horizontal chip, a vertical chip, or a chip having a via structure. The light emitting chip71may be mounted in a flip chip method. The light emitting chip71may selectively emit light within a wavelength range of ultraviolet to visible light. The light emitting chip71may emit, for example, ultraviolet or blue peak wavelength. The light emitting chip71may include at least one of a group II-VI compound and a group III-V compound. The light emitting chip71may be formed of, for example, a compound selected from the group consisting of GaN, AlGaN, InGaN, AlInGaN, GaP, AlN, GaAs, AlGaAs, InP, and mixtures thereof. A plurality of light emitting chips71may be connected in series or a plurality of light emitting chips71may be connected in parallel. One or a plurality of light emitting chips71disposed in the cavity20of the light emitting device100according to the embodiment may be disposed. The light emitting chip71may be selected from, for example, a red LED chip, a blue LED chip, a green LED chip, and a yellow green LED chip. Looking at the inner surface of the cavity20, the inner surface disposed around the cavity20may be inclined with respect to a horizontal straight line of the upper surfaces of the lead frames30and40. The inner surface of the cavity20may have a vertically stepped region from the first side portion15of the body10. The stepped region may be disposed to be stepped between the first side portion15and the inner surface of the body10. The stepped region may control a directivity characteristic of light emitted through the cavity20. A molding member81is disposed in the cavity20of the body10, and the molding member81includes a light-transmitting resin such as silicone or epoxy, and may be formed in a single layer or in multiple layers. The molding member81or the light emitting chip71may include a phosphor for changing the wavelength of the emitted light. emitted as light. The phosphor may be selectively formed from quantum dots, YAG, TAG, silicate, nitride, and oxy-nitride-based materials. The phosphor may include at least one of a red phosphor, a yellow phosphor, and a green phosphor, but is not limited thereto. The surface of the molding member81may be formed in a flat shape, a concave shape, a convex shape, or the like, but is not limited thereto. As another example, a light-transmitting film having a phosphor may be disposed on the cavity20, but the present disclosure is not limited thereto. A lens may be further formed on the upper portion of the body10, and the lens may include a structure of a concave and/or convex lens, and the light distribution of light emitted from the light emitting device100may be adjusted. A semiconductor device such as a light receiving device or a protection device may be mounted on the body10or any one of the lead frames, and the protection device may be implemented as a thyristor, a Zener diode, or a TVS (Transient voltage suppression), and the Zener diode protects the light emitting chip from electrostatic discharge (ESD). Referring toFIG.28, at least one or a plurality of light emitting devices100are disposed on the support member210, and a protective layer and/or a reflective member260is disposed around the lower portion of the light emitting device100. The light emitting device100is an example of the light emitting device disclosed in the embodiment, and emits light in the central axis Y0direction, and may be applied to the lighting device disclosed above. The first and second lead portions33and43of the light emitting device100are bonded to the electrode patterns213and215of the substrate210with solder or conductive tape as conductive adhesive members217and219. The lighting module according to an embodiment of the invention may be applied to a lamp as shown inFIG.29. The lamp is an example of a vehicle lamp, such as a head lamp, a side lamp, a side mirror lamp, a fog lamp, a tail lamp, a brake lamp, a daytime running lamp, a vehicle interior lighting, a door scar, a rear combination lamp, or Applicable to backup lamps. Referring toFIG.29, the lighting module200disclosed above may be coupled to a lamp in a housing503having an inner lens502. The thickness of the lighting module200is such that it can be inserted into the inner width of the housing503. The width Z3of the emitting portion515of the inner lens502may be equal to or less than twice the thickness of the lighting module200, thereby preventing a decrease in luminous intensity. The inner lens502may be spaced apart from the first surface of the lighting module200by a predetermined distance, for example, 10 mm or more. An outer lens501may be disposed on the emission side of the inner lens502. A lamp having such a lighting module200is an example, and may be applied to other lamps as a structure having a ductility, for example, a curved surface or a curved structure when viewed from the side. FIG.30is a plan view of a vehicle to which a vehicle lamp to which a lighting module is applied according to an embodiment is applied, andFIG.31is a view showing a vehicle lamp having a lighting module or a lighting device disclosed in the embodiment. Referring toFIGS.30and31, the tail light800in the vehicle900may include a first lamp unit812, a second lamp unit814, a third lamp unit816, and a housing810. Here, the first lamp unit812may be a light source for the role of a turn indicator, the second lamp unit814may be a light source for the role of a sidelight, and the third lamp unit816may be a light source for the role of a brake light, but is not limited thereto. At least one or all of the first to third lamp units812,814, and816may include the lighting device or module disclosed in the embodiment. The housing810accommodates the first to third lamp units812,814, and816, and may be made of a light-transmitting material. In this case, the housing810may have a curve according to the design of the vehicle body, and the first to third lamp units812,814, and816may implement a surface light source that may have a curved surface according to the shape of the housing810. Such a vehicle lamp may be applied to a turn signal lamp of a vehicle when the lamp unit is applied to a tail lamp, a brake lamp, or a turn signal lamp of a vehicle. | 63,520 |
11859780 | DESCRIPTION OF REFERENCE NUMERALS 1. Flashlight head;2. Mirror;3. Lens;4. Lens support;41. Positioning column;5. Lamp strip plate;51. First positioning hole;6. Heat dissipation gasket;7. Main lamp plate;8. Lamp holder;81. Second positioning hole;9. Floodlight source;10. Spotlight source;11. Concave part;12. Reflective coating;13. Sunken space;31. First incident surface;32. Second incident surface;33. First emergent surface;34. Second emergent surface;35. First reflecting surface;36. Transition surface; and37. Second reflecting surface. DETAILED DESCRIPTION OF THE EMBODIMENTS In order to describe the technical solutions in the embodiments of the present application or the relevant art more clearly, the present application will be further introduced below in combination with specific embodiments and drawings, obviously, the drawings described below are only some embodiments of the present application, and other drawings can further be obtained by those of ordinary skill in the art according to the drawings without creative work. It is to be understood that orientation or position relationships indicated by terms “upper”, “lower”, “front”, “rear”, “left”, “right”, “horizontal”, “top”, “inner” and the like are orientation or position relationships shown in the drawings, are adopted not to indicate or imply that indicated apparatuses or components must be in specific orientations or structured and operated in specific orientations but only to conveniently and simply describe the present application and thus should not be understood as limits to the present application. Terms “first”, “second” and “third” are only adopted for description and should not be understood to indicate or imply relative importance or implicitly indicate the number of indicated technical features. Therefore, a feature defined by “first”, “second” and “third” may explicitly or implicitly indicate inclusion of at least one such feature. In the description of the present application, “a group” means two or more, unless otherwise specified. As shown inFIG.1, a light source switching apparatus for a flashlight includes: a lamp strip plate5, a main lamp plate7, a heat dissipation gasket6, a lens support4, a lens3, a flashlight head1, a lamp holder8and a mirror2. The lamp strip plate5is provided with a floodlight source9and the main lamp plate7is provided with a spotlight source10, as shown inFIG.1, the floodlight source9is annular, the spotlight source10is square-block-shaped, and the floodlight source9and the spotlight source10are located on the same axis. The heat dissipation gasket6is disposed between the lamp strip plate5and the main lamp plate7, by means of the thickness of the heat dissipation gasket, the heat dissipation gasket6may separate the lamp strip plate5and the main lamp plate7, so that the installed lamp strip plate5and main lamp plate7have the same distance with the thickness value of the heat dissipation gasket in the axial direction, thus eliminating a dark area that may appear when the spotlight source and the floodlight source illuminate at the same time, and the preferred thickness of the cheat dissipation gasket is 0.5 mm. The lens support4is mounted on the lamp strip plate5, the lens3is carried on the lens support4, the lens3is trumpet-shaped, and the central circular part and the outer ring part have different setting cross sections, which are configured to pass through light of the spotlight source and the floodlight source. The lens support is hollow-trumpet-shaped and has a set size, when the two are installed, a protruding surface of the lens3may fit with a concave surface of the lens support. The lens3, the lens support4, the lamp strip plate5and the main lamp plate7are coaxially coated and mounted between the flashlight head1and the lamp holder8. The mirror2is disposed between the flashlight head1and the lens3. As shown inFIG.2, in the embodiment, the lamp holder8is provided with a concave part with a set shape, and the shape of the concave part matches the shape of the main lamp plate7, so that the main lamp plate7may be mounted on the lamp holder8in an embedded mode. In addition, two positioning holes81are further formed in the concave edge of the lamp holder8. As shown inFIG.3, in the embodiment, the lens support4is further provided with two positioning columns41, and the lamp strip plate5is provided with two first positioning holes51. The positioning columns41, the first positioning holes51and the second positioning holes81are in one-to-one correspondence, during mounting, the positioning columns on the lens support4penetrate through the first positioning holes51in the lamp strip plate5and are further inserted into the corresponding second positioning holes81in the lamp holder8, so that the lamp strip plate5and the heat dissipation gasket6are fastened on the lamp holder8, the rotation of the lens support4and the main lamp plate7around the axis is avoided, and therefore, the relative position of the lamp strip plate5and the main lamp plate7may be fixed by virtue of the above structure. In the embodiment, the connection between the flashlight head1and the lamp holder8is tightened by means of threads, and in other embodiments of the present application, the connection may also be made by means of a snap, etc. In the embodiment, when the flashlight works at the spotlight irradiation state, only the spotlight source on the main lamp plate7works; and when the flashlight works at the floodlight irradiation state, both the spotlight source on the main lamp plate7and the floodlight source on the lamp strip plate5are in the working state. Specifically,FIG.4,FIG.5andFIG.7illustrate the cross-section structure of lens3, the lens3is trumpet-shaped with the end close to the light source sinking inwards, the sunken space may contain the spotlight source inside, the sunken space has a first incident surface31and a second incident surface32, the surface, through which light is emitted, of the lens3includes a conical inner front surface, known as the first emergent surface33, and an annular front surface, known as the second emergent surface34. The back surface of the lens includes three conical surfaces with non-collinear buses, a first reflecting surface35, a transition surface35and a second reflecting surface37in sequence from back to front. As shown inFIG.4, taking the bottom of the sunken space of the end, close to the light source, of lens3as a starting point, junction points of the first incident surface31and the second incident surface32on the section ofFIG.5are connected and an extension line is made, the extension line will pass through the junction of transition surface36and second reflecting surface37(in other embodiments, the junction of the transition surface36and second reflecting surface37is located at the rear side of the extension line, which has the same technical effect). Therefore, in the lens3with the structure, most of forward light may emit into the lens body through the first incident surface31and be refracted, and then emerge from the first emergent surface33and refracted again, and light is emitted towards the front of the lens3; a small amount of light emitted to the first emergent surface33will be reflected to the second reflecting surface37and reflected again, emitted from the first emergent surface33, refracted again, and emitted forwards; most of the lateral light may enter the lens body through the second incident surface32and be refracted, then light is emitted to the first reflecting surface34, in such a case, because the refractive index inside the lens is higher than that of the outside, and light emitted to the first reflecting surface34meets the requirement that the incidence angle is greater than the critical angle, light will have total internal reflection, light is emitted to the emergent surface33after being reflected by the main reflecting surface34, after refraction, light is emitted towards the front of lens3, the lens enables light emitted by the light source be refracted and reflected for a plurality of times inside the lens so as to be converted into collimating light emitted from the emergent surface of the lens as far as possible, meanwhile, light condensing is enhanced under assistance of the support, which has a very high utilization efficiency of light, meanwhile, the collimation of the emergent light is high, and spotlight and long-range shooting effects may be realized. As shown inFIG.6, the surface, in contact with the lens3, of the lens support4is further coated with a reflective coating12for enhancing reflection of light on the second reflecting surface37, further reducing loss of light. The embodiments described above represent only several implementation modes of the present application, and the description thereof is specific and detailed, but should not be construed as limiting the scope of present application accordingly. It should be pointed out that those of ordinary skill in the art can also make some modifications and improvements without departing from the concept of the present application, and these modifications and improvements all fall within the scope of protection of the present application. Accordingly, the scope of protection of the patent of the present application should be subject to the appended claims. | 9,360 |
11859781 | DETAILED DESCRIPTION Detailed description will now be provided of exemplary embodiments, examples of which are illustrated in the accompanying drawings. The following description refers to the accompanying drawings in which the same numbers in different drawings represent the same or similar elements unless otherwise represented. The implementations set forth in the following description of exemplary embodiments do not represent all implementations consistent with the disclosure. Instead, they are merely examples consistent with aspects related to the disclosure as recited in the appended claims. In some implementations, illumination devices on the market generally either place the batteries inside a large chamber where the illuminator is located or in a dedicated battery box. In either case, the weight of the battery is concentrated in a small enclosed container, which makes the user of such illumination device feel and carry the full battery weight by holding onto a small point and make it tiresome to carry and hold this style of illumination device for a long period of time. In addition, the existing illumination devices have their control switch placed on the illumination device's light head chamber, which requires two hands to operate the illumination device. In particular, one hand must hold the illumination device, while the other hand activates the control switch (e.g., pushes a button that activates the control switch). An improved illumination device is disclosed herewith which solved these problems. The present disclosure provides illumination devices including light heads which each include a chamber or housing that contains components of the illumination device except for at least the battery cells and the control switch. In some embodiments, the light head may have all electronic or electrical components except for battery cells and control switch (along with any needed wiring). Some embodiments of the present disclosure include a C-shaped handle, a push button switch mounted onto a front portion top side of the C-shaped handle, and multiple battery cells placed inside this C-shaped handle. Placing the battery cells evenly inside the handle allows the battery weight to be evenly distributed along the C-shaped handle. The handle shape and the battery cell positions are placed so that the center of mass is located at the center point of the holding area. In this regard, the handle may be curved in a C or D-shape or in some other shape. Alternatively, the handle may be shaped differently with the battery weight being distributed evenly along the handle. When holding a curved handle shape (e.g., a C or D-shaped handle), since the whole illumination device's weight is evenly distributed, the user's hand will hold the handle portion at or near the equilibrium balance point. Thus, the hand won't feel the illumination device is heavy and tiresome to hold after a short while. Because the push button switch is located on the front top portion of the handle, it can easily be operated with only the carrying hand, with the control switch then being controlled by a thumb push from the same hand. Optionally, the illumination device can be turned on by sound or voice. In some embodiments, the illumination device can be water-proof to safeguard the electrical components As shown inFIGS.1-12, an illumination device includes: a light head having a light head chamber or housing (1), C-shaped handle (2), a rubber cap covered push button switch (3), a pair of ear shaped handle on the light head chamber for rotating the head chamber to either left or right way (4), an internal mechanism to have an detent action effect when rotating the light head chamber (5), a pair of foldable or stationary feet for letting the device stand upright along (6), reflector (7), LED light source (8), a few auxiliary LEDs inside the light head chamber (9), a printed circuit board which has all the control and drive circuits and components (10), a battery bank composed of a one to five or even more cells (11), Anti-skid textured surface on the C-shaped handle (12), a gear-shaped wheel with a wave-shaped surface (13), buffer frame (14), air hole(s) or vent(s) (15), a digital display (16), charging port (17), current indicator (18), remaining time indicator (19), the hook at the end of the handle (20), charge indicator (21), buzzer (22), center of mass (23), remaining battery percentage indicator (24), and buffer chamber (25). The light head chamber (1) is a significant component of the illumination device. The light head chamber (1) includes reflector (7), the light source (e.g., LED) (8), a few auxiliary light sources (e.g., LEDs) inside the head chamber (9), and the printed circuit board (10) which has the control and drive circuits and components. The battery cells (11), as shown inFIG.3, are placed inside the C-shaped handle (2). In this embodiment, the light head chamber (1) does not include any battery cells (11) or rubber cap covered push button switch (3). The advantages of placing the battery cells individually inside the handle (and not the light head) are as follows: A. It allows the battery cells to have improved heat dissipation since the surface of each cell can dissipate the heat individually to the handle's inside surface which has its other side of the surface having direct thermal contact with the ambient air. This results in good heat dumping to the ambient air so that each battery cell will not have significant temperature rise during operation. In conventional illumination devices, battery cells often bundled together thus they touch one another giving heat to each other, resulting in significant temperature rise of the whole bundle during operation. B. It distributes the weight of the battery cell evenly along the handle and the user will not feel the weight concentrated in the light head. As such, the light head will not be too heavy while the handle is generally too light, as is generally the case when using conventional illumination devices. The light head will get damaged easily when it is dropped to ground accidently due to the highly concentrated weight on the light head. After placing the battery cells in the handle, the light head is not too heavy, thus it will not be damaged easily when it is dropped to ground accidently. C. After distributing the weight along the handle, the illumination device will have its weight center located in the middle point (23) of the C-shaped handle, the same point where the user's hand center is located, giving the user a good feel when holding the handle. Since the light head chamber (1) does not have the battery cells (11), the light head chamber (1) can accommodate large size reflector(s) (7). The larger the size of the reflector(s) (7), the higher the efficiency for collecting light and reflecting it towards the front of the light head chamber (1) to form the beam, as opposed using a smaller reflector and reflecting less lights and having a large amount of light not being reflected and, ultimately, wasted. In some embodiments, the head chamber (1) has fish scale-shaped air holes or vents (15) to allow ambient air to flow into the light head chamber (1), so as to dissipate heat from the light source (e.g., LED) (8) while preventing raindrops from entering the head chamber. The Buzzer (22) may be located inside the light head chamber (1), next to the air hole(s) or vent(s) (15). With the buzzer, the illumination device can be used as an alarm for the illumination device. The LED light source (8), reflector (7) and a few auxiliary LEDs (9) are located inside the light head chamber (1). Light from the light source is collected via the mirror surface inside the reflector (7) to form a circular light spot. The large reflector can improve the quality of the light spot and the evenness of the light, i.e., to obtain a light beam spot with well uniformly distributed brightness. The auxiliary light source inside the head chamber got reflected with high efficiency through the outside surface of the reflector to let the beam be directed to the radial direction to the light head thus the lights can be seen by the user and others who are not in the front axial direction of the illumination device. This feature is especially useful for railway workers. The C-shaped handle (2) as inFIG.1, may be sized in such a way that it can either be held by hand or carried by arm or even shoulder. To ensure a firm grip, the handle surface is texturized to improve friction and reduce slippage. The C-shaped handle (2) is mounted on a pair of shafts which are formed onto a pair of buffer chambers (25), which provide a shock buffer when the whole illumination device falls to ground or hit by some objects and the handle receives too strong a shock, thus, the shafts or the head chamber won't be damaged. In some embodiments, the handle (2) can be removable from the light head, as shown inFIG.18. In addition, the handle (2) can be a charger which includes a battery controller to control charging and use of battery power, a charging port, and a charge level indicator on the handle. In addition, the handle may be couplable to the light head with a quick release mechanism (such as a latch on a male/female connector). In this way the curved handle charger with batteries can be charged independently from the light head, such that if one set of battery cells is drained in one handle charger, that handle charger may be quickly replaced by another fully charged handle charger. One or more quick release mechanism(s) can be integrated on the above-mentioned shaft outfitted with one or more electrical connectors (e.g., XLR (X Latching Resilient) connector) that can interface with one or more female electrical connectors on the light head which are electrically connected to the light source(s) via wires under the control of electronics on the PCB board. Note that the orientation of the male and female connectors may be reversed. Some embodiments provide output devices to output visual or audio information regarding the status of the illumination device. By way of example, the output devices may include the digital display (16), indicators (18), (19), (21), and (24) and/or buzzer (22). By way of example, the digital display (16) may show battery current, the percentage of the charge remaining in the battery, the run time remaining when using the device for illumination running at the current setting mode, and the charge time remaining when charging the battery. When showing the time remaining when being used as an illumination device, the current is coming out of the battery, thus, the current value shown has a negative sign. When showing the time remaining for charging the battery, the current comes into the battery, the current is a positive value and it does not have the negative sign; When the device is both being charged and used as an illumination device, the display will show a negative current value if the draining current for driving the light sources is larger than the charging current, or a non-negative value if the charging current is larger than the draining current. When the current shows a negative value, the time shown is the running time of the battery that remains if the current setting mode is active. If the current shown is a non-negative value, the time shown is the charge time needed for charging up the battery cells fully. As shown inFIG.4, there are four indicators which were made up by 4 individual LEDs (24), (19), (18) and (21): The top indicator shows “%” sign (24). When this is lit, the digital display (16) shows the percentage of energy left in the battery. Another indicator shows “h” (19) shows the number of hours needed to finish charging the battery when the device is being charged, or the number of hours the battery will last when the device is being used as an illumination device. Another indicator shows “A” (18) which is the charging current to the battery when the device is being charged or the battery discharging current when the device is being used as an illumination device and the current value is shown as a negative value because the current is being drawn out from the battery. When the device is both charged and being used as an illumination device, the charging current and the discharging current can be larger or smaller than each other, the current display value can sometimes be positive while being negative at the other times depending on whether the power supply is being used for charging, what light sources are turned on, and what the brightness level(s) are set to. There is a 4th indicator (21) located near the charging port connector (17), which will be lit up when the device is being connected to a charging power supply through a charging cable and when there is a charging current going into the battery. When the device is charged or used as an illumination device, the display (16) will rotate showing up to four parameters: percentage of the energy left in the battery, the time needed to finish the charge or the remaining run time of the battery, the charging or discharging current on the battery, and the remaining time the battery can run on the existing setting mode. By way of example, regarding the setting mode, when the illumination device is set to the front beam mode and/or side beam mode, the time shown on the display (16) will be the estimated time the battery cells will last by driving the main beam. In addition, in some embodiments, the indicators (24), (19), (18) and (21) can work in an automatically rotating manner (in either direction) to show percentage(s) for a few seconds, then show the charging current (with positive value), discharge current (negative value), or the balance of current when the device is charging while it is also being used to emit light(s). In this regard, if the battery is receiving current from the charging power supply, the current is positive; if the battery is providing current to the drive, the current values is shown as a negative value. The parameter display can be arranged in a fixed mode as well: it shows one of the 3 parameters, percentage, time and current, until the user quickly clicks the control switch button for one time (or other number of times) and the display will show the next parameter. The rotating sequence can be: percentage, time, then current, or other sequences. In addition, the remaining hours for charging during charging mode or for powering the lights during usage mode may be shown. In addition, the charging time required (if the battery is under being charged mode), or the remaining run time may be shown if the battery is in discharged mode. The hook (20) inFIG.1, located at the end of the handle (2) top portion, allows the illumination device to be hung onto a rope, a tree branch, a nail, another hook, or ring, on a wall, etc., while the illumination device is in use or storage, or being charged. For railway companies, a long rope can be hung along a wall and dozens of such illumination devices will be hung onto the rope and be charged and stored together without taking up precious surface areas of desks or tables. Inside the mechanism between the handle and the illumination device head, some embodiments of the present disclosure provide a gear-shaped wheel (13) with a wave-shaped surface which generates detent actions when the handle is rotated on the head. The detent action gives firm positioning of the handle vs. the head and results in steady beam pointing. To protect the wires that connect the components inside the handle and the head from being overly twisted, the handle rotation angle is limited to between −180° and +1800 or even a smaller range. In some embodiments, a kit as illustrated inFIG.9can be provided, including a wireless charging station (91). Although in the embodiments as illustrated wireless charging station (91) can have a single straight bar shape or be a cable, in some other embodiments wireless charging station (91) can be a plurality of hooks, loops, or handles. Wireless charging station (91) can be electrically coupled to an electrical power source, such as a wall socket. A plurality of the illumination devices can be hung on the wireless charging station91for wireless charging. In some implementations, as illustrated inFIG.9, the illumination devices are hung on the wireless charging station (91) with hooks (20), and hooks (20) have wireless charging receptor built therein. In some other embodiments, the illumination devices can be hung on the wireless charging station (91) directly through the “C”-shaped handles, which have wireless charging receptor built therein. Another aspect of the present disclosure provides the placement of the control button (3) onto the handle (2), as opposed to placing the button (3) on the main head of the illumination device as found in conventional illumination devices. This feature allows the users to control the illumination device using the thumb of the holding hand, as opposed to using one hand to hold the handle and another hand to press the button. This single-handed operation gives a much better feel and convenience for using the illumination device. In some embodiments, an SOS signal can be sent to a control center by the control button (3) for emergency, for example, by pressing the control button for multiple times consecutively. For some applications, such as the railway industry, light beams shining to the side of the light head are needed. To meet this need, the illumination device provides such side beams. To improve the light path efficiency, the illumination device relies on the reflective back surface of the reflector to collect and reflect the light beams of the side beam light sources (e.g., LEDs) towards the sides of the light head. This feature increases the final output side beam brightness by over double that of the conventionally designed illumination devices which do not rely on the reflector back side to collect and reflect the light beams of the side beam LEDs. In accordance with another aspect of the present disclosure, the printed circuit board10, inFIG.5, is placed inside the main head on a side of the board's surface that is exposed to ambient air, giving it a heat dissipating effect, which allows the heat generating components on the circuit board to operate at a low temperature and thereby have a high working efficiency and long lifetime. In the control circuit on the printed circuit board, some embodiments of the present disclosure provide a microprocessor with sophisticated firmware embedded therein. The firmware uses multiple measurement parameters to monitor and display the battery's charging and discharging current, and calculate and display the charge time and usage time respectively (in addition to the conventional battery remaining energy display). In some embodiments of the present disclosure, the illumination device may be referred to as a flashlight, a torch, a lantern, etc. In accordance with an embodiment, the illuminating device has a rotational light source in the light head chamber head. In accordance with at least one embodiment, the light head chamber (2) includes fish scale shaped vents on its walls to allow ambient air to ventilate the air inside the chamber housing and to cool down the large metal reflector which serves both as the light beam forming reflector and the heat sink for the light emitting component, LED. The ambient air coming in through the vents will also cool down the bottom side of the PCB having the controller components located on the other side to improve the controller's power efficiency and prolong its lifetime. In accordance with at least one embodiment, the control switch for the lights is mounted on the top side of the handle, just a little distance in front of the hand-holding place. It can be conveniently pressed by the thumb finger of the holding hand. Thus, the device can be operated by one hand. Optionally, the device can by turned on or off by sound or voice. In accordance with at least one embodiment, there is a connection port provided for charging the battery cells and updating the firmware embedded inside the controller circuitry. By way of example, the connection port may include a USB C, USB, mini USB, micro USB, or DC jack connector. In accordance with at least one embodiment, there is a buzzer device, which gives audio signals to provide operating or warning signals to the user. The buzzer can also be used as alarm(s). By way of example, the audio alarms can include SOS signal(s) after pressing the control button for a longer period of time, such as 5 seconds. At the same time, the lights of the digital display (16) and/or indicator(s) (18), (19), (21), and (24) will flash SOS pattern(s). The bottom portion of the handle has three foldable feet, which allow the device to stand alone upwards. To ensure a firm grip, the handle surface is texturized to increase friction and reduce slippage. In accordance with at least one embodiment, there is a hook (41) located at the middle point of the C-shaped handle, as shown inFIG.17. It allows the illumination device to be easily hung for example on a rope, a tree branch, a nail, another hook, or ring, on a wall, etc., while the illumination device is in use, storage, or being charged. By way of example, the hook (41) may be a foldable hook, shown inFIG.17it is at its open position and inFIG.18it is at its closed position. on the hook is at the center position of the handle, it allows hanging the illumination device downward thus it can be used like a lantern. The electronic circuit block diagram for the electronics of the illumination device is shown inFIG.13. As shown inFIG.13, there are 2 DC-DC converters,33and34in the figure, one is for charging the battery cell bank (30), the other is for changing battery's constant voltage into controllable constant currents for driving the light sources (e.g., LEDs)31and32. The current sensors37and38are for sensing the charging and discharge currents of the battery bank respectively. The PWM (Pulse Width Modulation) signal and the low pass filter, C1, C1, R3 and R4 generates a controllable DC signal for setting the output voltage of the 2nd DC-DC converter (34). The final output currents for each of the LEDs is set by S1 and S2 respectively. The two signals can be of constant on and off type, and/or of PWM type to reduce and regulate the average output currents send to the light source LEDs. Except for the battery cell bank30and control switch36shown inFIG.13, the remaining electronic components can be located on the light head or curved handle. FIG.17andFIG.18show the handle's central position has a foldable hook (41) which is at its open position and close position respectively. FIG.19shows a detachable handle being separated from the head chamber. This feature allows quick refueling the illuminating device with a pre fully charged battery bank of another handle, as opposed to wait for hours to recharge battery bank in the handle fixed with the device. It is also useful to reduce the total size of the illumination for easier shipping and storage. FIG.20shows a section view of the light head chamber where the vents (10) allow for ambient cool fresh air flow (40) to pass into the light chamber to cool down the reflector and the PCB. FIG.21shows a gang of illumination devices being hung and charged simultaneously, each by its own charger. This feature saves table surface space and allows the illumination devices be charged and/or stored in a well organized way. In the present disclosure, it is to be understood that the terms “lower,” “upper,” “center,” “longitudinal,” “transverse,” “length,” “width,” “thickness,” “upper,” “lower,” “front,” “back,” “left,” “right,” “vertical,” “horizontal,” “top,” “bottom,” “inside,” “outside,” “clockwise,” “counterclockwise,” “axial,” “radial,” “circumferential,” “column,” “row,” and other orientation or positional relationships are based on example orientations illustrated in the drawings, and are merely for the convenience of the description of some embodiments, rather than indicating or implying the device or component being constructed and operated in a particular orientation. Therefore, these terms are not to be construed as limiting the scope of the present disclosure. Moreover, the terms “first” and “second” are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, elements referred to as “first” and “second” may include one or more of the features either explicitly or implicitly. In the description of the present disclosure, “a plurality” indicates two or more unless specifically defined otherwise. In the present disclosure, the terms “installed,” “connected,” “coupled,” “fixed” and the like shall be understood broadly, and may be either a fixed connection or a detachable connection, or integrated, unless otherwise explicitly defined. These terms can refer to mechanical or electrical connections, or both. Such connections can be direct connections or indirect connections through an intermediate medium. These terms can also refer to the internal connections or the interactions between elements. The specific meanings of the above terms in the present disclosure can be understood by those of ordinary skill in the art on a case-by-case basis. In the present disclosure, a first element being “on,” “over,” or “below” a second element may indicate direct contact between the first and second elements, without contact, or indirect through an intermediate medium, unless otherwise explicitly stated and defined. Moreover, a first element being “above,” “over,” or “at an upper surface of” a second element may indicate that the first element is directly above the second element, or merely that the first element is at a level higher than the second element. The first element “below,” “underneath,” or “at a lower surface of” the second element may indicate that the first element is directly below the second element, or merely that the first element is at a level lower than the second feature. The first and second elements may or may not be in contact with each other. In the description of the present disclosure, the terms “one embodiment,” “some embodiments,” “example,” “specific example,” or “some examples,” and the like may indicate a specific feature described in connection with the embodiment or example, a structure, a material or feature included in at least one embodiment or example. In the present disclosure, the schematic representation of the above terms is not necessarily directed to the same embodiment or example. Moreover, the particular features, structures, materials, or characteristics described may be combined in a suitable manner in any one or more embodiments or examples. In addition, various embodiments or examples described in the specification, as well as features of various embodiments or examples, may be combined and reorganized. While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any claims, but rather as descriptions of features specific to particular implementations. Certain features that are described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination. Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described program components and systems can generally be integrated together in a single software/firmware product or packaged into multiple software/firmware products. Thus, particular implementations of the subject matter have been described. Other implementations are within the scope of the following claims. In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results. In certain implementations, multitasking or parallel processing may be utilized. It is intended that the specification and embodiments be considered as examples only. Other embodiments of the disclosure will be apparent to those skilled in the art in view of the specification and drawings of the present disclosure. That is, although specific embodiments have been described above in detail, the description is merely for purposes of illustration. It should be appreciated, therefore, that many aspects described above are not intended as required or essential elements unless explicitly stated otherwise. Various modifications of, and equivalent acts corresponding to, the disclosed aspects of the example embodiments, in addition to those described above, can be made by a person of ordinary skill in the art, having the benefit of the present disclosure, without departing from the spirit and scope of the disclosure defined in the following claims, the scope of which is to be accorded the broadest interpretation so as to encompass such modifications and equivalent structures. | 30,384 |
11859782 | Reference signs:1light guide column;2knob;3knob sealing ring;4controller power board;5upper housing;6color adjustment switch;7connector;8tail plug joint;9threaded connection seat;10screw sealing ring;11high voltage control box sealing ring;12bottom plate;13screw;14plug;15timing switch;16lampshade;17lighting module;18power board module;19connecting shell;20lamp cap;21conducting cap;22first power supply module;23switch control circuit;24overload protection module;25control module;251first microcontrol unit;252storage chip;253power indicator light;26second power supply module;27carrier signal detecting module;28lighting execution module;281second microcontrol unit. DETAILED DESCRIPTION OF THE INVENTION The present invention is further described below in detail in combination with the drawings and embodiments. As shown inFIG.1, an AC two-wire LED high voltage lamp string with synchronous dimming and color adjustment comprises a high voltage controller and a lamp string group. The high voltage controller comprises a control box. As shown inFIGS.3,5,6,7and8, a first power supply module22, a switch control circuit23, an overload protection module24and a control module25are arranged in the control box; the control module25comprises a first microcontrol unit251, a storage chip252, a mode adjustment switch and a power indicator light253; and the mode adjustment switch comprises a color adjustment switch6and a timing switch15. In the present embodiment, the first microcontrol unit251can be the existing AS3010 chip, etc. The first power supply module22is provided with a first AC input end for external connection, and the first AC input end comprises a live line end and a neutral line end. The first power supply module22, the switch control circuit23and the first microcontrol unit251are connected in sequence; and the first microcontrol unit251is respectively connected with the color adjustment switch6and the timing switch15. After the color adjustment switch6or the timing switch15is pulled, the switch signal is transmitted to the first microcontrol unit251. The switch control circuit23is used for waveform modulation encoding of AC sine waves inputted by the first power supply module22under the control of the first microcontrol unit251. The high voltage controller is also provided with an AC output end; the AC output end comprises a first AC output end connected with the first power supply module22and a second AC output end connected with the switch control circuit23. The first microcontrol unit251is respectively connected with the first power supply module22, the storage chip252and the power indicator light253. The first microcontrol unit251is also used for zero-crossing detection of AC of the first power supply module22. The storage chip252is used to store operating state data and realize power off memory. The overload protection module24is respectively connected with the first power supply module22, the switch control circuit23and the first microcontrol unit251. A silicon controlled rectifier is arranged in the switch control circuit23. When the first power supply module22and the switch control circuit23are overloaded, the overload protection module24transmits a voltage signal for the first microcontrol unit251. After receiving the overload voltage signal, the first microcontrol unit251controls the switch control circuit23to close the silicon controlled rectifier, thereby cutting off the circuit. As shown inFIG.1, the control box comprises an upper housing5and a bottom plate12; the upper housing5is provided with a containing cavity; the upper housing5is covered on the bottom plate12; a high voltage control box sealing ring11is arranged between the upper housing5and the bottom plate12; the bottom plate12is provided with a threaded connection seat9; the upper housing5is connected with the bottom plate12through a screw13; a screw sealing ring10is arranged between the screw13and the bottom plate12; the bottom plate is provided with a controller power board4; and the first power supply module22, the switch control circuit23, the first microcontrol unit251, the overload protection module24, the color adjustment switch6, the timing switch15, the storage chip252and the power indicator light253are arranged on the controller power board4. The color adjustment switch6is a button switch, and the timing switch15is a knob switch. A knob2is arranged outside the upper housing5, and the knob2is connected with the timing switch15. A through hole through which the color adjustment switch6passes is arranged outside the upper housing5; the color adjustment switch6extends out from the upper housing5; the upper housing5is provided with a light guide column1; and the light guide column1is connected with the power indicator light253. The control box is provided with a connecting hole, and the first AC input end and the AC output end are respectively connected with the outside through the connecting hole; the AC output end is connected with a connector7, and the connector7is a waterproof connector; and the connector7is detachably connected with the LED lamp string group. The LED lamp string group comprises LED lamps which are connected mutually; the end of the LED lamp string group is provided with a tail plug joint8connected with the connector7; and the tail plug joint8is inserted into the connector7to realize electrical connection between the LED lamp string group and the controller. As shown inFIGS.9,10and11, a second power supply module26, a carrier signal detecting module27and a lighting execution module28are arranged in the LED lamps; and the lighting execution module28comprises a second microcontrol unit281and a lighting module17. The second power supply module26is provided with a second AC input end electrically connected with the AC output end, and the second power supply module26is used for supplying power for the second microcontrol unit281and the lighting module17. The second power supply module26is connected with the carrier signal detecting module27, the second microcontrol unit281and the lighting module17in sequence; the carrier signal detecting module27is used for detecting a carrier signal received by the second AC input end and transmitting a carrier code value to the second microcontrol unit281; and after receiving the carrier code value, the second microcontrol unit281executes a corresponding lighting instruction so that the lighting module17enters a lighting mode which is set by the code value. In the lighting mode, the carrier signal detecting module27detects the weekly zero crossing signal of the AC sine wave and sends the signal to the second microcontrol unit as a flashing frequency reference to ensure that a plurality of bulbs flash synchronously. The second microcontrol unit281is also connected with a photodiode for realizing light control. As shown inFIG.2, the LED lamp comprises a conducting cap21, a lamp cap20, a connecting shell19and a lampshade16which are connected in sequence through threads; a power board module18and a lighting module17are arranged in the connecting shell19; the power board module18comprises a power board, and a second power supply module26, a carrier signal detecting module27and a second microcontrol unit281which are arranged on the power board; a slot is arranged in the connecting shell19; and the power board is inserted into the slot. The lighting module17comprises an LED board and an LED lamp bead arranged on the LED board; the LED board is fixedly connected with the power board; and the LED lamp bead is electrically connected with the second microcontrol unit281. The conducting cap21is inserted into the lamp cap20from the upper part of the lamp cap20and is electrically connected with the second power supply module26; the upper part of the conducting cap21is connected with a conducting wire; the LED lamps are mutually connected through the conducting wire to form the lamp string group; and the end of the lamp string group is provided with a tail plug joint8. During use, a plurality of LED lamps are connected in series or in parallel to form the lamp string group; and the lamp string group is inserted into the high voltage controller through the tail plug joint8. In the present embodiment, the high voltage controller is connected with a lamp string group formed by connecting10lamp strings in parallel, wherein each lamp string comprises 12 0.25 W LED lamps and each LED lamp can emit white, red, green and blue light. The AC input end of the high voltage controller is connected with an external power supply through a plug14. The color adjustment switch6arranged on the high voltage controller has the functions of short pressing and long pressing. After long pressing, four colors of white, red, green and blue in the LED lamp string group can synchronously flash circularly, and after short pressing, fixed-color normal lighting, waterfall lamp and horse race lamp modes can be selected. When restarting after power cut, the LED lamp string group has a power cut memory function. The timing switch15arranged on the high voltage controller is a knob switch which comprises 8 options of OFF, ON, 2H, 4H, 6H, 8H, auto and straightway. When the knob switch is turned to “OFF”, the LED lamp string group is turned off under the control of the high voltage controller. When the knob switch is turned to “ON”, the LED lamp string group is normally lighted. When the knob switch is turned to “2H”, the LED lamp string group has a light control function and is turned off after lighting for 2H every evening; and during the countdown process, the color adjustment switch6does not affect timing. When the knob switch is turned to “4H”, the LED lamp string group has the light control function and is turned off after lighting for 4H every evening; and during the countdown process, the color adjustment switch6does not affect timing. When the knob switch is turned to “6H”, the LED lamp string group has a light control function and is turned off after lighting for 6H every evening; and during the countdown process, the color adjustment switch6does not affect timing. When the knob switch is turned to “8H”, the LED lamp string group has a light control function and is turned off after lighting for 8H every evening; and during the countdown process, the color adjustment switch6does not affect timing. When the knob switch is turned to “auto”, the LED lamp string group has the light control function only without countdown; and when the LED lamp string group is restarted, the LED lamps have a color memory function. When the knob switch is turned to “straightway”, if a plurality of lamp strings are connected for use, each lamp string is only controlled by the high voltage controller. When the LED lamps are short-circuited or the LED lamp string causes current overload due to too many LED lamps connected in parallel, the overload protection module24transmits a voltage signal for the first microcontrol unit251. After receiving the overload voltage signal, the first microcontrol unit251controls the switch control circuit23to close the silicon controlled rectifier and lock the circuit. The high voltage controller needs to be restarted to turn on the LED lamp string group. The power indicator light253has two colors, i.e., red light and green light. When the LED lamp string group and the controller are in a normal state, the power indicator light253shows green. When the LED lamp string group and the controller are in an overcurrent protection state, the power indicator light253shows red. Finally, it should be noted that the above embodiments are only used for describing the technical solutions of the present invention rather than limitation. Although the present invention is described in detail by referring to the above embodiments, those ordinary skilled in the art should understand that the technical solution recorded in each of the above embodiments can be still amended, or some technical features therein can be replaced equivalently. However, these amendments or replacements do not enable the essence of the corresponding technical solutions to depart from the spirit and the scope of the technical solutions of various embodiments of the present invention. | 12,284 |
11859783 | DETAILED DESCRIPTION Although certain embodiments and examples are disclosed below, inventive subject matter extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses, and to modifications and equivalents thereof. Thus, the scope of the claims appended hereto is not limited by any of the particular embodiments described below. For example, in any method or process disclosed herein, the acts or operations of the method or process may be performed in any suitable sequence and are not necessarily limited to any particular disclosed sequence. Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding certain embodiments; however, the order of description should not be construed to imply that these operations are order dependent. Additionally, the structures, systems, and/or devices described herein may be embodied as integrated components or as separate components. For purposes of comparing various embodiments, certain aspects and advantages of these embodiments are described. Not necessarily all such aspects or advantages are achieved by any particular embodiment. Thus, for example, various embodiments may be carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other aspects or advantages as may also be taught or suggested herein. REFERENCE NUMERALS 10— convertible light device12— housing14—battery pack16— elongate flexible light source18— plurality of LEDs20— rope mode22— lantern mode24—exterior (of housing)26— first end (of elongate flexible light source)28— second end (of elongate flexible light source)30— magnetic end cap32— attaching mechanism34— plurality of lithium-ion batteries36—hole (in magnetic end cap)38— storage compartment40— lid42— locking knob44— handle46—battery indication button48— top portion (of housing)50— base portion (of housing)52— middle portion (of housing)54— at least one charging port56—power boost button58— brightness knob60— at least one battery level indication light62— first width64— second width66—flashlight button68— flashlight70— frosted material72— wrapping guide rail74— elongate flexible light source port76—elongate flexible light source connector78— magnet80— metal plate100— convertible light device102— device housing104—battery pack106— elongate flexible light source108— handle110— battery pack housing112— interior portion (of device housing)114— charging port116—flashlight118— activation mechanism120— connector122a— first plurality of magnets122b— second plurality of magnets124—attaching mechanism126— control panel128— plurality of mode buttons130a— first input button130b— second input button132—mobile device134— plurality of mode buttons200— convertible light device202— device housing204— battery pack206—elongate flexible light source210— battery pack housing212— interior portion (of device housing)300— convertible lighting system FIG.1Aillustrates the convertible light device10in a rope mode20andFIG.1Billustrates the convertible light device10in a lantern mode22. In some embodiments, the convertible light device10includes an elongate flexible light source16that is configured to coil around the housing of the convertible light device10. In the rope mode20, the elongate flexible light source16may be configured to uncoil from the housing and extend from the housing to an external anchor point, as shown inFIG.1A. Examples of external anchor points include, but are not limited to, a tree, a tent, a vehicle, a fence, a building, a boom on a boat, and the like. Accordingly, the convertible light device10may be particularly useful, in both the rope mode20and lantern mode22, in a variety of circumstances, including: camping (e.g., inside a tent and/or to provide light to larger campsite area for cooking/food prep, playing games, reading, socializing, etc.), boating (e.g., yachting, cabin of a sailboat, etc.), RV use/“glamping” (e.g., use inside or outside vehicle, similar to camping), road trips, picnics, trade shows, backyards, and photography (e.g., indoor studio or off-site photoshoot). In addition, the convertible light device10may provide significant safety benefits, for example to illuminate a bicycle/bicyclist, pedicab/pedicab driver, and emergency lighting for individual users/families during a power outage, in addition to law enforcement and/or search and rescue for nighttime operations. It should be noted that the recited uses are included as examples and intended to be non-limiting. In the lantern mode22, the elongate flexible light source16may be configured to coil around the housing12of the light device10such that the light device10emits light from a concentrated area, as illustrated byFIG.1B. In many embodiments, the elongate flexible light source16comprises a plurality of light sources, such as a plurality of LEDs18(shown inFIG.9), that extend substantially the entire length of the elongate flexible light source16. The elongate flexible light source16may be detachably coupled to the housing12and electrically coupled to a battery pack14, which will be discussed in greater detail with reference toFIG.9. More details of the elongate flexible light source16will be discussed later in the disclosure. FIG.2shows a front perspective view of the convertible light device10. As illustrated, in some embodiments, the light device10includes a housing12, an elongate flexible light source16, a handle44, and an attaching mechanism32. The first end26of the elongate flexible light source16may be coupled to a magnetic end cap30, as illustrated inFIG.2. In many embodiments, the magnetic end cap30includes a hole36(shown inFIG.4) configured to receive the attaching mechanism32. The attaching mechanism32may thereby be configured to couple the first end26of the elongate flexible light source16to an external anchor when the convertible light device10is in the rope mode20. When the convertible light device10is in the lantern mode22, a magnet78of the magnetic end cap30may be configured to couple to a metal plate80located on the housing12, as indicated inFIG.3, thereby coupling the elongate flexible light source16to the housing12. FIG.2also includes a brightness knob58coupled to the housing12. The brightness knob58may be located adjacent an end of the housing12opposite the handle44, as shown inFIG.2. In many embodiments, the brightness knob58is configured to control a brightness of the light emitted by the plurality of LEDs18of the elongate flexible light source16. The brightness knob58may comprise a knob, switch, button (i.e., digital control), slider, or the like. In some embodiments, the brightness knob58serves as a power on/off feature, where turning the brightness knob58to at least a minimum level comprises turning on the convertible light device10. The brightness knob58may include any number of brightness settings, ranging from very dim light emission to full light emission. In some embodiments, the brightness knob58is configured to provide finely-tuned control over a large range of brightness levels, such that a user is able to adjust the brightness to a precise level. The brightness knob58may comprise a number of pre-set levels rather than precise control. In some embodiments, the brightness knob58is configured to facilitate a “ramp up” sequence of illuminating the elongate flexible light source16, such that a portion of the elongate flexible light source16turns on prior to another portion of the elongate flexible light source16. FIG.3shows a perspective view of a top portion48of the housing12. As previously mentioned, the convertible light device10may include a metal plate80located on the housing12and a magnet78located on the magnetic end cap30of the elongate flexible light source16, wherein the magnet78is configured to couple to the metal plate80, thereby coupling the elongate flexible light source16to the housing12in the lantern mode22. The housing12may include a plurality of metal plates80. In some embodiments, the housing12comprises a metal material configured to couple to the magnetic end cap30. The magnetic end cap30may comprise a non-magnetic end cap, and may be configured to couple to the housing12via a friction fit, hook-and-loop fastener, or any other suitable means. Also illustrated inFIG.3are the handle44, lid40, and attaching mechanism32. In many embodiments, the lid40is configured to receive the attaching mechanism32when the convertible light device10is in lantern mode22and the attaching mechanism32is not coupled to the magnetic end cap30. The removable coupling between the attaching mechanism32and the lid40will be discussed further with reference toFIGS.10A and10B. In many embodiments, the handle44is configured to rotate about 180 degrees. Stated another way, the handle44may be configured to pivot or “flip” such that it is able to rest on top of either side of the lid40. The handle44may be configured to “lock” or remain in an upright position. In some embodiments, the handle44is comprised of a rigid, inflexible material, such as metal or hard plastic. The handle44may be comprised of a soft, flexible material, such as rubber, leather, or another fabric. In some embodiments, the handle44is removably coupled to the convertible light device10such that a user may “switch out” different types of handle44, depending on desired utility or aesthetic. In some embodiments, the handle44is configured to open in a manner similar to a carabiner to enable the handle44to hook onto an external anchor so that the housing12of the convertible light device10can be suspended, such as from a tree, as illustrated inFIG.1A. The handle44may also be configured to at least partially detach from the housing12to facilitate coupling the light device10to an external anchor. In some embodiments, the handle44is not configured to open or partially detach, and instead the external anchor is threaded through the opening between the handle44and the housing12. The handle44may comprise any suitable type of clip, clasp, tie, hook, loop, magnet, and the like. FIG.4shows an enlarged view of the attaching mechanism32coupled to the first end26of the elongate flexible light source16via the hole36in the magnetic end cap30. As previously discussed, in many embodiments, the attaching mechanism32is configured to detachably couple to the magnetic end cap30and, when not coupled to the magnetic end cap30, the attaching mechanism32is configured to couple to the lid40. Though illustrated as a carabiner-style mechanism, similar to the handle44, the attaching mechanism32may comprise any suitable type of attaching mechanism, including, but not limited to, other types of clips, clasps, ties, hooks, loops, magnets, and the like. In addition, the attaching mechanism32may comprise any suitable shape, including, but not limited to, rectangle, circle, triangle, oval, teardrop, diamond, trapezoid, and heart. In some embodiments, the attaching mechanism32defines a substantially similar shape as the lid40. The attaching mechanism32may also define a size suitable to couple to the lid40. Rather than a magnetic end cap30, the first end26of the elongate flexible light source16may comprise a clip or other type of mechanical connector similar to the attaching mechanism32. In some embodiments, the first end26is fixedly coupled to a mechanical connector similar to the attaching mechanism32. The first end26may comprise an electrical connector configured to couple to a second elongate flexible light source16. Accordingly, in some embodiments, the convertible light device10comprises a plurality of elongate flexible light sources16. Using a plurality of elongate flexible light sources16may allow a user to illuminate a larger area without requiring more than one housing12and battery pack14. In some embodiments, the electrical connection between multiple elongate flexible light sources16allows a single brightness knob58to control the brightness of multiple elongate flexible light sources16, either independently or as a group. FIG.5illustrates a perspective view of a base portion50of the housing12. It should be noted that the base portion50shown inFIG.5may be considered a “back” side of the housing12, while the side of the housing12shown inFIG.2featuring the brightness knob58may be considered a “front” side. Of course, each user of the convertible light device10may consider any side “front” or “back” without any impact on the operation of the device10. As shown inFIG.5, in some embodiments, the elongate flexible light source16comprises a second end28configured to detachably couple adjacent the base portion50of the housing12. The second end28may comprise an elongate flexible light source connector76, while the housing12may comprise an elongate flexible light source port74configured to receive the elongate flexible light source connector76. In many embodiments, the elongate flexible light source connector76is configured to mechanically couple to the housing12and electrically couple to the battery pack14, thus providing power to the elongate flexible light source16. At least one of the elongate flexible light source port74and the elongate flexible light source connector76may be magnetic. In some embodiments, the elongate flexible light source connector76is configured to couple to the elongate flexible light source port74via a friction fit, similar to a typical electrical connection (e.g., charging cable and an electronic device, plug and an electrical socket, etc.). Alternatively, the second end28of the elongate flexible light source16may be configured to fixedly couple to the housing12, and the convertible light device10may not include the elongate flexible light source connector76or the elongate flexible light source port74as shown inFIG.5. In some embodiments, the elongate flexible light source16is configured to illuminate even when detached from the elongate flexible light source port74of the housing12. Accordingly, the elongate flexible light source16may be able to “hold” or maintain a charge and emit light even when disconnected from the battery pack14within the convertible light device10. When detached, a user may be able to use the elongate flexible light source16in additional ways, such as wearing the elongate flexible light source16, wrapping it around a bicycle or scooter, wrapping it around a pet (e.g., as a harness for a dog when walking at night or early in the morning), and/or any number of other ways. In addition, the ability to detach the elongate flexible light source16from the housing12may increase the portability of the convertible light device10. For example, a user may desire to use the flashlight68(shown inFIG.6) located on the base portion50of the housing12to walk a distance away from the current location of the device10. If the device10were in the rope mode20, it would be a hassle to wind up the elongate flexible light source16prior to walking away with the device10. Instead, the user may detach the elongate flexible light source16at the second end28and simply leave the elongate flexible light source16behind as the user walks away with the device10and uses the flashlight68, such as to walk to a restroom, into a tent, etc. As such, the convertible light device10may be configured to provide light to two different locations simultaneously, as the elongate flexible light source16may continue emitting light while the user moves away with the flashlight68of the housing12. At least some portion of the second end28may not include the plurality of LEDs that make up the elongate flexible light source16. As such, the second end28may comprise some distance of the elongate flexible light source16that comprises a plain cable without any LEDs. In some embodiments, the distance is a few inches. Referring now toFIG.6, another perspective view of the convertible light device10is illustrated, including a flashlight68located on the base portion50of the housing12. The flashlight68will be discussed in greater detail later in the disclosure, in particular with reference toFIG.11. Similar toFIG.5,FIG.6may be considered to show a “back” side of the housing12, opposite the “front” side including the brightness knob58. As shown inFIG.6, in some embodiments, the base portion50of the housing12includes a plurality of buttons located below the second end28of the elongate flexible light source16. In addition to the plurality of buttons, the base portion50may include at least one charging port54and at least one battery level indication light60. It should be noted that at least some of these components may be included on the top portion48of the housing12, along with the handle44. In many embodiments, the at least one charging port54is configured to enable charging of at least one of the battery pack14(shown inFIG.9) and at least one external device, such as a mobile phone, tablet, laptop, speaker, or the like. The at least one charging port54may be configured to provide “quick charging” to at least one of the battery pack14and the external device. In some embodiments, the at least one charging port54is configured to charge the battery pack14and/or at least one external device while the convertible light device10is in use (i.e., while at least one of the flashlight68and elongate flexible light source16are illuminated). Details of the battery pack, including the rechargeable nature of the batteries, will be discussed with reference toFIG.9. The at least one charging port54may comprise a USB port, a USB-C port, a barrel-plug, or any other suitable connection type. It should be noted that each port of the at least one charging port54may comprise the same type of port connection, or may comprise different types of port connections. In some embodiments, one port is an input port, and one port is an output port. The at least one charging port54may comprise a single input/output port. The light device10may also be configured to charge wirelessly via a charging dock, rather than a charging port. Among the plurality of buttons shown inFIG.6are a power boost button56and a flashlight button66. In many embodiments, the flashlight button66is operatively coupled to the flashlight68located on the bottom of the housing12, and is configured to power on/off the flashlight68. It should be noted that any and/or all of the plurality of buttons (battery indication button46, power boost button56, flashlight button66) may comprise dials or other selection mechanisms, rather than buttons. In addition, the plurality of buttons, the at least one charging port54, and the at least one battery level indication light60may be arranged in a different layout than shown in the Figures. In many embodiments, the power boost button56is configured to amplify a light output of the plurality of LEDs18of the elongate flexible light source16. Stated another way, the power boost button56may serve as a way to increase the light output of the elongate flexible light source16without using the brightness knob58. In some embodiments, the power boost button56is configured to enable a maximum emission of light to a level beyond what can be reached with the brightness knob58. Rather than a power boost button56, the brightness knob58may be configured to turn past a certain point (i.e., the highest “normal” level) to reach the same level of light emission achieved by the power boost button56. The power boost button56may be configured to enable an increased level of light emission for an extended period of time. In some embodiments, the power boost button56is configured to enable an increased level of light emission for a shorter period of time (e.g., 5 minutes, 2 minutes, 90 seconds, 60 seconds, 30 seconds, 10 seconds, etc.) in order to preserve battery life. The power boost button56may be operatively coupled to at least one of the elongate flexible light source16and the flashlight68. FIG.6also indicates that, in some embodiments, the convertible light device10includes a battery indication button46and at least one battery level indication light60coupled to at least one of the housing12and the battery pack14. The battery indication button46and at least one battery level indication light60may be located on a top portion48, base portion50(as shown), or anywhere else on the housing12, either in the same or different locations. In many embodiments, when pressed, the battery indication button46is configured to illuminate the at least one battery level indication light60according to a power level of the battery pack14. For example, as shown inFIG.7A, a full charge of the battery pack14may be configured to illuminate all of the lights of the at least one battery level indication light60. As indicated inFIG.7B, a low charge of the battery pack14may be configured to illuminate fewer of the at least one battery level indication light60, for example, two lights. In some embodiments, as shown inFIGS.7A and7B, the at least one battery level indication light60comprises five lights. Each light may represent 20% of battery life, such thatFIG.7Aindicates 100% battery life andFIG.7Bindicates 40% battery life. Of course, the at least one battery level indication light60may comprise any number of lights. In some embodiments, while the convertible light device10is charging, the at least one battery level indication light60is configured to illuminate to indicate progress of the charging cycle. The at least one battery level indication light60may illuminate continuously or non-continuously (i.e., “blinking”). In many embodiments, the at least one battery level indication light60comprises LED light(s). The at least one battery level indication light60may comprise another type of light. Rather than at least one battery level indication light60, the convertible light device10may be configured to indicate battery life another way(s). For example, the elongate flexible light source16may be configured to illuminate in a distinct color and/or pattern to indicate battery level. In addition, a user may be able to see battery life on a mobile application communicatively coupled to the convertible light device10. FIG.8shows the convertible light device10, including the top portion48, middle portion52, and base portion50of the housing12. As previously discussed, in many embodiments the top portion48includes the handle44and the base portion50includes the brightness knob58, at least one charging port54, flashlight button66, power boost button56, battery indication button46, and at least one battery level indication light60, as shown inFIGS.2and6.FIG.8also illustrates the middle portion52, which, in many embodiments, is where the elongate flexible light source16winds around the housing12. It should be noted thatFIG.8is shown without much of the elongate flexible light source in order to better illustrate the features of the housing12, particularly the middle portion52. FIG.8demonstrates that, in some embodiments, the exterior24of the middle portion52of the housing12comprises a wrapping guide rail72. The wrapping guide rail72may be configured to receive the elongate flexible light source16, and may enable winding of the elongate flexible light source16in an even and orderly manner. In some embodiments, winding the elongate flexible light source16in an even manner facilitates substantially even distribution of the plurality of LEDs18when the convertible light device10is in the lantern mode22. The wrapping guide rail72may be configured to receive at least a single layer of the elongate flexible light source16, such that in the lantern mode22there may be at least a single layer of the elongate flexible light source16wrapped around the exterior24of the housing12. In some embodiments, the wrapping guide rail72is configured to receive multiple layers of the elongate flexible light source16. Some embodiments of the convertible light device10do not include the wrapping guide rail72, and instead include a smooth, even surface extending the length of the middle portion52of the housing12. The convertible light device10may include the ability to automatically wind the elongate flexible light source16around the housing12, either with or without the wrapping guide rail72. For example, in some embodiments, the light device10includes a winding mechanism configured to facilitate winding of the elongate flexible light source16around the exterior24of the housing12. The winding mechanism may be operated mechanically or electrically, and may include any type of winding mechanism (e.g., crank, gear, and the like). The winding mechanism may be detachably or fixedly coupled anywhere on the light device10. FIG.8also illustrates the first width62of the base portion50and the second width64of the middle portion52. It should be noted that, in many embodiments, the first width62also represents the width of the top portion48. As shown inFIG.8, the first width62may be larger than the second width64. In some embodiments, the first width62is smaller than the second width64. The first width62and second width64may also define substantially the same width. In many embodiments, when the elongate flexible light source16is wrapped around the middle portion52, the width of the middle portion52is still less than the first width62of the base portion50. When the elongate flexible light source16is wrapped around the middle portion52, the width of the middle portion52may be substantially equal to the first width62of the base portion50. FIG.9shows a cross-section view of the convertible light device10. The cross-section includes the interior of the housing12, which, in many embodiments, is configured to receive the battery pack14. The housing12may be configured to slideably receive the battery pack14, such that the battery pack14is at least partially held within the housing12. The housing12may be configured to receive the battery pack14in any other suitable manner. In some embodiments, the battery pack14is fixedly coupled to the housing12, and comprises a permanent battery pack14. The battery pack14may be removably coupled to the housing12. In many embodiments, as illustrated inFIG.9, the battery pack14defines a height less than a height of the housing12, such that there is space within the housing12above the battery pack14. This space may define a storage compartment38, as will be discussed further with reference toFIGS.10A and10B. The battery pack14may define a height and/or width greater or smaller than illustrated inFIG.9. In some embodiments, the battery pack14comprises a plurality of lithium-ion batteries34. The plurality of lithium-ion batteries34may comprise six lithium-ion batteries. The plurality of lithium-ion batteries34may comprise any other number of batteries. In some embodiments, the battery pack14comprises a different type of battery than lithium-ion battery. The batteries in the battery pack14may comprise rechargeable batteries. The batteries in the battery pack14may comprise any suitable type of rechargeable batteries. As previously discussed, in many embodiments, the battery pack14is configured to charge via the at least one charging port54. The battery pack14may be configured to charge via a solar panel, kinetic energy (e.g., a hand crank), or any number of other suitable methods. In some embodiments, the batteries are configured to illuminate the elongate flexible light source16for a first amount of time on a full charge and at full brightness. The elongate flexible light source16may remain illuminated for longer than the first amount of time at a lower brightness level. The first amount of time may be a few hours. In some embodiments, the battery pack14comprises a plurality of battery packs. The battery pack14may also include a battery control board. FIG.9also illustrates the plurality of LEDs18that make up the elongate flexible light source16. The elongate flexible light source16may be thought of as a “rope light,” and the plurality of LEDs18may be visible from either side of the “rope” (the elongate flexible light source16). The plurality of LEDs18may be visible from only one side of the “rope.” In some embodiments, the elongate flexible light source16comprises a frosted material70configured to diffuse the light emitted by the plurality of LEDs18. The convertible light device10may include a sheath configured to fit over (e.g., similar to a sleeve) the elongate flexible light source16, wherein the sheath may comprise a frosted material70to diffuse light. In some embodiments, the sheath comprises a hard cover configured to slideably receive the elongate flexible light source16. The sheath may protect the elongate flexible light source16while also diffusing light emitted by the plurality of LEDs18. In some embodiments, the plurality of LEDs18extends substantially the entire length of the elongate flexible light source16. The plurality of LEDs18may extend less than substantially the entire length of the elongate flexible light source16. In some embodiments, the plurality of LEDs18comprises a light source other than LEDs. The plurality of LEDs18may comprise LEDs of different colors/configured to emit different colors (i.e., RGB LEDs). The convertible light device10may be configured to operate in different “modes,” where each mode illuminates the plurality of LEDs in a different pattern, color, brightness, etc. For example, a “party mode” may include flashing/strobing the LEDs while a “normal mode” includes steady, even illumination of the LEDs. The brightness knob58may be configured to control and select the different modes of the elongate flexible light source16. In some embodiments, the light device10includes at least one of Wi-Fi, Bluetooth, and cellular connectivity. This connectivity may be integrated into the different modes of the light device10; for example, “party mode” may sync with music playing from a device connected (wirelessly or wired) to the light device such that the LEDs18flash on beat with the music. As previously mentioned, the convertible light device10may be communicatively coupled to a mobile application on a computing device, such as a smartphone or tablet. The mobile application may enable a user to program different “modes” and control the mode selection. FIG.9also shows that, in some embodiments, the convertible light device10defines a shape that is generally rectangular. A generally rectangular shape may prevent the light device10from rolling when placed on its side, such as on a table or ground surface. Instead, the convertible light device10may define a shape that is generally circular. The convertible light device10may define a shape that is generally triangular, generally ovoid, or any other suitable shape. In many embodiments, the convertible light device10further comprises a lid40removably coupled to the top portion48of the housing12.FIGS.10A and10Billustrate a method of removing the lid40to gain access to the storage compartment38, shown inFIG.9. In some embodiments, as shown inFIG.10A, the lid40comprises a locking knob42configured to lock and unlock the lid40. As mentioned with reference toFIG.3, the attaching mechanism32may be configured to couple to the lid40when the attaching mechanism32is not coupled to the elongate flexible light source16. The attaching mechanism32may be configured to detachably couple to the lid40via a friction fit, magnet(s), or any suitable coupling mechanism. A method of removing the lid40begins with the attaching mechanism32coupled to the lid40and the locking knob42in the locked position, as indicated in step1002ofFIG.10A. From that point, a user may remove the attaching mechanism32from the lid40(at step1004). As shown inFIG.10B, the user may then turn the locking knob42to the unlocked position (at step1006), and remove the lid40from the housing12, thereby exposing the storage compartment38(at step1008). In many embodiments, the storage compartment38is at least one of water resistant and waterproof. The storage compartment may be sized to hold any number of items, including, but not limited to, key(s), a small wallet, loose cash and/or credit card(s), a multi-tool, jewelry, small food items, and the like. In some embodiments, the storage compartment38measures about 67 mm×67 mm×74 mm. The storage compartment38may be larger than the listed dimensions. In some embodiments, the storage compartment is smaller than the listed dimensions. Turning now toFIG.11, a bottom perspective view of the convertible light device10is shown, including the flashlight68coupled to the base portion50of the housing12. As previously discussed, the flashlight68may be operatively coupled to the flashlight button66. In some embodiments, the flashlight68is instead turned on/off by depressing the lens. The flashlight68may comprise a single LED configured to emit light in a singular “beam” or direction. The flashlight68may also be configured to emit light in all directions, and as such, “light up” at least the base portion50of the housing12. The flashlight68may also “light up” more of the housing12than just the base portion50. The flashlight68may comprise a single-color LED, an RGB LED, or any other suitable type of light source. Similar to the elongate flexible light source16, the flashlight68may comprise a programmable light capable of emitting light in different “modes” comprising different colors, patterns, sequences, etc. The flashlight button66may be configured to select at least one mode of the flashlight68. The flashlight68may be communicatively coupled to a mobile application configured to program and control light emission from the flashlight68. In some embodiments, the flashlight68is located within the base portion50of the housing12. The flashlight68may be located at least partially within the base portion50of the housing12. The flashlight68may be located on a base of the battery pack14. In addition to and/or instead of the flashlight button66, the flashlight68may be controlled via the brightness knob58, and may also be operatively coupled to the power boost button56. The convertible light device10may comprise more than one brightness knob58, where one brightness knob58controls the elongate flexible light source16and one brightness knob58controls the flashlight68. Similarly, the light device10may comprise more than one power boost button56. The convertible light device10may be configured such that both the flashlight68and the elongate flexible light source16may be illuminated at the same time. In some embodiments, the base portion50of the housing12comprises a protective material configured to absorb impact. For example, the base portion50may comprise a border, ring, pad, or the like comprised of silicone, rubber, or a similar material to prevent damage to the convertible light device10if the device10is dropped, knocked over, etc. Substantially an entire portion of the base portion50of the housing12may comprise the protective material. The protective material may be located on only certain areas of the base portion50, such as around a perimeter of the flashlight68and on the corners. Other parts of the housing12, in addition to or in place of the base portion50, may comprise the protective material. The light device10may also include a cover configured to fit over at least a portion of the housing12. For example, in some embodiments, the cover is configured to fit over a middle portion52of the housing12such that the cover substantially encloses the elongate flexible light source16when the light device10is in the lantern mode22. The cover may comprise a material, such as a frosted material, such that the cover diffuses the light emitted by the elongate flexible light source16. The cover may be slideably coupled to the housing12, and may be configured to slide toward the base of the housing12. In some embodiments, the cover serves as a stand for the light device10when the cover slides toward the base of the housing12. The cover may be configured to act as the winding mechanism, and thereby may be configured to facilitate coiling the elongate flexible light source16around the housing12. The cover may be detachably coupled to the light device10. In some embodiments, the cover is fixedly coupled to the housing12. The different elements of the light device10may comprise any number of suitable materials and/or combinations of materials. For example, the housing12may comprise polymer plastic (e.g., ABS plastic), metallic, rubber, or a combination of materials. The handle44and attaching mechanism32may also comprise metallic, plastic, or combination materials. The elongate flexible light source16may comprise the plurality of LEDs18inside flexible plastic tubing. In some embodiments, the plastic tubing is clear. The plastic tubing may comprise a frosted material70to provide light diffusion. As previously mentioned, the cover may also comprise a frosted material, such as plastic, to provide light diffusion. In some embodiments, the LEDs of the plurality of LEDs18emit light at about 1000 W. Any of the materials used to comprise any of the elements of the light device10may comprise substantially waterproof materials. The materials may also be substantially “tough” and resistant to breaking, wear-and-tear, etc., even after being dropped, knocked over, and the like. In some embodiments, the convertible light device10comprises a single battery pack14and a single “rope” of the elongate flexible light source16. The rope may measure about 10 feet in length. In some embodiments, the rope measures more than 10 feet in length. The rope may also be fewer than ten feet in length. Another embodiment of the convertible light device10may comprise two battery packs14and the elongate flexible light source16may comprise two or more ropes. The flexible light source16may comprise a single rope, but the single rope may be longer than the single rope of the single battery pack14embodiments. A light device10including two battery packs14may comprise a housing12that is at least one of wider and longer than the housing12of a light device10including a single battery pack14. In addition to the attaching mechanism32and handle44, the convertible light device10may be configured for additional mounting and/or hanging options. For example, a base portion50of the housing12may comprise a magnetic material in order to enable the housing12to magnetically couple to a metal surface (e.g., to the side of a camper, RV, passenger vehicle, etc.). The convertible light device10may also be configured to couple to a stand when hanging the device10is not possible. For example, the device10may comprise a connector and/or mount suitable for coupling to a tri-pod typically used for a camera. The convertible light device10may be configured to couple to a more portable and/or wearable type of mount, similar to a camera accessory commonly used to record a user or the user's point of view during physical activity (e.g., mountain biking, skiing, snowboarding, surfing, running, etc.). FIG.12illustrates a perspective view of a convertible light device100. The convertible light device100may be similar to the convertible light device10previously discussed in this disclosure. For example, in some embodiments, the convertible light device100includes a device housing102with a handle108, an elongate flexible light source106, and a battery pack104. The handle108may be substantially the same as the handle44previously discussed in this disclosure. In some embodiments, the device housing102, the battery pack104, and the elongate flexible light source106of the convertible light device100differ from the corresponding components of the convertible light device10. Each of these components will be discussed in greater detail with reference toFIGS.13-17. Similar to the convertible light device10andFIGS.1A and1B, the convertible light device100may be configured to convert between a rope mode and a lantern mode. In some embodiments, in the lantern mode, the elongate flexible light source106is configured to wrap around an exterior portion of the device housing102. In the rope mode, the elongate flexible light source106may be configured to unwrap and extend from the exterior of the device housing102. In some embodiments, the elongate flexible light source comprises a rope light. Though not specifically shown inFIGS.12-17depicting the convertible light device100, it should be noted that the ends of the elongate flexible light source106may be substantially similar to the ends of the elongate flexible light source16of the convertible light device10. For example, the elongate flexible light source106may comprise a first end with a magnetic end cap configured to couple to the device housing102, as illustrated inFIG.2. The magnetic end cap may also comprise a hole configured to receive an attaching mechanism, as shown inFIG.4. In some embodiments, a second end of the elongate flexible light source106is configured to detachably couple to an elongate flexible light source port in the device housing102, as demonstrated inFIG.5. Similar to the elongate flexible light source16, the elongate flexible light source106may comprise a plurality of LEDs. In some embodiments, as illustrated inFIGS.13A and13B, the battery pack104is configured to removably couple to an interior portion112of the device housing102. The battery pack104may comprise a battery pack housing110configured to house at least one rechargeable battery. Similar to the battery pack14of the convertible light device10, the battery pack104may comprise a plurality of lithium-ion batteries. The battery pack104may comprise a single lithium-ion battery. The battery pack104may comprise any suitable type of rechargeable battery. Additionally,FIG.13Bshows a first light convertible light device100and a second convertible light device200that also includes a battery pack204, with a battery pack housing210, configured to removably couple to an interior portion212of a device housing202. The second convertible light device200may be substantially similar to the first convertible light device100. FIGS.14A and14Bshow perspective views of the battery pack104. As illustrated inFIG.14A, the battery pack104may include a charging port114. In some embodiments, the charging port114is configured to receive a charging cable to thereby charge the at least one rechargeable battery within the battery pack housing110. The charging port114may also be configured to receive a charging cable to thereby charge an external device, such as, but not limited to, a phone, a tablet, a speaker, a smartwatch, or any other similar rechargeable electronic device. The battery pack104may comprise more than one charging port114. Rather than a charging port114, the battery pack104may be configured to couple to a charging dock to thereby charge the at least one battery within the battery pack housing110. In some embodiments, as demonstrated inFIG.14A, the convertible light device100comprises a flashlight116coupled to the battery pack housing110. The battery pack104may comprise an activation mechanism118coupled to the battery pack housing110and operatively coupled to the flashlight116. The activation mechanism118may comprise a button, a switch, or a similar mechanism configured to turn the flashlight116on and off. In some embodiments, as shown inFIG.14A, the activation mechanism118comprises a lens of the flashlight116. Accordingly, the flashlight116may be considered a “push button,” “touch,” or “tap” flashlight116, where the flashlight116is turned on/off by pressing the lens. Due to the removable nature of the battery pack104with respect to the device housing102, the flashlight116may serve as a portable light source. For example, a user may desire to use the flashlight116to walk a distance away from the current location of the convertible light device100without bringing along the entire device100. Instead, the user may remove the battery pack104from the device housing102and utilize the flashlight116to walk to a restroom, into a tent, over to a vehicle, etc. As shown inFIG.14B, the battery pack104may include a connector120located on an opposite end of the battery pack housing110from the flashlight116. In some embodiments, the connector120is configured to contact a component within the device housing102to thereby electrically couple the battery pack104to the elongate flexible light source106in order to power the elongate flexible light source106. Removing the battery pack104from the device housing102may result in terminating light emission from the elongate flexible light source106until the battery pack104is re-coupled to the device housing102. In some embodiments, the elongate flexible light source106is configured to “hold” at least a partial charge such that the battery pack104can be removed from the device housing102without immediately terminating light emission from the elongate flexible light source106. This ability to “hold” a charge and continue emitting light even when disconnected from the battery pack104, in combination with the ability to detach the elongate flexible light source106from the device housing (similar to the discussion of the elongate flexible light source16with reference toFIG.5) may enable a user to wear the elongate flexible light source106. For example, a user may wrap the elongate flexible light source106around their torso like a belt or vest to increase visibility, such as when working, biking, walking, or jogging outdoors between sunset and sunrise. The elongate flexible light source106could also serve as a vest for a pet or wrap around a leash to increase visibility for both pet and owner. Turning now toFIG.15, another view of the convertible light device100is shown. As demonstrated, the device100may include a first plurality of magnets122alocated on the device housing102. The device100may also include a second plurality of magnets122blocated along the elongate flexible light source106. In some embodiments, the first plurality of magnets122ais configured to magnetically couple to the second plurality of magnets122b, thereby coupling the elongate flexible light source106to the device housing102. To ensure magnetic coupling, the first plurality of magnets122aand the second plurality of magnets122bmay define opposite magnetic poles. In some embodiments, the second plurality of magnets122bare evenly spaced along substantially an entire length of the elongate flexible light source106. Having a magnetic connection may increase the ease of winding the elongate flexible light source106around the device housing102, as the attraction of the second plurality of magnets122bto the first plurality of magnets122amay help guide the elongate flexible light source106into a correct position as it wraps around the device housing102. In addition to increasing the general ease of wrapping the elongate flexible light source106, the magnetic connection may also reduce the time to convert from “rope mode” to “lantern mode,” as the user may not need to take as much time to carefully and precisely wrap the elongate flexible light source106. Rather than needing to ensure precise positioning by hand, the magnetic connection may help guide the elongate flexible light source106into a correct position. Instead of (or in addition to) the first and second plurality of magnets122a,122b, the convertible light device100may comprise an automatic winding mechanism to wind the elongate flexible light source106around the device housing102. For example, the convertible light device100may include a retractable mechanism similar to a retractable pet leash to wrap the elongate flexible light source106around the device housing102. The elongate flexible light source106may comprise a built-in coil to encourage shape retention of the wound-up position (i.e., “lantern mode”) to increase the ease of wrapping the elongate flexible light source106around the device housing102. In some embodiments, the second plurality of magnets122bis configured to couple to an external magnetic surface. For example, the second plurality of magnets122bmay be configured to couple to a vehicle, tent pole(s)/frame (e.g., of a pop-up canopy), a boat, a garage door, or any other magnetic surface to provide area lighting. Further, the convertible light device100may comprise an attaching mechanism124coupled to the elongate flexible light source106, as shown inFIG.15. Similar to the attaching mechanism32previously discussed in this disclosure, the attaching mechanism124may be configured to couple to an external anchor (e.g., a tree, fence, building, etc.) to thereby couple the elongate flexible light source106to the external anchor when the convertible light device100is in the rope mode. FIG.16illustrates a control panel126with a plurality of mode buttons128, as well as a first input button130aand a second input button130b. In some embodiments, the control panel126is coupled to the device housing102, and the plurality of mode buttons128is configured to control the emission of light from the plurality of LEDs of the elongate flexible light source106. As indicated by the numbers on the plurality of mode buttons128, the control panel126may include a first mode button configured to select a first light mode, a second mode button configured to select a second light mode, a third mode button configured to select a third light mode, and a fourth mode button configured to select a fourth light mode. The fifth mode button may comprise an “Other” option for light emission and may be programmed for any number of functions. For example, the fifth mode button may comprise a predetermined pattern of light emission (e.g., slow fade, fast blinking, a strobe function), a timer, or any other suitable function. Further, the first and second input buttons130a,130bmay be configured to control light emission or some other aspect of the convertible light device100. For example, the first and/or second input button130a,130bmay be used to turn on/off the elongate flexible light source106, to turn on/off the flashlight116, to turn on/off the charging port114, or some other function not explicitly disclosed here. In some embodiments, the convertible light device100is operatively coupled to a mobile application loaded on a mobile device132such as a tablet, laptop, or smartphone, as shown inFIG.17. The mobile application may comprise a plurality of mode buttons134corresponding to the plurality of mode buttons128located on the control panel126. For example, moving from top to bottom on the mobile device132, each mode listed may correspond to the numbered buttons on the control panel126shown inFIG.16. To illustrate the numbered buttons, their corresponding light modes, and the effect carried out by the plurality of LEDs of the elongate flexible light source106, please refer to the following table: Button No.FunctionEffect1Party ModeFollows the beat of musicusing a built-in equalizerand microphone2Emergency SOS ModeFlashes SOS in Morse Code3Red Light ModeChanges color of LED lightto red4Custom Color ModeAllows for customized RGBcolor5OtherOther functions Though discussed in terms of the elongate flexible light source106, any of the light modes discussed herein may also be carried out via the flashlight116. Similar toFIGS.7A and7B, the control panel126may include a plurality of battery level indication lights and a battery level indication button, wherein the battery indication button may be configured to illuminate at least one battery level indication light of the plurality of battery level indication lights. In some embodiments, the convertible light device100includes multiple control panels located on the device housing102. For example, the device100may include a first control panel comprising the control panel126illustrated inFIG.16, and may include a second control panel similar to that shown inFIGS.7A and7B. It should also be noted that the mobile device132may be configured to display an indication of the battery level. In some embodiments, the convertible light device100includes a storage compartment located within an interior portion112of the device housing102. The storage compartment may be accessible via a lid removably coupled to a top portion of the device housing102, as illustrated inFIGS.10A and10Bwith reference to the convertible light device10. The storage compartment of the convertible light device100may be larger than the storage compartment38of the convertible light device10. In some embodiments, the storage compartment of the convertible light device100is smaller than the storage compartment38of the convertible light device10. The storage compartment of the convertible light device100may be substantially the same size as the storage compartment38of the convertible light device10. As illustrated inFIGS.18and19, the convertible light device100may be configured to couple to another convertible light device100, such as a second convertible light device200, forming a convertible lighting system300. For example, a convertible lighting system300may comprise a first convertible light device100detachably electrically coupled to a second convertible light device200. In some embodiments, the two convertible light devices are communicatively coupled such that light emission from a first elongate flexible light source106of the first convertible light device100is synced with light emission from a second elongate flexible light source206of a second convertible light device200. For example, selecting the “Custom Color Mode” on the first convertible light device100may cause the second convertible light device200to emit the same custom color selection. In some embodiments, the first and second convertible light devices are detachably coupled together but operate independently. The first and second convertible light devices may be detachably mechanically coupled together. In some embodiments, a second elongate flexible light source206is configured to couple to a first elongate flexible light source106, thereby “daisy-chaining” multiple elongate flexible light sources from a single device housing102. The second elongate flexible light source206may define a shorter length than the first elongate flexible light source106. In some embodiments, the second elongate flexible light source206defines a longer length than the first elongate flexible light source106. The first and second elongate flexible light sources may define substantially the same length. A single convertible light device100may be configured to support one, two, three, four, or more than four elongate flexible light sources coupled together. When coupled together, multiple elongate flexible light sources may be configured to emit light synchronously. Multiple elongate flexible light sources coupled together may be configured to emit light asynchronously. The convertible light device100may comprise waterproof materials such that the convertible light device100can be used for work or recreation underwater. For example, the convertible light device100may be used to provide lighting for diving, watercraft maintenance, underwater photoshoots, and many other types of underwater activities. The use of waterproof materials may also enable the convertible light device100to withstand use in wet, though not completely submerged, environments. For example, use above deck on a watercraft, use in rainy/snowy weather, and activities like spelunking, gardening, construction, plumbing work, and many others may benefit from use of the convertible light device100. In some embodiments, the convertible light device100is configured to receive power via a power source other than the battery pack104. For example, the convertible light device100may be configured to couple to a solar charger, a wind power source, or a hand-crank power source. Any number of alternative energy sources may be suitable to power the convertible light device100. INTERPRETATION None of the steps described herein is essential or indispensable. Any of the steps can be adjusted or modified. Other or additional steps can be used. Any portion of any of the steps, processes, structures, and/or devices disclosed or illustrated in one embodiment, flowchart, or example in this specification can be combined or used with or instead of any other portion of any of the steps, processes, structures, and/or devices disclosed or illustrated in a different embodiment, flowchart, or example. The embodiments and examples provided herein are not intended to be discrete and separate from each other. The section headings and subheadings provided herein are nonlimiting. The section headings and subheadings do not represent or limit the full scope of the embodiments described in the sections to which the headings and subheadings pertain. For example, a section titled “Topic1” may include embodiments that do not pertain to Topic1and embodiments described in other sections may apply to and be combined with embodiments described within the “Topic1” section. Some of the devices, systems, embodiments, and processes use computers. Each of the routines, processes, methods, and algorithms described in the preceding sections may be embodied in, and fully or partially automated by, code modules executed by one or more computers, computer processors, or machines configured to execute computer instructions. The code modules may be stored on any type of non-transitory computer-readable storage medium or tangible computer storage device, such as hard drives, solid state memory, flash memory, optical disc, and/or the like. The processes and algorithms may be implemented partially or wholly in application-specific circuitry. The results of the disclosed processes and process steps may be stored, persistently or otherwise, in any type of non-transitory computer storage such as, e.g., volatile or non-volatile storage. The various features and processes described above may be used independently of one another, or may be combined in various ways. All possible combinations and subcombinations are intended to fall within the scope of this disclosure. In addition, certain method, event, state, or process blocks may be omitted in some implementations. The methods, steps, and processes described herein are also not limited to any particular sequence, and the blocks, steps, or states relating thereto can be performed in other sequences that are appropriate. For example, described tasks or events may be performed in an order other than the order specifically disclosed. Multiple steps may be combined in a single block or state. The example tasks or events may be performed in serial, in parallel, or in some other manner. Tasks or events may be added to or removed from the disclosed example embodiments. The example systems and components described herein may be configured differently than described. For example, elements may be added to, removed from, or rearranged compared to the disclosed example embodiments. Conditional language used herein, such as, among others, “can,” “could,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without author input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular embodiment. The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations and so forth. Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list. Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to each be present. The term “and/or” means that “and” applies to some embodiments and “or” applies to some embodiments. Thus, A, B, and/or C can be replaced with A, B, and C written in one sentence and A, B, or C written in another sentence. A, B, and/or C means that some embodiments can include A and B, some embodiments can include A and C, some embodiments can include B and C, some embodiments can only include A, some embodiments can include only B, some embodiments can include only C, and some embodiments include A, B, and C. The term “and/or” is used to avoid unnecessary redundancy. The term “about” is used to mean “approximately”. For example, the disclosure includes “The rope may measure about 10 feet in length.” In this context, “about 10 feet” is used to mean “approximately 10 feet”. A range of rope length from 8 feet to 12 feet may be used to fall within the understanding of “about 10 feet”. The term “substantially” is used to mean “completely” or “nearly completely”. For example, the disclosure includes “ . . . the elongate flexible light source16comprises a plurality of light sources, such as LEDs, that extend substantially the entire length of the elongate flexible light source16.” In this context, “substantially the entire length” is used to mean “completely or nearly completely” the entire length. An embodiment where the plurality of light sources extend at least three-quarters of the entire length of the elongate flexible light source would fall within the understanding of “substantially the entire length”. While certain example embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions disclosed herein. Thus, nothing in the foregoing description is intended to imply that any particular feature, characteristic, step, module, or block is necessary or indispensable. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions, and changes in the form of the methods and systems described herein may be made without departing from the spirit of the inventions disclosed herein. | 62,819 |
11859784 | In the above drawings, the names of parts corresponding to the reference numerals are as follows: 1refers to flexible sleeve,2refers to light shielding body,3refers to lead,4refers to cuttable window,5refers to light guiding surface,6refers to power wire,7refers to plug,8refers to mounting clasp,9refers to cutting extension wire,10refers to FPCBA assembly,11refers to LED independent circuit,12refers to FPCB,13refers to arc-shaped notch,14refers to cuttable position,15refers to positive electrode bonding pad,16refers to negative electrode bonding pad,17refers to matrix, and18refers to light diffusing body. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS The present invention is further described hereinafter with reference to the drawings and embodiments, and implementations of the present invention comprise, but are limited to, the following embodiments. Embodiment As shown inFIG.1toFIG.5, a LED lighting capable of being bent and twisted at will comprises a flexible sleeve1, a FPCBA assembly10and a lead3. The FPCBA assembly is formed by sequentially mounting multiple groups of LED independent circuits11on a strip-shaped FPCB12by a SMT, a plurality of arc-shaped notches13are evenly arranged on long edges of two sides of the FPCB at intervals, and each arc-shaped notch corresponds to a position between two adjacent LED luminous elements on the FPCB respectively, so as to ensure that the FPCB may be bent and twisted at will. The LED independent circuit comprises a plurality of LED luminous elements connected in series and a peripheral electronic element, as shown inFIG.5. A conducting line is arranged between each group of LED independent circuits on the FPCB, so that the FPCBA assembly forms one complete FPCBA. A back surface of the FPCB is provided with a positive electrode bonding pad15and a negative electrode bonding pad16corresponding to each group of LED independent circuits respectively, two leads are provided, one lead is communicated with all positive electrode bonding pads in a welded mode and the other lead is communicated with all negative electrode bonding pads in a welded mode, and the positive and negative electrode bonding pads are also provided with a tin melting space, so as to improve welding reliability of the FPCB and the lead. The welded connection mode of the lead and the FPCB expands a main current, thus achieving a long cascade effect, and having a small brightness difference between a head and a tail when a long-length lighting is configured (for example, a conventional flexible light strip can have no obvious brightness difference within a length range of 15 m at most, while the LED lighting of the present invention can have no obvious brightness difference within a length range of 30 m under the configuration of the same electrical elements), and the configuration of welding the leads with the LED independent circuits also ensures overall connectivity and electric conductivity of the FPCBA assembly, and greatly improves a mechanical strength of the lighting itself. Even if a cuttable position between each group of independent circuits is disconnected, the independent circuits can be conducted through the leads respectively. Specifically, the FPCB is provided with the cuttable position14between each group of LED independent circuits, and a bottom portion of the flexible sleeve is provided with a cuttable window4corresponding to the cuttable position, so that cutting may be performed conveniently according to a required length, and adaptability to a mounting scene is improved. The flexible sleeve wraps and packages the FPCBA assembly and the leads, and reserves a power wire6at an end portion, wherein a top surface of the flexible sleeve corresponding to the LED luminous elements is configured as a light guiding surface5, and the light guiding surface is a serrated optical refracting surface, so as to ensure that emitted light achieves a linear effect and forms required light diffusing effect or light focusing effect, and a side surface and a bottom surface of the flexible sleeve are provided with a light shielding body2to reduce light source leakage. The flexible sleeve is specifically manufactured by a secondary extrusion process, a transparent material is co-extruded with the FPCBA assembly connected with the leads to form a matrix17wrapping the leads and the FPCBA assembly in first extrusion, and a transparent material or a light diffusing material is co-extruded with the matrix to form the flexible sleeve with the light guiding surface in second extrusion, so as to realize packaging. As shown inFIG.1, a middle part of the flexible sleeve is integrated by extrusion twice with the same material, and as shown inFIG.6, the middle part of the flexible sleeve is layered by extrusion twice with different materials, wherein the first extrusion forms the light guiding surface on the surface of the matrix17, and the light diffusing material of the second extrusion forms a light diffusing body18with the light guiding surface inside. Plugs7are arranged at two ends after packaging, and the power wire is led out from the plugs to finish the whole product, so that an IP67 ingress protection level can be reached, and the product may be provided with a mounting clasp8to facilitate mounting. In further configuration, one group of exposed cutting extension wires9is arranged on the bottom surface of the flexible sleeve by each specified distance, and the cutting extension wires are connected with the leads in the position. A part of colloid may be cut off in a position on the bottom surface after packaging to bridge the cutting extension wire to the lead in manufacturing, so as to facilitate a user to replenish power or access a power supply after cutting. The above embodiments are only the preferred embodiments of the present invention, and do not limit the scope of protection of the present invention. However, any changes made by adopting the design principle of the present invention and performing non-creative work on this basis should be within the scope of protection of the present invention. | 6,123 |
11859785 | DETAILED DESCRIPTION InFIG.9, a lighting apparatus includes a driver601, an elongated housing602, an extending connector604, a light source and an extension module605. InFIG.9, the light source is composed a first light part606and a second light part607. In some other embodiments, the light source may have one or more than three parts. The driver601converts an external power source to a driving current. For example, a power wire607guides an indoor power source of 110V alternating current power to the driver601. The driver601includes a transformer, a rectifying circuit, filter circuits or other components to convert the alternating current power to a direct current power supplied to the light source and the extension module. In some embodiments, the extension module may carry a battery to be charged in normal time and supplying power to the light source when the external power is not available abnormally. The elongated housing has a lighting area610, an extension area611and a light opening612. The extending connector has a holder613and an electrode614connecting to the driver601. For example, the holder613may include a box for inserting the extension module. The electrode614is disposed inside the box so that when the extension module is inserted, the extension module is electrically connected to the driver601via the electrode614. The holder613is placed in the extending area611of the elongated housing602. The light source is attached to the lighting area610for generating a first light616escaping from the light opening612. The extension module605is attached to the holder613of the extending connector to electrically connect to the driver601via the electrode614. In some embodiments, the extension module is detachable to be replaced with another extension module. For example, users may buy several extension modules with the same housing but with different functions to be inserted into the holder613of the extending connector604. A first extension module may be a speaker and a second extension module may be a wireless module to provide wireless connectivity to the driver601. The extension module may be a camera module, a sensor module, a Wi-Fi hotspot device or other function modules. In some embodiments, the holder has a sliding track621for inserting the extension module605from the direction of the light opening612, e.g. the bottom side of the elongated housing602. In some embodiments, the elongated housing602has two lateral covers623,624disposed on opposite sides of the elongated housing602. A power wire608is connected to one of the lateral cover for transmitting the external power to the driver601. In some embodiments, the elongated housing has two lateral covers disposed on opposite sides of the elongated housing. A light device connector625is disposed on one of the lateral cover to connect to another lighting apparatus626for routing electricity to said another lighting apparatus626. Said another lighting apparatus may have the same structure as the lighting apparatus. In some usage examples, the two lighting apparatuses may be the same but are installed with different extension modules, e.g. one for a camera and another for a spot light. In some embodiments, the lighting apparatus may also include a rotation button631and a manual switch632. The rotation button and the manual switch are electrically connected to the driver. The rotation button is used for perform a continuous operation for setting a continuous parameter continuously to operate the driver. Specifically, the continuous operation refers to a continuous parameter range. For example, a light intensity from 200 intensity units to 1000 intensity units is a parameter range. When the light intensity is selected by rotating the rotation button, the value may be selected like 250.002323 or 250.21235, which falls in the range but has unlimited options, which is called continuous. In contrast, the manual switch provides a limited set of options to be selected, which is called discrete options. The manual switch provides multiple discrete options for a user to select one of the multiple discrete options to operate the driver. The manual switch and the rotation button may be used for controlling the same type of parameters, e.g. intensity or different types of parameters, e.g. the rotation button for intensity adjustment while the manual switch is used for indicating a required color temperature. The manual switch may be configured to co-work with the rotation button. For example, the manual switch determines a parameter type and the rotation button determines a specific value of the parameter type. InFIG.10, the lighting apparatus671is connected to a series of other lighting apparatuses672,673,674. The lighting apparatus and the series of other lighting apparatuses are configured to receive a wall switch command from a wall switch675to adjust a color temperature at the same time. The control signal may be transmitted to the lighting apparatus671first, and the lighting apparatus671routes or translates the control signal to supply to other lighting apparatuses672,673,674. In some embodiments, the lighting apparatus is connected to another lighting apparatus. The light source of the lighting apparatus has a first type of light modules and a second type of light modules. For example, inFIG.9, the first light part has a first type of light modules631and a second type of light modules632. Specifically, the first type of light modules631may emit light of a first color temperature and the second type of light modules632may emit light of a second color temperature. Said another lighting apparatus has the first type of light modules and the second type of light modules. Said another lighting apparatus may have the same structure as the lighting apparatus illustrated and explained above inFIG.9. The first type of light modules and the second type of the light modules of the lighting apparatus and said another lighting apparatus are alternatively turned on periodically to keep a portion of the first type of light modules and the second type of light modules of the lighting apparatus and said another lighting apparatus to rest to control an operation temperature of the lighting apparatus. For example, if two lighting apparatuses are placed together, and the two lighting apparatuses have the same structures. To mix a required color temperature, in a first time period, the first set of light modules of a first lighting apparatus is turned on to accompany the second set of light modules of a second lighting apparatus. In a second time period, the first set of light modules of the first lighting apparatus is turned on. The second type of light modules are turned on in the first lighting apparatus to accompany the first type of light modules in the second lighting apparatus to mix the required color temperature. In other words, some portion of light modules are rest even the required color temperature is continuously provided. Such design increase life span of the overall light devices and provide a nice heat dissipation scheme. In some embodiments, the light source includes a first light part and a second light part. The first light part and the second light part are disposed on two opposite sides of the extension module, as illustrated inFIG.9. InFIG.11, the extension module includes an air filter by guiding an air through a filter653of the extension module. In some embodiments, the extension module includes an ultra-violet light module654for sanitizing. The ultra-violet module emits an ultra-violet light to kill undesired objects. Some ultra-violet light does not cause harm to human and may be placed outside while some other ultra-violet light may cause danger to human and is therefore disposed in a concealed space for sanitizing air flowing by. In some embodiments, the extension module has a motion sensor656to turn off the ultra-violet light module when a person is detected. In some embodiments, the extension module receives a timer command to turn on the ultra-violet light module after a predetermined time period. For example, a timer655is used to determine a timing to activate the sanitizing, e.g. when people leave the store or home and the sanitizing is started one hour later after the setting. In some embodiments, the lighting apparatus may also include a fan657for creating an air652flowing by the ultra-violet light module654. In some embodiments, the extension module is a speaker for generating a sound. In some embodiments, the light source is detachable from the elongated housing. In some embodiments, the extension module is a spot light module for emitting a second light. Please seeFIG.12, which shows an example of configuration. The second light631is surrounded by the first light632, and the second light631has a larger intensity than the first light632. InFIG.9, the driver sends a status signal to an external device626when the driver detects insertion of the spot light module to change a control interface for controlling the lighting apparatus via a wireless interface. For example, the external device is a remote control or a mobile phone installed with a corresponding App. The corresponding App adjusts a control interface by determining the status signal indicating the type of the extension module. For example, when the extension module is a speaker, the interface is different from the case which the extension module is a spot light module. In some embodiments, a pulling string628is selectively attached to a string connector641connected to a string switch642of the driver601to control the light source by pulling the pulling string628. In some embodiments, a button629is disposed at an end of the pulling string628. The button629is operated to send an instruction to the driver601in addition to the pulling of the pulling string628. For example, the button629may switch an operation mode, control the extension module or change a color temperature of the light source. Please refer toFIG.1. InFIG.1, a lighting apparatus embodiment has a top cover3. In addition to the top cover3, the elongated housing1has a connector6for connecting to other lighting apparatuses. There is a switch7placed in an escaping groove9. The hook8is used for hanging the lighting apparatus on a bracket. Please refer toFIG.2, which illustrates a side view of the example inFIG.1. The same reference numerals among drawings refer to the same components and are not repeated for brevity. InFIG.2, the light source12emits light passing through a light passing cover4. The hinge axial10is used for attaching the hook8. The switch7is used for operating the lighting apparatus. There is a magnetic unit5for attaching an inserted extension module. A battery2may be added for emergency lighting. FIG.3shows another view of the example inFIG.2andFIG.1. FIG.4shows the same example with more details. A hanging wire883has a connecting column886is attached to the top cover. The switch885is used for operating the lighting apparatus, e.g. to change a color temperature or to turn on the lighting apparatus. There is a socket882for connecting to another lighting apparatus. The plug884of a power wire is connected to a power socket for getting external power. FIG.5shows a zoom-up view of an electrode which is an elastic metal pin887disposed in the light housing881for providing electricity to an inserted extension module. FIG.6shows another view of the example inFIG.5. FIG.7shows the example with further details like illustrating a light module8810and a spot light module8811. FIG.8shows a connector888and a magnetic unit889for connecting other devices, like another lighting apparatus or an extension module. The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the techniques and their practical applications. Others skilled in the art are thereby enabled to best utilize the techniques and various embodiments with various modifications as are suited to the particular use contemplated. Although the disclosure and examples have been fully described with reference to the accompanying drawings, it is to be noted that various changes and modifications will become apparent to those skilled in the art. Such changes and modifications are to be understood as being included within the scope of the disclosure and examples as defined by the claims. | 12,769 |
11859786 | MODE FOR THE INVENTION Hereinafter, the embodiments disclosed herein will be described in detail with reference to the accompanying drawings, and the same or similar elements are designated with the same numeral references regardless of the numerals in the drawings and their redundant description will be omitted. In describing an embodiment disclosed herein, moreover, the detailed description will be omitted when specific description for publicly known technologies to which the invention pertains is judged to obscure the gist of the present disclosure. Also, it should be understood that the accompanying drawings are merely illustrated to easily explain the concept of the invention, and therefore, they should not be construed to limit the technological concept disclosed herein by the accompanying drawings, and the concept of the present disclosure should be construed as being extended to all modifications, equivalents, and substitutes included in the concept and technological scope of the invention. The terms including an ordinal number such as first, second, etc. can be used to describe various elements, but the elements should not be limited by those terms. The terms are used merely for the purpose to distinguish an element from the other element. A singular representation may include a plural representation unless it represents a definitely different meaning from the context. Terms “include” or “has” used herein should be understood that they are intended to indicate the existence of a feature, a number, a step, a constituent element, a component or a combination thereof disclosed in the specification, and it may also be understood that the existence or additional possibility of one or more other features, numbers, steps, constituent elements, components or combinations thereof are not excluded in advance. A vehicle lamp according to the present disclosure reflects or refracts light emitted from a light-emitting device at least once to emit the light to the outside. When light is reflected or refracted, a separate optical structure is disposed, which complicates a structure of the lamp and increases a size of the lamp. A reflection or refraction effect of the optical structure may vary according to a relative position between the optical structure and a light source. Accordingly, positions at which the light source can be disposed based on a specific optical structure are limited. When a plurality of light sources are spaced apart from each other by a predetermined distance or more, it is difficult for at least one of the plurality of light sources to be affected by the effect of the specific optical structure. For this reason, as the number of types of light sources included in a single lamp increases, an optical structure required for the lamp may increase. For example, when a single lamp is implemented to selectively emit red light and blue light, the single lamp must include both a structure for reflecting or refracting the red light and a structure for reflecting or refracting the blue light. The present disclosure provides a structure capable of allowing an effect of a single optical structure to be applicable to a plurality of different types of light sources. More specifically, the present disclosure provides a structure capable of implementing the same light pattern when light sources spaced apart from each other are respectively turned on. To this end, the present disclosure includes a substrate510, first and second light sources520aand520b, and a lens530. Hereinafter, the foregoing elements will be described in detail. The substrate510, which is a base layer on which a structure is formed through an entire process, may be a wiring substrate on which a wiring electrode for applying power to a light source is disposed. Furthermore, the substrate may be made of glass, polyimide (PI), or a thin metal. In addition, as far as it is an insulating and flexible material, any one such as polyethylene naphthalate (PEN), polyethylene terephthalate (PET) or the like may be used. Furthermore, the substrate510may be either one of transparent and non-transparent materials. Meanwhile, a heat dissipation sheet, a heat sink, or the like may be mounted on the substrate510to implement a heat dissipation function. In this case, the heat dissipation sheet or the heat sink may be mounted on a surface opposite to a surface on which the wiring electrode is disposed. The first and second light sources and the lens are disposed on one surface of the substrate510. The first and second light sources520aand520bmay include a plurality of semiconductor light-emitting devices. The semiconductor light-emitting device has excellent luminance, and thus may be used as a light source of a vehicle lamp. A size of an individual semiconductor light-emitting device150may have a side length of 80 μm or less, and may be a rectangular or square device. In this case, an area of a single semiconductor light-emitting device may have a range of 10−10˜10−5m2, and a distance between the light-emitting devices may have a range of 100 μm to 10 mm. Referring toFIG.3, the semiconductor light-emitting device may be a flip-chip type light-emitting device. For example, the semiconductor light-emitting device may include a p-type electrode156, a p-type semiconductor layer155formed with the p-type electrode156, an active layer154formed on the p-type semiconductor layer155, an n-type semiconductor layer153formed on the active layer154, and an n-type electrode152disposed to be separated from the p-type electrode156in a horizontal direction on the n-type semiconductor layer153. In this case, the p-type electrode156may be electrically connected to an auxiliary electrode170, and the n-type electrode152may be electrically connected to a second electrode140. Referring toFIG.4, such a vertical semiconductor light-emitting device250includes a p-type electrode256, a p-type semiconductor layer255formed on the p-type electrode256, an active layer254formed on the p-type semiconductor layer255, an n-type semiconductor layer253formed on the active layer254, and an n-type electrode252formed on the n-type semiconductor layer253. In this case, the p-type electrode256located at the bottom thereof may be electrically connected to the first electrode220by the conductive adhesive layer230, and the n-type electrode252located at the top thereof may be electrically connected to the second electrode240which will be described later. The electrodes may be disposed in a top-down direction in the vertical semiconductor light-emitting device250, thereby providing a great advantage capable of reducing a chip size. Each of the first and second light sources520aand520bincludes a plurality of semiconductor light-emitting devices arranged in a line. Accordingly, when the semiconductor light-emitting devices provided in each of the first and second light sources520aand520bare turned on, a bar shape extending in one direction is displayed. In the present specification, a direction in which a plurality of semiconductor light-emitting devices are arranged in a line is defined as an extension direction of the light source. Meanwhile, even though the first and second light sources520aand520beach have a bar shape, it does not mean that the plurality of semiconductor light-emitting devices are disposed without a separation distance. The semiconductor light-emitting devices provided in the light source may be disposed to be spaced apart from each other by a predetermined distance, and when all of the semiconductor light-emitting devices provided in the light source are turned on and displayed in a bar shape, the light source is referred to as a bar-shaped light source. The first and second light sources520aand520bare respectively disposed on one surface of the substrate, and disposed in parallel to each other. The wiring electrode formed on the substrate is implemented such that the first and second light sources520aand520bcan be individually turned on. Meanwhile, the lens530is disposed on one surface of the substrate510to overlap the first and second light sources520aand520b. The lens530does not need to be in contact with the first and second light sources520aand520b, and an air gap may be disposed between the lens530and the first and second light sources520aand520b. A shape of the lens530may be implemented in various ways, but with a structure of the lens in the related art, when two light sources spaced apart from each other are respectively turned on, the same light pattern cannot be implemented. Prior to describing a structure of the lens according to the present disclosure, a light pattern will be described when a lens in the related art is disposed on the first and second light sources. FIG.5is a conceptual view showing a lamp including a lens having a circular pattern,FIG.6is a cross-sectional view of a lamp illustrated inFIG.5, andFIG.7is a conceptual view showing a light pattern when any one of light sources included in the lamp illustrated inFIG.5is turned on. Referring toFIG.5, a cylindrical lens has been used in the related art. When the lamp shown inFIG.5is cut along an imaginary plane (refer to line A-A′) perpendicular to extension directions of the two light sources and perpendicular to the substrate, a cross-section of the lamp is shown inFIG.6. Referring toFIG.6, the lens330surrounding the two light sources320aand320bincludes a portion of a circular shape. According to the structure of the lens330illustrated inFIGS.5and6, a different light pattern is implemented whenever light sources spaced apart from each other are respectively turned on. For example, when either one of the light sources320aand320bincluded in a lamp300according toFIGS.5and6is turned on, a light pattern shown inFIG.7is implemented. Specifically, a light pattern is formed to be bright at a position adjacent to a light source that is turned on, and a light pattern is formed to be dark at a position adjacent to a light source that is not turned on. When a light source different from the turned-on light source is turned on, a light pattern in which the light pattern shown inFIG.7is inverted is formed. That is, the lamp according toFIGS.5and6cannot implement the same light pattern when two light sources spaced apart from each other are respectively turned on. FIG.8is a conceptual view showing a lamp including a lens having a circular pattern,FIG.9is a cross-sectional view of a lamp illustrated inFIG.8, andFIG.10is a conceptual view showing a light pattern when any one of light sources included in the lamp illustrated inFIG.8is turned on. Referring toFIG.8, a cuboid-shaped lens430has been used in the related art. When a lamp400illustrated inFIG.8is cut along an imaginary plane (refer to line B-B′) perpendicular to extension directions of the two light sources420aand420band perpendicular to the substrate410, a cross-section of the lamp400is shown inFIG.9. Referring toFIG.9, the lens430surrounding the two light sources420aand420bhas a rectangular shape. According to a structure of the lens430illustrated inFIGS.8and9, a different light pattern is implemented whenever the light sources420aand420bspaced apart from each other are respectively turned on. For example, when either one of the light sources420aand420bincluded in a lamp according toFIGS.8and9is turned on, a light pattern shown inFIG.10is implemented. Specifically, a light pattern is formed to be bright at a position adjacent to a light source that is turned on, but the light pattern is not formed at a position adjacent to a light source that is not turned on. When a light source different from the turned-on light source is turned on, a light pattern in which the light pattern shown inFIG.10is inverted is formed. That is, the lamp according toFIGS.8and9cannot implement the same light pattern when two light sources spaced apart from each other are respectively turned on. Hereinafter, a structure of the lens530according to the present disclosure will be described. FIG.11is a conceptual view showing a lamp according to the present disclosure,FIG.12is a cross-sectional view of a lamp illustrated inFIG.11,FIG.13is a conceptual view showing an embodiment in which two elliptical portions are disposed, andFIG.14is a conceptual view showing a light pattern when any one of light sources included in the lamp illustrated inFIG.11is turned on. Referring toFIG.11, the lens530according to the present disclosure is disposed to extend along a direction in which the first and second light sources520aand520bextend so as to overlap the first and second bar-shaped light sources520aand520b. When a lamp illustrated inFIG.11is cut along an imaginary plane (refer to line C-C′) perpendicular to extension directions of the two light sources520aand520band perpendicular to the substrate510, a cross-section of the lamp500is shown inFIG.12. Hereinafter, a structure of the lens according to the present disclosure will be described with reference toFIG.12. A cross-section of the lens530cut along an imaginary plane perpendicular to the extension directions of the two light sources520aand520band perpendicular to the substrate510includes a portion of an ellipse. Specifically, the cross-section of the lens includes a shape in which a plurality of portions of an ellipse overlap each other. In an embodiment, the cross-section of the lens includes a first elliptical portion R1defined in a shape of a portion the ellipse, and a second elliptical portion R2configured to overlap the first elliptical portion R1, and defined in a shape of a portion of the ellipse. The second light source520bis disposed at a focal point of the first elliptical portion R1. Preferably, the center of the second light source520bmay be disposed at the focal point of the first elliptical portion R1. Meanwhile, the first light source520amay be disposed at a focal point of the second elliptical portion R2. Preferably, the center of the first light source520amay be disposed at the focal point of the second elliptical portion R2. Here, a focal point of the elliptical portion denotes either one of two focal points included in a virtual ellipse when the virtual ellipse including an edge of the elliptical portion is drawn. That is, even when the elliptical portion is not a perfect ellipse, a focus of the elliptical portion may exist. Meanwhile, a major axis, a minor axis, and a focal point of the elliptical portion to be described below are all based on a virtual ellipse including an edge of the elliptical portion. An angle defined by a major axis of each of the first and second elliptical portions R1and R2and an imaginary axis perpendicular to the substrate510is a half of a beam angle of either one of the first and second light sources520aand520b. Here, the beam angle denotes a value twice the angle until an output of the light source becomes 50% of the peak value (in a direction of a central axis of the light source). A major axis of each of the first and second elliptical portions R1and R2may be disposed in a direction in which the output of the first and second light sources520aand520bbecomes 50% of the peak value. For example, an angle defined by a major axis of each of the first and second elliptical portions R1and R2and an imaginary axis perpendicular to the substrate may be 50 to 60 degrees. However, the angle defined by a major axis of each of the first and second elliptical portions R1and R2and an imaginary axis perpendicular to the substrate may vary depending on a refractive index of a material constituting the lens530. In an embodiment, the lens may be made of PMMA. In an embodiment, the first and second elliptical portions R1and R2are preferably disposed in a shape as shown inFIG.13. Specifically, inFIG.13, a is a length of a major axis of each of the first and second elliptical portions R1and R2, and b is a length of a minor axis of each of the first and second elliptical portions R1and R2. When the first and second elliptical portions R1and R2are disposed as described above, light emitted from the first light source520aand incident to a first point P1where a major axis of the second elliptical portion R2meets an edge of the second elliptical portion R2is emitted in a direction perpendicular to the substrate520. Meanwhile, according to the present disclosure, an amount of light emitted to the outside through the first point P1is similar to that emitted to the outside through a seventh point P7. Here, the seventh point P7is a point where a major axis of the second elliptical portion R2meets to an edge of the second elliptical portion R2. When the amount of light emitted to the first point P1and the amount of light emitted to the seventh point P7are similar to each other, a light pattern similar to that when the first light source520ais turned on and when the second light source520bis turned on may be implemented. To this end, the lens530further includes a fixing portion531extending from each of the first and second elliptical portions R1and R2to be in contact with the substrate. The fixing portion531supports the first and second elliptical portions R1and R2, fixes the first and second elliptical portions R1and R2onto the substrate510, as well as reflects light traveling to a side surface of the light source. For example, while the first light source520ais turned on, a fixing portion disposed adjacent to the first light source520atotally reflects light traveling to a side surface of the first light source520a. To this end, an angle between a tangent line in contact with the fourth point P4and the substrate510is preferably smaller than a total reflection critical angle. For example, when the lens530is made of PMMA, the angle between the tangent line and the substrate is preferably 50 degrees or less. A portion of light reflected from the fixing portion531adjacent to the first light source520atravels toward the first point P1to increase an amount of light emitted to the outside through the first point P1. Meanwhile, in order to minimize total reflection at the first point P1and the seventh point P7, an inclination at the two points is preferably implemented to be less than or equal to the total reflection critical angle. Meanwhile, an air gap may exist between the lens and the first and second light sources520aand520b. In this case, reflection occurring at an interface between the air gap and the lens530is preferably minimized. For example, reflectance at second and third points P2and P3is preferably minimized. Meanwhile, an inclination at a fifth point P5included in the fixing portion is preferably defined such that light emitted to the outside through the fifth point P5is preferably emitted in a direction perpendicular to the substrate. In addition, a curvature of the ellipse is preferably maintained at a sixth point P6to induce total reflection. Meanwhile, an inclination at an eighth point P8is preferably defined to emit light incident on the eighth point P8to the outside as it is. Meanwhile, in order to increase an amount of light emitted to a central portion of the lens530, the present disclosure may further include a protruding portion protruding in a direction toward which one surface of the substrate510faces between the first and second elliptical portions R1and R2. The protruding portion532is disposed such that light emitted to the outside through the protrusion532is emitted in a direction perpendicular to the substrate. A vertical distance between each of ninth and tenth points P9and P10defined on the protruding portion532and the substrate is preferably greater than a vertical distance between each of the first and seventh points P1and P7and the substrate. As described above, the lens530according to the present disclosure allows the same light pattern to be formed even when either one of the first and second light sources520aand520bis turned on. Specifically, referring toFIG.14, when the first light source520ais turned on, it can be seen that light having a similar brightness is emitted from the first elliptical portion R1and the second elliptical portion R2. Accordingly, even when the second light source520bis turned on, a light pattern similar to that ofFIG.14is generated. As described above, according to the present disclosure, when light sources spaced apart from each other are respectively turned on, the same light pattern may be implemented. It is obvious to those skilled in the art that the present disclosure can be embodied in other specific forms without departing from the concept and essential characteristics thereof. In addition, the above detailed description should not be construed as restrictive in all aspects and should be considered as illustrative. The scope of the invention should be determined by reasonable interpretation of the appended claims and all changes that come within the equivalent scope of the invention are included in the scope of the invention. | 21,019 |
11859787 | DETAILED DESCRIPTION It should be noted herein that for clarity of description, spatially relative terms such as “top,” “bottom,” “upper,” “lower,” “on,” “above,” “over,” “downwardly,” “upwardly” and the like may be used throughout the disclosure while making reference to the features as illustrated in the drawings. The features may be oriented differently (e.g., rotated 90 degrees or at other orientations) and the spatially relative terms used herein may be interpreted accordingly. Referring toFIGS.3to5, an embodiment of an adaptive headlamp device2according to the disclosure is adapted to be mounted to a motorcycle (not shown), and the motorcycle may be provided with an adaptive headlamp set that includes a plurality of adaptive headlamp devices2. Since the structure of each of the adaptive headlamp devices2in the adaptive headlamp set is the same, and since each of the adaptive headlamp devices2is only different in its angle of inclination relative to the motorcycle for illuminating in different directions, only the topmost adaptive headlamp device2will hereafter be elaborated. Referring toFIGS.6to9, the adaptive headlamp device2includes a light emitting unit21, and a lens22that is located in front of the light emitting unit21. The adaptive headlamp device2may further include a mounting unit27through which the adaptive headlamp device2is mounted to the motorcycle. Since the structure of the mounting unit27is widely-understood by those skilled in the art and does not fall within the scope of the disclosure, a detailed description thereof is omitted, and illustration thereof is omitted inFIGS.7to9. The light emitting unit21includes an LED chip, and a light emitting source211that is capable of emitting light rays forwardly toward the lens22. Since generating light rays via the LED chip is widely-understood by those skilled in the art, a detailed description of the light emitting unit21is omitted. The lens22has a central axis (A1) that extends in a direction perpendicular to a radial direction (D1) (seeFIGS.8and9) of the lens22, and a front lens portion23and a rear lens portion24that are integrally connected in a front-rear direction. The front lens portion23is substantially configured to be disc-shaped, and has a light-emergent surface231that is located at a front end thereof and that is configured to be planar. The rear lens portion24has a rear end240, a light-incident surface25, and a light-reflecting surface26. The rear end240defines a light-incident opening251. The light-incident surface25is recessed forwardly from the rear end240, and defines a light-incident space252that faces the light emitting unit21and that communicates with the light-incident opening251such that the light rays emitted by the light emitting unit21enter the light-incident space252through the light-incident opening251. The light-reflecting surface26extends forwardly from the rear end240to the front lens portion23, and surrounds the light-incident surface25about the central axis (A1). The light-incident surface25has a main surface portion253that is spaced apart from and located in front of the light-incident opening251, and an annular surface portion254that interconnects a periphery of the light-incident opening251and a periphery of the main surface portion253. The main surface portion253is configured to be a curved surface of a plano-convex lens that has a focal point coinciding with the light emitting source211of the light emitting unit21. As a result, the light rays emitted by the light emitting unit21will become parallel to each other after being refracted by the main surface portion253. The annular surface portion254surrounds the light-incident opening251, and cooperates with the main surface portion253to define the light-incident space252. When the light rays emitted by the light emitting surface2encounter the light-reflecting surface26, the light rays reflect off and travel to the light-emergent surface231. The light-reflecting surface26includes a first surface portion3and a second surface portion4that extend forwardly from the rear end240and that are respectively located at upper and lower sides of the light-incident surface25, a third surface portion5and a fourth surface portion6that extend forwardly from the rear end240and that are respectively located at left and right sides of the light-incident surface25, and a plurality of interconnecting surface portions7that are separated from each other. Each of the interconnecting surface portions7interconnects two adjacent one of the first, second, third, and fourth surface portions3,4,5,6. Each of the first, second, third, and fourth surface portions3,4,5,6is unsmooth. Referring toFIGS.7to9again, the first surface portion3includes a left surface section31and a right surface section32that are arranged in a left-right direction, a partition33that is between the left and right surface sections31,32, a left interconnecting surface section34that is located at a leftmost side of the left surface section31opposite to the partition33and that interconnects the left surface section31and the interconnecting surface portion7adjacent thereto, and a right interconnecting surface section35that is located at a rightmost side of the right surface section32opposite to the partition33and that interconnects the right surface section32and the interconnecting surface portion7adjacent thereto. Some of the light rays that are emitted by the light emitting unit21and that travel through the annular surface portion254of the light-incident surface encounter the partition33of the first surface portion3of the light-reflecting surface26, and are defined as first light rays (L1) (seeFIG.8). The partition33has a front end point331that is connected to the front lens portion23, and a rear end point332that is connected to the rear end240. A junction of the left interconnecting surface section34and the left surface portion31is at an angle so that the left surface portion31is offset from the interconnecting surface portion7adjacent thereto (seeFIG.6). A junction of the right interconnecting surface section35and the right surface portion32is at an angle so that the right surface portion32is offset from the interconnecting surface portion7adjacent thereto (seeFIG.6). The second surface portion4includes a left surface section41and a right surface section42that are arranged in the left-right direction, a partition43that is between the left and right surface sections41,42, a left interconnecting surface section44that is located at a leftmost side of the left surface section41opposite to the partition43and that interconnects the left surface section41and the interconnecting surface portion7adjacent thereto, and a right interconnecting surface section45that is located at a rightmost side of the right surface section42opposite to the partition43and that interconnects the right surface section42and the interconnecting surface portion7adjacent thereto. Some of the light rays that are emitted by the light emitting unit21and that travel through the annular surface portion254of the light-incident surface encounter the partition43of the second surface portion4of the light-reflecting surface26, and are defined as second light rays (L2) (seeFIG.8). A junction of the left interconnecting surface section44and the left surface section41is at an angle so that the left surface section41is offset from the interconnecting surface portion7adjacent thereto. A junction of the right interconnecting surface section45and the right surface section42is at an angle so that the left surface section42is offset from the interconnecting surface portion7adjacent thereto. Since the offset structures among the first, second, third, fourth, and interconnecting surface portions3,4,5,6,7are similar, only the offset structures among the first surface portion3and the adjacent interconnecting surface portions7are clearly shown in the Figs. The third surface portion5includes an upper section51and a lower section52that are arranged in an up-down direction, a partition53that is between the upper and lower sections51,52, an upper interconnecting surface section54that is located at a topmost side of the upper surface section51opposite to the partition53and that interconnects the upper surface section51and the interconnecting surface portion7adjacent thereto, and a lower interconnecting surface section55that is located at a bottommost side of the lower surface section52opposite to the partition53and that interconnects the lower surface section52and the interconnecting surface portion7adjacent thereto. Some of the light rays that are emitted by the light emitting unit21and that travel through the annular surface portion254of the light-incident surface encounter the partition53of the third surface portion5of the light-reflecting surface26, and are defined as third light rays (L3) (seeFIG.9). The partition53has a front end point531and a rear end point532. A junction of the upper interconnecting surface section54and the upper surface section51is at an angle so that the upper surface section51is offset from the interconnecting surface portion7adjacent thereto. A junction of the lower interconnecting surface section and the lower surface section52is at an angle so that the lower surface section52is offset from the interconnecting surface portion7adjacent thereto. The fourth surface portion6includes an upper surface section61and a lower surface section62that are arranged in the up-down direction, a partition63that is between the upper and lower surface sections61,62, an upper interconnecting surface section64that is located at a topmost side of the upper surface section61opposite to the partition63and that interconnects the upper surface section61and the interconnecting surface portion7adjacent thereto, and a lower interconnecting surface section65that is located at a bottommost side of the lower surface section62opposite to the partition63and that interconnects the lower surface section62and the interconnecting surface portion7adjacent thereto. Some of the light rays that are emitted by the light emitting unit21and that travel through the annular surface portion254of the light-incident surface encounter the partition63of the fourth surface portion6of the light-reflecting surface26, and are defined as fourth light rays (L4). A junction of the upper interconnecting surface section64and the upper surface section61is at an angle so that the upper surface section61is offset from the interconnecting surface portion7adjacent thereto. A junction of the lower interconnecting surface section65and the lower surface section62is at an angle so that the lower surface section62is offset from the interconnecting surface portion7adjacent thereto. The partition33of the first surface portion3and the partition43of the second surface portion4cooperatively define a first imaginary plane (P1). The partition53of the third surface portion5and the partition63of the fourth surface portion6cooperatively define a second imaginary plane (P2). Line VIII-VIII and line IX-IX inFIG.7respectively lie on the first and second imaginary planes (P1, P2). As shown inFIG.8, the central axis (A1) lies on the second imaginary plane (P2). Referring toFIG.7again, the main surface portion253is asymmetrical with respect to the first imaginary plane (P1). The left surface section31and the right surface section32are asymmetrical with respect to the first imaginary plane (P1). The left surface section41and the right surface section42are asymmetrical with respect to the first imaginary plane (P1). The upper surface section51and the lower surface section52are asymmetrical with respect to the second imaginary plane (P2). The upper surface section61and the lower surface section62are asymmetrical with respect to the second imaginary plane (P2). The lens22defines an imaginary parabola (V11) that has an imaginary focal point (F11), an imaginary parabola (V12) that has an imaginary focal point (F12), an imaginary parabola (V13) that has an imaginary focal point (F13), and an imaginary parabola (V14) that has an imaginary focal point (F14). For clarity purposes, the imaginary parabola (V11), the imaginary parabola (V12), the imaginary parabola (V13), and the imaginary parabola (V14) will hereinafter be respectively referred to as the first imaginary parabola (V11), the second imaginary parabola (V12), the third imaginary parabola (V13), and the fourth imaginary parabola (V14), while the imaginary focal point (F11), the imaginary focal point (F12), the imaginary focal point (F13), and the imaginary focal point (F14) will hereinafter be respectively referred to as the first imaginary focal point (F11), the second imaginary focal point (F12), the third imaginary focal point (F13), and the fourth imaginary focal point (F14). The first imaginary parabola (V11) and the second imaginary parabola (V12) are respectively located at upper and lower sides of the central axis (A1), and the third imaginary parabola (V13) and the fourth imaginary parabola (V14) are respectively located at left and right sides of the central axis (A1). In this embodiment, the first imaginary parabola (V11), the second imaginary parabola (V12), the third imaginary parabola (V13), and the fourth imaginary parabola (V14) are rotationally symmetric with respect to the central axis (A1). The first imaginary parabola (V11), the second imaginary parabola (V12), the third imaginary parabola (V13), and the fourth imaginary parabola (V14) cooperatively define an ideal reflecting surface (V1) of the lens22that surrounds the central axis (A1) (i.e., the ideal reflecting surface (V1) is formed by rotating any one of the first imaginary parabola (V11), the second imaginary parabola (V12), the third imaginary parabola (V13), and the fourth imaginary parabola (V14) about the central axis (A1)). The first imaginary parabola (V11) and the second imaginary parabola (V12) are intersection curves of the ideal reflecting surface (V1) and the first imaginary plane (P1). The third imaginary parabola (V13) and the fourth imaginary parabola (V14) are intersection curves of the ideal reflecting surface (V1) and the second imaginary plane (P2). Some of the light rays emitted by the light emitting unit21that are refracted by the annular surface portion254will become parallel to the central axis (A1) after encountering and being refracted by the ideal reflecting surface (V1). The first imaginary focal point (F11) is spaced apart from the central axis (A1) in the radial direction (D1) of the lens22. The light emitting source211is located in front of the first imaginary focal point (F11). Extensions of the first light rays (L1) that are refracted by the annular surface portion254of the light-incident surface25intersect at the first imaginary focal point (F11). Therefore, the first light rays (L1) travel in a path similar to a path in which imaginary light rays that are emitted from the first imaginary focal point (F11) and that are reflected by the partition33travel. The second imaginary focal point (F12) is spaced apart from the central axis (A1) in the radial direction (D1) of the lens22. The light emitting source211is located in front of the second imaginary focal point (F12). Extensions of the second light rays (L2) that are refracted by the annular surface portion254of the light-incident surface25intersect at the second imaginary focal point (F12). Therefore, the second light rays (L2) travel in a path similar to a path in which imaginary light rays that are emitted from the second imaginary focal point (F12) and that are reflected by the partition43travel. The third imaginary focal point (F13) is spaced apart from the central axis (A1) in the radial direction (D1) of the lens22. The light emitting source211is located in front of the third imaginary focal point (F13). Extensions of the third light rays (L3) that are refracted by the annular surface portion254of the light-incident surface25intersect at the third imaginary focal point (F13). Therefore, the third light rays (L3) travel in a path similar to a path in which imaginary light rays that are emitted from the third imaginary focal point (F13) and that are reflected by the partition53travel. The fourth imaginary focal point (F14) is spaced apart from the central axis (A1) in the radial direction (D1) of the lens22. The light emitting source211is located in front of the fourth imaginary focal point (F14). Extensions of the fourth light rays (L4) that are refracted by the annular surface portion254of the light-incident surface25intersect at the fourth imaginary focal point (F14). Therefore, the fourth light rays (L4) travel in a path similar to a path in which imaginary light rays that are emitted from the fourth imaginary focal point (F14) and that are reflected by the partition63travel. The front end point331of the partition33is located between the first imaginary parabola (V11) and the central axis (A1) in the radial direction (D1). The rear end point332of the partition33is located at one side of the first imaginary parabola (V11) opposite to the central axis (A1) in the radial direction (D1). That is to say, the first imaginary parabola (V11) has an imaginary rear end point that is located between the rear end point332and the central axis (A1) in the radial direction (D1). The second imaginary parabola (V12) is located between the partition43and the central axis (A1) in the radial direction (D1). The front end point531of the partition53is located between the third imaginary parabola (V13) and the central axis (A1) in the radial direction (D1). The rear end point532of the partition53is located at one side of the third imaginary parabola (V13) opposite to the central axis (A1) in the radial direction (D1). That is to say, the third imaginary parabola (V13) has an imaginary rear end point that is located between the rear end point532and the central axis (A1) in the radial direction (D1). The fourth imaginary parabola (V14) is located between the partition63and the central axis (A1) in the radial direction (D1). FIGS.10to19are contour plots that illustrate different light distributions formed by the light rays which exit the embodiment and which are projected to a vertical surface under different circumstances. The vertical surface is kept at a distance of 10 meters in front of the embodiment. Referring toFIG.10, in cooperation withFIGS.8and9, some of the light rays that are emitted by the light emitting unit21travel through the main surface portion253and exit the light-emergent surface231to form a light distribution pattern901that is configured to be substantially rectangular. Another distribution pattern that is located higher than the light distribution pattern901inFIG.10is formed by stray light rays, and thus a detailed description thereof will be omitted. Referring toFIG.11, in cooperation withFIGS.8and9, some of the light rays that are emitted by the light emitting unit21and that travel through the annular surface portion254encounter the first surface portion3, reflect off the first surface portion3, and exit the light-emergent surface231to form a light distribution pattern902. Another distribution pattern that is located higher than the light distribution pattern902inFIG.11is formed by stray light rays, and thus a detailed description thereof will be omitted. Referring toFIG.12, in cooperation withFIGS.8and9, some of the light rays that are emitted by the light emitting unit21and that travel through the annular surface portion254encounter the second surface portion4, reflect off the second surface portion4, and exit the light-emergent surface231to form a light distribution pattern903. Another distribution pattern that is located higher than the light distribution pattern903inFIG.12is formed by stray light rays, and thus a detailed description thereof will be omitted. Referring toFIG.13, in cooperation withFIGS.8and9, some of the light rays that are emitted by the light emitting unit21and that travel through the annular surface portion254encounter the third surface portion5, reflect off the third surface portion5, and exit the light-emergent surface231to form a light distribution pattern904. Another distribution pattern that is located higher than the light distribution pattern904inFIG.13is formed by stray light rays, and thus a detailed description thereof will be omitted. Referring toFIG.14, in cooperation withFIGS.8and9, some of the light rays that are emitted by the light emitting unit21and that travel through the annular surface portion254encounter the fourth surface portion6, reflect off the fourth surface portion6, and exit the light-emergent surface231to form a light distribution pattern905. Another distribution pattern that is higher than the light distribution pattern905inFIG.14is formed by stray light rays, and thus a detailed description thereof will be omitted. Referring toFIG.15, in cooperation withFIGS.7to9, some of the light rays that are emitted by the light emitting unit21and that travel through the annular surface portion254encounter the interconnecting surface portion7which interconnects the first and third surface portions3,5, reflect off the interconnecting surface portion7which interconnects the first and third surface portions3,5, and exit the light-emergent surface231to form a light distribution pattern906. Another distribution pattern that is located higher than the light distribution pattern906inFIG.15is formed by stray light rays, and thus a detailed description thereof will be omitted. Referring toFIG.16, in cooperation withFIGS.7to9, some of the light rays that are emitted by the light emitting unit21and that travel through the annular surface portion254encounter the interconnecting surface portion7which interconnects the second and fourth surface portions4,6, reflect off the interconnecting surface portion7which interconnects the second and fourth surface portions4,6, and exit the light-emergent surface231to form a light distribution pattern907. Another distribution pattern that is located higher than the light distribution pattern907inFIG.16is formed by stray light rays, and thus a detailed description thereof will be omitted. Referring toFIG.17, in cooperation withFIGS.7to9, some of the light rays that are emitted by the light emitting unit21and that travel through the annular surface portion254encounter the interconnecting surface portion7which interconnects the first and fourth surface portions3,6, reflect off the interconnecting surface portion7which interconnects the first and fourth surface portions3,6, and exit the light-emergent surface231to form a light distribution pattern908. Another distribution pattern that is located higher than the light distribution pattern908inFIG.17is formed by stray light rays, and thus a detailed description thereof will be omitted. Referring toFIG.18, in cooperation withFIGS.7to9, some of the light rays that are emitted by the light emitting unit21and that travel through the annular surface portion254encounter the interconnecting surface portion7which interconnects the second and third surface portions4,5, reflect off the interconnecting surface portion7which interconnects the second and third surface portions4,5, and exit the light-emergent surface231to form a light distribution pattern909. Another distribution pattern that is located higher than the light distribution pattern909inFIG.18is formed by stray light rays, and thus a detailed description thereof will be omitted. Each of the light distribution patterns906,907,908,909is configured to be substantially triangular. The light distribution patterns906,907,908,909are different from each other. FIG.19is a contour plot that is formed by overlapping the light distributions inFIGS.10to18. All of the light rays that are emitted by the light emitting unit21exit the light-emergent surface231to form a light distribution pattern900as shown inFIG.19. Therefore, when the motorcycle is inclined, the adaptive headlamp device2may light up a dark area (not shown) that a main headlamp device (not shown) of the motorcycle cannot illuminate due to inclination of the motorcycle. In summary, by virtue of the light-incident surface25defining the light-incident space252that faces the light-emitting unit21, and by virtue of the light-reflecting surface26reflecting the light rays, the light rays emitted by the light-emitting unit21may be utilized. Via the structure of the light-reflecting surface26, the adaptive headlamp device2provides the light distribution pattern900that is a combination of the light distribution patterns901to909. Moreover, the asymmetrical configuration of each of the main surface portion253, the first, second, third, and fourth surface portions3,4,5,6has not been adopted in conventional adaptive headlamp devices, and therefore the purpose of the disclosure is achieved. In the description above, for the purposes of explanation, numerous specific details have been set forth in order to provide a thorough understanding of the embodiment(s). It will be apparent, however, to one skilled in the art, that one or more other embodiments may be practiced without some of these specific details. It should also be appreciated that reference throughout this specification to “one embodiment,” “an embodiment,” an embodiment with an indication of an ordinal number and so forth means that a particular feature, structure, or characteristic may be included in the practice of the disclosure. It should be further appreciated that in the description, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of various inventive aspects; such does not mean that every one of these features needs to be practiced with the presence of all the other features. In other words, in any described embodiment, when implementation of one or more features or specific details does not affect implementation of another one or more features or specific details, said one or more features may be singled out and practiced alone without said another one or more features or specific details. It should be further noted that one or more features or specific details from one embodiment may be practiced together with one or more features or specific details from another embodiment, where appropriate, in the practice of the disclosure. While the disclosure has been described in connection with what is(are) considered the exemplary embodiment(s), it is understood that this disclosure is not limited to the disclosed embodiment(s) but is intended to cover various arrangements included within the spirit and scope of the broadest interpretation so as to encompass all such modifications and equivalent arrangements. | 26,935 |
11859788 | MODE FOR CARRYING OUT THE INVENTION FIG.1is a diagram showing a configuration of a vehicle lighting system according to one embodiment. The vehicle lighting system shown inFIG.1is configured to include a pair of lamp units (vehicle headlamps)100aand100b, a camera101, and a controller102. The vehicle headlight system detects the position of a front vehicle, face of a pedestrian, etc. existing around an own vehicle based on the image taken by the camera101, sets a certain region including the position of the front vehicle and the like as a non-irradiated region (dimming region), and sets the other region as an irradiated region and performs selective light irradiation. The lamp units100aand100bare arranged at predetermined positions on the left and right sides of the front of the vehicle, and form irradiation light for illuminating the front of the vehicle. In the vehicle lighting system of the present embodiment, the irradiation lights of the lamp units100aand100bare superimposed in front of the vehicle to form an irradiation light. The camera101captures the front of the own vehicle and outputs the image (information) thereof, and is arranged at a predetermined position in the vehicle (for example, the upper part inside the windshield). Here, if the vehicle is equipped with a camera for other purposes (for example, an automatic braking system), the camera may be shared. The controller102is for controlling the operation of each lamp unit100aand100b. In detail, the controller102detects the position of the vehicle in front or the like by performing image processing based on the image obtained by the camera101, sets a light distribution pattern in which the detected position of the vehicle in front, etc. is set as a non-irradiated region and the other region is set as an irradiated region, generates a control signal in order to form an image corresponding to the light distribution pattern, and supplies the control signal to the drive unit9(refer toFIG.2to be described later) provided in each of the lamp units100a,100b. The controller102is realized by executing a predetermined operation program in a computer system having, for example, a CPU, a ROM, a RAM, or the like. Here, the controller102and the drive unit9correspond to the “control unit”. FIG.2is a diagram showing the configuration of the lamp unit. Here, since the lamp unit100aand100bhave the same configuration, only the lamp unit100awill be described here. The lamp unit100ais configured to include a light source1, a concave reflector2, a polarized beam splitter3, a reflector4, a ½ wave plate (λ/2 plate)5, a pair of polarizers6a,6b, a liquid crystal element7, a projection lens8, and a drive unit9. The light source1is configured to include, for example, a white LED configured by combining a light emitting diode (LED) that emits blue light with a yellow phosphor. The light source1includes, for example, a plurality of white LEDs arranged in a matrix or a line. Here, as the light source1, other than LEDs, lasers, or light sources commonly used in a lamp unit for vehicles such as light bulbs and discharge lamps can be used. The light on-off state of the light source1is controlled by the controller102. The light emitted from the light source1is made incident to the liquid crystal element (liquid crystal panel)7via an optical system which includes the concave reflector2, the polarized beam splitter3, and the reflector4. Here, another optical system (for example, a lens, a reflecting mirror, or a combination thereof) may exist on the path from the light source1to the liquid crystal element7. The concave reflector (reflecting member)2reflects the light incident from the light source1and makes it incident to the polarized beam splitter3. The polarized beam splitter (optical branching element) separates the incident light reflected by the concave reflector2into two polarized lights. One of the polarized light separated by the polarized beam splitter3is reflected by the polarized beam splitter3and is made incident to the polarizer6a. Further, the other polarized light separated by the polarized beam splitter3passes through the polarized beam splitter3and is made incident to the reflector4. The polarized beam splitter3is arranged at an angle of about 45° with respect to the traveling direction of the light from the concave reflector2. In order to carry out polarization separation, it is desirable that the polarization direction of the polarized beam splitter3is set to either a vertical direction or a horizontal direction. In this case, the polarization direction of the light incident to the liquid crystal element7becomes either a vertical direction or a horizontal direction. The reflector (reflecting member)4reflects the light transmitted through the polarized beam splitter3(polarized light) and causes it to enter the ½ wave plate5. The ½ wave plate5rotates the polarization direction of the incident light (polarized light) reflected by the reflector4by 90°, and is made incident to the polarizer6a. The pair of polarizers6aand6bhave their polarization axes substantially orthogonal to each other, for example, and are arranged so as to face each other with the liquid crystal element7interposed therebetween. In the present embodiment, a normally black mode, which is an operation mode in which light is shielded (transmittance becomes extremely low) when no voltage is applied to the liquid crystal layer, is assumed. As each of the polarizers6aand6b, an absorption-type polarizer made of a general organic material (iodine-based or dye-based) can be used, for example. Further, when heat resistance is desired, it is also preferable to use a wire grid type polarizer. A wire grid type polarizer is a polarizer made by arranging ultrafine wires made of a metal such as aluminum. Further, the absorption-type polarizer and the wire grid type polarizer may be stacked and used. The liquid crystal element7has, for example, a plurality of pixel regions (optical modulation regions) which can be individually controlled, and the transmittance of each pixel region is variably set in accordance with the magnitude of the voltage applied to the liquid crystal layer supplied by the drive unit9. By irradiating the liquid crystal element7with light, an image having brightness corresponding to the above-described irradiated region and non-irradiated region is formed. In the present embodiment, two polarized lights which are the polarized light reflected by the polarized beam splitter3(to be incident) and the polarized light transmitted through the polarized beam splitter3and reflected by the reflector4(to be incident) are made incident to the liquid crystal element7to be used, thereby, the light utilization efficiency is high. The above-described liquid crystal element7includes, for example, a liquid crystal layer having a substantially vertical alignment, and is arranged between a pair of polarizers6aand6bwhich are in a crossed Nicol arrangement. And when no voltage (or a voltage below a threshold value) is applied to the liquid crystal layer, the light transmittance becomes extremely low (light-shielding state), and when a voltage is applied to the liquid crystal layer, the light transmittance becomes relatively high (light-transmitting state). The projection lens8spreads an image (an image having brightness corresponding to the irradiated region and the non-irradiated region) formed by the light transmitted through the liquid crystal element7so as to suit headlight light distribution, and projects it to the front of the own vehicle, and an appropriately designed lens is used. In this embodiment, a reverse projection type projector lens is used. The drive unit9individually controls the alignment state of the liquid crystal layer in each pixel region of the liquid crystal element7by supplying a drive voltage to the liquid crystal element7based on a control signal supplied from the controller102. FIG.3is a cross-sectional view for explaining the configuration of the liquid crystal element. The liquid crystal element7shown inFIG.3is configured to include a first substrate21and a second substrate22arranged to face each other, a plurality of pixel electrodes23provided on the first substrate21, a common electrode24provided on the second substrate22, a first alignment film25provided on the first substrate21, a second alignment film26provided on the second substrate22, and a liquid crystal layer27arranged between the first substrate21and the second substrate22. The first substrate21and the second substrate22are rectangular substrates in a plan view, respectively, and are arranged so as to face each other. As each substrate, for example, a transparent substrate such as a glass substrate or a plastic substrate can be used. A plurality of spherical spacers made of resin are dispersedly arranged between the first substrate21and the second substrate22, for example, and the spacers keep the substrate gap at a desired size (for example, about a few μm). Here, columnar spacers made of resin may be used instead of the spherical spacers. Each pixel electrode23is provided on one surface side of the first substrate21. Each pixel electrode23is configured by appropriately patterning a transparent conductive film such as indium tin oxide (ITO). A pixel region is defined in each of the overlapping regions of each pixel electrode23and the common electrode24. The common electrode24is provided on one surface side of the second substrate22. The common electrode24is provided so as to overlap each pixel electrode23in a plan view. The common electrode24is configured by appropriately patterning a transparent conductive film such as indium tin oxide (ITO). The first alignment film25is provided so as to cover each pixel electrode23on one surface side of the first substrate21. Further, the second alignment film26is provided so as to cover the common electrode24on one surface side of the second substrate22. As each alignment film, a vertical alignment film which regulates the alignment state of the liquid crystal layer27to a vertical alignment is used. Each alignment film is subjected to a uniaxial aligning treatment such as a rubbing treatment, and has a uniaxial alignment regulating force that regulates the alignment of the liquid crystal molecules of the liquid crystal layer27in that direction. The alignment treatment direction for each alignment film is set to be staggered (anti-parallel), for example. The liquid crystal layer27is interposed between the first substrate21and the second substrate22. In the present embodiment, the liquid crystal layer27is configured by using a nematic liquid crystal material having a negative dielectric anisotropy A and having fluidity. The liquid crystal layer27of the present embodiment is set so that the alignment direction of the liquid crystal molecules when no voltage is applied is substantially vertically aligned (for example, a pretilt angle of about 89.7°). FIG.4is a diagram for explaining the relationship between the alignment treatment direction, the viewing direction, and the reverse viewing direction. Here, there is schematically shown a state in which each of the alignment treatment directions of the first alignment film25and the second alignment film26shown inFIG.3is viewed from the second substrate22side. The alignment treatment direction RB1of the first alignment film25is in the direction toward the upper left in the figure, and the alignment treatment direction RB2of the second alignment film26is in the direction toward the lower right in the figure. That is, the alignment treatment directions RB1and RB2are arranged alternately (anti-parallel). In this case, the viewing direction (best viewing direction) becomes the same as the alignment treatment direction RB1in a plan view, and the reverse viewing direction becomes the opposite direction to the alignment treatment direction RB1in a plan view. FIG.5is a diagram for explaining the relationship between the viewing direction, the reverse viewing direction, and the alignment direction (director direction) of the liquid crystal molecules of the liquid crystal layer. Here, there is schematically shown a liquid crystal molecule27aat the substantially center in the layer thickness direction of the liquid crystal layer27provided between the first substrate21and the second substrate22. As shown in the figure, the alignment treatment direction RB1is directed to the left in the figure, and the alignment treatment direction RB2is directed to the right in the figure. When a voltage which corresponds to intermediate tone is applied to the liquid crystal layer27, in relation to the alignment treatment directions RB1and RB2, the liquid crystal molecule27aat the substantially center in the layer thickness direction of the liquid crystal layer27is aligned to rise on the left side in the figure. At this time, the viewing direction becomes opposite to the alignment direction of the liquid crystal molecule27a, and the reverse viewing direction becomes the same as the viewing direction. Here, the phrase “a voltage which corresponds to intermediate tone” is a voltage between the threshold voltage and the saturation voltage (voltage at which optical changes such as transmittance hardly occurs) of the liquid crystal layer27. FIG.6is a diagram showing an example of transmittance difference between the viewing direction and the reverse viewing direction. Here, there is shown transmittance change in each of the viewing direction and the reverse viewing direction with respect to the voltage applied to the liquid crystal layer27in the liquid crystal element7. In this example, the directions of ±20° with respect to the polar angle direction are defined as the viewing direction and the reverse viewing direction. As shown in the figure, in the liquid crystal element7, when the same voltage is applied, there is a difference between the transmittance in the viewing direction and the transmittance in the reverse viewing direction. For example, when comparing a case where the voltage is 4 V, the transmittance is about 32% in the viewing direction, whereas the transmittance is about 10% in the reverse viewing direction, and there is a difference of more than 3 times in the transmittance. The transmittance tends to be higher in the viewing direction up to a voltage of about 8 V, and the transmittance is almost the same at a voltage of 10 V. That is, especially when a voltage which corresponds to intermediate tone is applied, the irradiation light formed by the lamp units100aand100bcauses uneven brightness corresponding to the difference between the viewing direction and the reverse viewing direction. Therefore, in the present embodiment, in each of the liquid crystal elements7of the pair of lamp units100aand100b, the difference in the transmittance of the irradiation light is suppressed by means such as providing a difference in the drive voltage for each region where the light is incident, thereby reducing uneven brightness in each irradiation light of these lamp units100aand100b. FIG.7Ais a diagram schematically showing a plan view of the light incident surface of the liquid crystal element.FIG.7Bis a diagram schematically showing a top view of the light incident surface of the liquid crystal element shown inFIG.7A. Here, the left-right direction in each figure corresponds to the depth direction of the liquid crystal element7shown inFIG.2. In the vehicle lighting system of the present embodiment, a wide-angle optical system is used in order to increase the brightness (luminous intensity) of the irradiation light, and for example, light is made incident to the light incident surface of the liquid crystal element7in a wide range of 20° to 40° in the polar angle direction with reference to the normal direction of the light incident surface. Thus, as the average traveling direction of the incident light is schematically shown in each ofFIGS.7A and7B, the angle of the incident light with respect to the liquid crystal element7differs depending on the position within the light incident surface of the liquid crystal element, and uneven brightness may occur due to the difference. Therefore, in the vehicle lighting system of the present embodiment, the incident surface of the liquid crystal element7is divided into a plurality of regions, and different light control is carried out for each region. Since the angle of the light incident to the light incident surface of the liquid crystal element7is different for each region R1, R2, R3, the light transmittance differs in each region R1, R2, R3. Specifically, light is evenly incident to the left and right sides of the region R2, whereas light is incident mainly from the right direction on the region R1and light is incident mainly from the left direction on the region R3. That is, it can be said that a relatively large amount of light is made incident to the region R3from the direction along the viewing direction of the liquid crystal element7, and a relatively large amount of light is made incident to the region R1from the direction not along the viewing direction of the liquid crystal element7. Here, the phrase “direction along the viewing direction” is not necessarily limited to being parallel to the viewing direction, but includes a direction which is roughly parallel thereto. Whereas, for example, by setting the voltage supplied from the drive unit9to a different magnitude for each region R1, R2, R3, it is possible to reduce the difference in the transmittance of the lights transmitted through each region R1, R2, R3. Here, the region R3corresponds to “a first region” in the present invention, the region R1corresponds to “a second region” in the present invention, and the region R2corresponds to “a third region” in the present invention. FIG.8Ais a diagram showing an example of the relationship between the voltage from the drive unit and the transmittance of each region. Here, as an example, there is shown the relationship between the voltage and the transmittance of each region in a liquid crystal element that is produced having a layer thickness (cell thickness) of the liquid crystal layer27of 4 μm and uses a liquid crystal material having a dielectric anisotropy of about 0.13. In this liquid crystal element, the region R1corresponds to the reverse viewing direction, the region R2corresponds to the normal direction, and the region R3corresponds to the viewing direction. Therefore, for example, when a voltage with the same magnitude as a voltage corresponding to a particular gradation is applied to each pixel region of the liquid crystal layer27, the general tendency is that the transmittance of the region R3corresponding to the viewing direction becomes relatively high, and the transmittance of the region R1corresponding to the reverse viewing direction becomes relatively low. On the contrary, when a voltage applied to the region R3corresponding to the viewing direction is set relatively low while a voltage applied to the region R1corresponding to the reverse viewing direction is set relatively high and a voltage applied to the region R2is set between these two voltages, the difference in transmittance between the regions R1, R2, and R3can be reduced. As shown inFIG.8A, for example, in a case where gradation level is “3”, by applying a voltage of 3.6 V to the region R1, a voltage of 3.4 V to the region2, and a voltage of 2.8 V to the region R3, the difference in transmittance between each region can be made extremely small. The same applies to other gradations. The numerical values given here is merely an example, and since specific numerical values differ depending on the characteristics of the liquid crystal element7and the characteristics of the optical system, etc., suitable values may be determined by experiments or simulations. FIG.8Bis a diagram showing the transmittance at each gradation level in each region shown inFIG.8A. As shown in the figure, it can be seen that the difference in transmittance can be extremely reduced at every gradation level by setting the voltage for each region in accordance with the viewing direction. Thereby, the brightness of the light irradiated from each lamp unit100aand100bcan be made uniform. As a different method from the above, for example, by setting the brightness of the light emitted from the light source1to be different for each region R1, R2, R3, the difference in the brightness of the light transmitted through each region R1, R2, R3can be reduced. Hereinafter, this method will be described. FIG.9Ais a diagram schematically showing the relationship between a light incident surface of the liquid crystal element, a light source, and an optical system. Similar toFIG.7Bdescribed above, a top view of the light incident surface of the liquid crystal element7is shown, and the left-right direction in the figure corresponds to the depth direction of the liquid crystal element7shown inFIG.2. Here, in order to make light incident to the light incident surface of the liquid crystal element7in a wide angle range of, for example, 20° to 40°, a light source1having a light emitting element unit1a(a first unit) and a light emitting element unit1b(a second unit), which are two independently controllable light emitting element units, is exemplified. Further, the lights emitted from the light emitting element units1aand1bof the light source1are made incident to the liquid crystal element7via an optical system including a concave reflector2, a polarized beam splitter3, a reflector4, and a ½ wave plate5. And it is assumed that the light emitted from the light emitting element unit1ais made incident mainly to the regions R1and R2, and the light emitted from the light emitting element unit1bis made incident mainly to the regions R2and R3. FIG.9Bis a diagram showing the difference in the brightness of the light emitted from each light emitting element unit. Here, the term “brightness” is luminance, for example. Further, it is assumed that, as the voltage associated with each gradation level, the voltage with the same magnitude is applied to each pixel region of the liquid crystal layer27. In this case, if the brightness of the lights emitted from each of the light emitting element units1aand1bare the same, the general tendency is that the light transmitted through the region R3which corresponds to the viewing direction becomes relatively bright, and the light transmitted through the region R1which corresponds to the reverse viewing direction becomes relatively dark. Whereas, by individually carrying out the gradation control of the drive voltage for each of the light emitting element units1aand1bby the controller102, the brightness of the light incident to each of the regions R1and R3can be made substantially uniform. In the illustrated example, by setting the brightness of the light emitted from the light emitting element unit1arelatively low and setting the brightness of the light emitted from the light emitting element unit1brelatively high, the difference in the light transmitted from the region R1and the region R3can be reduced, and the brightness of the light irradiated from the lamp units100aand100bcan be made uniform. Here, with regard to the brightness control of the light emitted from the light emitting element units1aand1b, instead of carrying out variable control of the drive voltage, of the plurality of light emitting elements included in each light emitting element unit1aand1b, the number of light emitting elements to be emitted may be set variably. For example, by carrying out a control to set the number of light emitting elements to be emitted to three for the light emitting element unit1a, and to set the number of light emitting elements to be emitted to four for the light emitting element unit1b, the brightness of the emitted lights can be variably controlled. FIG.10is a diagram for explaining the arrangement state of a pair of lamp units. Here, a front part of a vehicle200is schematically shown. In the front part of the vehicle200, a lamp unit100ais installed on the left side in the figure (the front right side of the vehicle200), and a lamp unit100bis installed on the right side in the figure (the front left side of the vehicle200). The lamp units100aand100bare arranged at positions 0.7 meters away from their respective intermediate position a. As shown in the figure, the lamp unit100ais installed so that the viewing direction S1is in the upper left 45° direction with respect to the vehicle width direction in the figure. Further, the lamp unit100bis installed so that the viewing direction S2is in the upper right 45° direction with respect to the vehicle width direction in the figure. In other words, each of the viewing directions S1and S2are arranged so as to extend outward in the vehicle width direction of the vehicle200. Here, note that each of the viewing directions S1and S2may be arranged so as to extend inward in the vehicle width direction of the vehicle200. The viewing directions S1and S2referred to here are directions that are viewed in a plan view from the second substrate22side of the liquid crystal element7(refer toFIG.4). In this way, the pair of lamp units100aand100bare arranged so that the viewing directions S1and S2have a line-symmetrical relationship with the intermediate position a interposed therebetween. As a result, since uneven brightness of the light irradiated from each of the lamp units100aand100bcan be offset, uneven brightness of the light emitted by superimposing each irradiation light can be further reduced. Here, as a way to arrange the viewing directions S1and S2of the lamp units100aand100bin line symmetry, for example, there is a way such that, when manufacturing each liquid crystal element7, the alignment treatment directions RB1and RB2are set in accordance with the respective viewing directions S1and S2. Further, there may also be a way such that, when manufacturing each liquid crystal element7, viewing from the second substrate22side, the viewing directions S1and S2are set so that they are aligned in the same direction, and the second substrate22side is set to face the light emitting side with respect to one liquid crystal element7, and the first substrate21side is set to face the light emitting side with respect to the other liquid crystal element7. Further, in the embodiment shown inFIG.10, the pair of lamp units100aand100bare arranged so that the viewing directions S1and S2have a line-symmetrical relationship with the intermediate position a interposed therebetween, but as illustrated inFIG.11, a similar outcome can be obtained when the viewing directions S1and S2are arranged so as to have a point-symmetrical relationship. In a modified example shown inFIG.11, in the vehicle200, the viewing direction S1of the lamp unit100ais set in the upper left direction, and the viewing direction S2of the lamp unit100bis set in the lower right direction. FIG.12is a diagram showing an example of the luminosity distribution of irradiation light formed by superimposing irradiation lights emitted from each lamp unit. The luminous intensity distribution displayed on a screen which is disposed 10 meters in front of the vehicle is illustrated in the figure, and the light irradiated from each of the lamp units100aand100bis formed by applying a voltage such that an intermediate tone of about ⅓ of the maximum luminous intensity is achieved. As shown in the illustrated example, by arranging the viewing directions S1and S2of the lamp units100aand100bso that they have a line-symmetrical relationship with the intermediate position a interposed therebetween, it can be seen that, in a wide range of about ±25° in the horizontal direction and about ±10° in the vertical direction, irradiation light having light intensity distribution with less uneven brightness is obtained. According to the above embodiments, it is possible to reduce uneven brightness of the light irradiated from the vehicle lighting system using a liquid crystal element. The present invention is not limited to the contents of the above-described embodiments, and can be variously modified and implemented within the scope of the gist of the present invention. For example, in the above-described embodiments, as an example of the liquid crystal element, the liquid crystal layer is set to be substantially vertically aligned, but the alignment mode of the liquid crystal layer is not limited thereto. Regardless of the alignment mode of the liquid crystal layer, the arrangement of a pair of lamp units may be set in accordance with the viewing direction and the reverse viewing direction. For example, as shown inFIG.13, in a case where the alignment treatment directions RB1and RB2which corresponds to the first alignment film25and the second alignment film26are orthogonal to each other, and the alignment mode of the liquid crystal layer27is set to a TN (twisted nematic) type, the alignment direction of the liquid crystal molecules27aat the substantially center in the layer thickness direction of the liquid crystal layer27becomes 45° with respect to the alignment treatment directions RB1and RB2in a plan view, as shown in the figure. In this case, since the viewing direction (best viewing direction) becomes the direction toward the lower right in the figure, and the reverse viewing direction becomes the direction toward the upper left in the figure, based on these, the arrangement of the pair of lamp units100aand100bmay be set in the same manner as in the above-described embodiments (refer toFIGS.10and11). Further, in the above-described embodiments, a lamp unit has been exemplified where it adopts a so-called recycled optical system in which all of the polarized lights separated by the polarized beam splitter are used, but the configuration of the lamp unit is not limited thereto. For example, as illustrated inFIG.14, a pair of lamp units100c,100dwith a relatively simple configuration where light from a light source1is directly incident to a liquid crystal element7arranged between a pair of polarizing6aand6b, and the transmitted light is collected and projected by a projection lens8, may be used. Further, in the above-described embodiments, cases where the present invention is applied to a vehicle headlight system which irradiates light to the front of the vehicle has been described, but present invention can also be applied to a system where light is irradiated to the periphery other than the front of the vehicle. DESCRIPTION OF REFERENCE NUMERALS 1: Light source1a,1b: Light emitting element unit (of light source)2: Concave reflector3: Polarized beam splitter4: Reflector5: ½ wave plate (λ/2 plate)6a,6b: Pair of polarizers7: Liquid crystal element8: Projection lens9: Drive unit21: First substrate22: Second substrate23: Pixel electrode24: Common electrode25: First alignment film26: Second alignment film27: Liquid crystal layer27a: Liquid crystal moleculeRB1, RB2: Alignment treatment directionS1, S2: Viewing direction100a,100b: Lamp unit (vehicle headlamp)101: Camera102: ControllerR1, R2, R3: Region | 31,224 |
11859789 | DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Please refer toFIGS.1to7for a preferable embodiment of the present invention. A vehicle roof rack1of the present invention includes a main body10and a light assembly20. The main body10includes a plurality of rod members11and a plurality of connecting portions12. The plurality of connecting portions12is detachably connected with the plurality of rod members11to form a frame13, and at least one of the plurality of rod members11includes at least one recession111disposed thereon. The light assembly20includes at least one light-emitting member21and at least one power supply unit22electrically connected with the at least one light-emitting member21. The at least one light-emitting member21is received within the at least one recession111, and light emitted from the at least one light-emitting member21is projected outward through an opening111aof the at least one recession111. Therefore, the vehicle roof rack1has a simple structure and provides lighting effect, preferable appearance and easy assembling. Each of the at least one recession111extends in a longitudinal direction of one of the plurality of rod members11and includes at least one end opening111bopen in an end of one of the plurality of rod members11. Each of the at least one power supply unit22is disposed within one of the plurality of connecting portions12, and each of the at least one light-emitting member21is electrically connected with one of the at least one power supply unit22through one of said end opening111b, which avoids wires to be exposed outward and is safe to use. In assembling, the at least one light-emitting member21may be inserted into the at least one recession111through one of said end opening111b. The opening111aof each of the at least one recession111is open outward in a direction lateral to the longitudinal direction of one of the plurality of rod members11, and a width of each of the at least one light-emitting member21is larger than a width of the opening111aof one of the at least one recession111so as to stably restrict the at least one light-emitting member21without adhesive or fasteners, which has a simple structure and is easy to assemble. In this embodiment, each of the at least one light-emitting member21includes a LED strip211and a basement212surrounded the LED strip211, and an outer contour of each of said basement212corresponds to a cross-sectional contour of one of the at least one recession111. The basement212is relatively rigid and prevents the LED strip211from bending arbitrary for easy assembling, and the basement212provides waterproof and protection effects. For example, each said basement212may include an aluminum base and a lampshade covered on the aluminum base, and the LED strip211is arranged between the aluminum base and the lampshade so as to provide uniform light and good heat dissipation. In other embodiments, each said LED strip may be directly attached to a portion of one of the plurality of rod members surrounded one of the at least one recession; the at least one light-emitting member may be other types of light sources. Two ends of each of the plurality of rod members11respectively have a first insertion portion112disposed thereon, and two ends of each of the plurality of connecting portions12respectively have a second insertion portion121connected with one of said first insertion portion112and a supporting portion122. Each of said supporting portion122is spaced apart from one of said second insertion portion121and abutted against an outer circumferential wall of one of the plurality of rod members11, which is easy to assemble. Said supporting portions122can avoid relative movements between the plurality of connecting portions12and the plurality of rod members11and disperse force therebetween. In this embodiment, each of the plurality of rod members11is an aluminum extruded member, and each of said first insertion portion112is an insertion groove integrally formed as a part of one of said aluminum extruded member so as to have a simple structure, lightweight and easy manufacturing. Each of the plurality of rod members11further includes a shoulder portion113located at an inner side of the frame13, and each of said supporting portion122is abutted against one of said shoulder portion113for good assembling stability. In other embodiments, the plurality of rod members may be made by other methods; each of said shoulder portion may be located at an outer side of the frame. Specifically, each of the plurality of connecting portions12includes an upper cover123and a lower cover124which are detachably assembled with each other. At least one of the upper cover123and the lower cover124has a notch124acommunicated with one of the at least one recession111, and the at least one notch124ais configured for a wire of the at least one light-emitting member21to be arranged therethrough. One of the upper cover123and the lower cover124of at least one of the plurality of connecting portions12includes a first receiving portion125receiving the at least one power supply unit22therewithin and a drawing member126. The first receiving portion125has at least one mouth125a, and the drawing member126openably closes the at least one mouth125a, which is convenient to assemble and disassemble the at least one power supply unit22for replacement or charging. Moreover, one of the upper cover123and the lower cover124has a plurality of first connecting holes123a, and the other of the upper cover123and the lower cover124has a plurality of second connecting holes124bcorresponding to the plurality of first connecting holes123a. The upper cover123and the lower cover124are connected with each other by a plurality of locking members127engaged within the plurality of first connecting holes123aand the plurality of second connecting holes124b, which is convenient to be positioned and assembled. In other embodiments, one of the upper cover and the lower cover may have a plurality of positioning protrusions, the other of the upper cover and the lower cover may have a plurality of positioning recessions so as to achieve similar effects. The light assembly20further includes at least one control unit23, and the upper cover123and the lower cover124of at least one of the plurality of connecting portions12define a second receiving portion128therebetween. The at least one control unit23is received within the second receiving portion128and electrically connected with the at least one power supply unit22so that the at least one control unit23can control operation of the at least one light-emitting member21. In this embodiment, each of said first receiving portion125is located at a side of one of said lower cover124remote from one of said second receiving portion128for good heat dissipating effect; the upper cover123and the lower cover124of each of the plurality of connecting portions12are made of plastic materials, and each of said second insertion portion121is a projection integrally formed as a part of one of said upper cover123. Each of said projection is inserted into one of said insertion groove so as to have good structural strength. In other embodiments, each of said first insertion portion may be a projection, and each of said second insertion portion may be an insertion groove. Preferably, each of the plurality of connecting portions12further includes a reinforcing member129disposed between the upper cover123and the lower cover124, and each of the plurality of rod members11includes a hollow portion114. Two ends of each of said reinforcing member129respectively penetrate into the hollow portion114of one of the plurality of rod members11, and one of said reinforcing member129, one of the plurality of rod members11and at least one of the upper cover123and the lower cover124are connected with one another by a plurality of fasteners14, as shown inFIG.6, so as to increase structural strength and assembling stability. In this embodiment, each of said reinforcing member129is a hollow tube which may be made of metal or plastic for lightweight. The at least one power supply unit22includes at least one of a battery, a solar cell, an electrical interface (such as USB ports, DC ports, etc.) and a vehicle power. In this embodiment, the main body10includes four said rod members11and four said connecting portions12, and an outer contour of the frame13is octagonal; the light assembly20includes four said power supply units22which are electrically connected with the same one of said control unit23, and each of the four said power supply units22includes a battery and supplies power to respective one of said light-emitting members21so that the four said power supply units22can be replaced or charged individually; each of the plurality of rod members11has one of said recession111extending and being open in the longitudinal direction, each of said recession111has at least one of said light-emitting member21received therewithin. The main body10further includes at least one first cross rod15and a plurality of second cross rods16. Each of the at least one first cross rod15is detachably arranged between two of the plurality of rod members11, and each of the plurality of second cross rods16is detachably arranged between one of the at least one first cross rod15and one of the plurality of rod members11corresponding to each other. Arrangements of the at least one first cross rod15and the plurality of second cross rods16are changeable to meet various requirements. In other embodiments, the at least one power supply unit22amay include a solar cell221and a USB port222disposed on one of the plurality of connecting portions12, as shown inFIG.8, so as to provide various methods for power supply. Although particular embodiments of the invention have been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims. | 10,061 |
11859790 | DETAILED DESCRIPTION The present inventive concept is best described through certain embodiments thereof, which are described in detail herein with reference to the accompanying drawings, wherein like reference numerals refer to like features throughout. It is to be understood that the term invention, when used herein, is intended to connote the inventive concept underlying the embodiments described below and not merely the embodiments themselves. It is to be understood further that the general inventive concept is not limited to the illustrative embodiments described below and the following descriptions should be read in such light. Additionally, the word exemplary is used herein to mean, “serving as an example, instance or illustration.” Any embodiment of construction, process, design, technique, etc., designated herein as exemplary is not necessarily to be construed as preferred or advantageous over other such embodiments. Particular quality or fitness of the examples indicated herein as exemplary is neither intended nor should be inferred. FIG.1is an illustration of a vehicle100in which the present invention can be embodied. As illustrated in the figure, vehicle100includes a rear lighting assembly107used for stop/tail automotive lighting functions and mounted in vehicle body105. The present invention can be realized to emit essentially any color, however, automotive embodiments will typically employ clear, amber or red light guide media. In this disclosure, rear lighting assembly107, which performs redtail/stop functions using a light blade, will exemplify typical embodiments. However, lighting functions other than those described herein can be realized by embodiments of the invention, as the skilled artisan will attest upon review of this disclosure. Rear lighting assembly107includes at least one light guide110in the form of a light blade, an example of which is illustrated inFIGS.2A-2B, collectively referred to herein asFIG.2.FIG.2Ais an illustration of the front, light emitting side of light guide110andFIG.2Bis an illustration of a side view of light guide110. Light guide110will be described herein as having an inboard side202, corresponding to the inboard direction of vehicle100, and an outboard side204, corresponding to the outboard direction of vehicle100. In certain embodiments, light guide110can be made relatively thick, e.g., 40-50 mm corresponding to an increased light path length as compared to traditional designs. Exemplary light guide110includes an exit face210from which light, provided by a light source at entrance face220, is emitted to meet a lighting profile criterion. Such lighting profile may specify homogeneous lighting across exit face210at intensity levels that meet certain photometric specifications, such as the exterior automotive lighting requirements of FMVSS No. 108. As used herein, “homogenous lighting” refers to a lighting profile over which the intensity of light is evenly distributed over exit face210when light guide110is illuminated by a set of evenly spaced light sources, as described below. Such homogeneous lighting avoids abrupt changes or gaps in the lighting profile to the extent that individual light sources may be indiscernible at exit face210. However, it is to be understood that non-homogeneous effects are possible by changing the illumination by the light sources. Such homogeneity may be achieved by various features described herein including the aforementioned increased light guide thickness. Light guide110may include side walls—inboard side wall240and outboard side wall230—that extend between exit face210and entrance face220. Exit face210, entrance face220, outboard side wall230and inboard side wall240enclose a light guide medium, e.g., a polymer such as polycarbonate that has a refractive index relative to air that results in light being totally reflected internally at the outboard side wall230and the inboard side wall240. The present invention is not limited to particular refractive indexes so long as the total internal reflection is realized. In certain embodiments of the present invention, the light guide medium may be tuned to a light source with which it is illuminated. The term “tune,” as used herein, refers to optimizing the transmittance efficiency (minimizing the absorbance) of the medium at the wavelength of light emitted by the light source under the constraint that the color of light guide medium must meet a predetermined color criterion, e.g., must fall within Society of Automotive Engineers (SAE) and/or Economic Commission for Europe (ECE) color space for a given automotive lighting function. As a first measure for optimizing transmittance efficiency, a base polycarbonate of high clarity may be utilized. e.g., a polycarbonate exhibiting approximately 90% transmittance through 4 mm of the material. A colorant (a dye, pigment, etc.) may be added to the base polycarbonate by which the actual tuning is achieved. Attenuation of light through a medium follows the Beer-Lambert law A=.sub..lamda.lc, where .sub..lamda. is the wavelength-dependent molar extinction coefficient of the attenuating species, 1 is the optical path length over which the light travels through the medium and c is the concentration of the attenuating species. To tune the medium to the light source in accordance with the present invention, a colorant may be selected that has a minimum molar extinction coefficient .sub..lamda. (as compared to other colorants that can be used to meet the color criterion) at the light source wavelength (e.g., 645 nm) while meeting the color requirements stipulated by a photometric specification (e.g., red that is within SAE and/or ECE color space). The selected colorant may be added to the base polycarbonate at a concentration that is no more than sufficient to achieve the specified hue. Empirical techniques may also be used to tune the light blade medium to a particular light source. Once the thickness (e.g., 40-50 mm) and shape of the targeted light blade has been established and the emission wavelength (e.g., .about.645 nm) of a light source has been chosen, color values may be determined with which the light blade medium meets a color criterion, e.g., falls within a specified color space for a legal automotive lighting function. The color values may be specified as coordinates or samples in a wide variety of color spaces; for purposes of description and not limitation, L*a*b* color values are used herein. In certain embodiments, the color values must meet the color criterion to within a certain tolerance, e.g., less than or equal to a Delta E of 2, where Delta E is a calculated number representing the total difference in color between 2 samples. A Delta E of 2 or less is equivalent to limits of the human eye at distinguishing different colors. As one non-limiting example, color values of L*=32.24, a*=67.91, b*[email protected] mm material thickness defines a red color that meets SAE and ECE color criteria for an automotive stop function. Once the color of the light source and the light guide medium have been established, colorants and base materials may be selected that realize the maximum transmission at the defined light source wavelength (e.g., 645 nm). One example colored material realizing the present invention exhibits maximum transmission from 580 nm to 740 nm, which is .about.80% @ 18.5 mm thickness. Light guide110may be molded into a single formation, such as that illustrated inFIGS.2A and2B. In addition to the high clarity discussed above, the base polycarbonate may be a high flow polymer, e.g., having a melt flow index (MFI) of 25-34 g/10 min. When so embodied, fine details of the part can be formed in an injection molding or similar polymer forming process. However, it is to be understood that such single formation may be realized by more than one pass of a molding or similar process, as will be discussed further below. FIGS.3A-3B, collectively referred to herein asFIG.3, illustrate example fine details that can be used in embodiments of the invention. In certain embodiments, exit face210may have a micro-texture310illustrated inFIG.3Awhile entrance face220may have a micro-texture320illustrated inFIG.3Bformed thereon. In one embodiment, micro-texture310has a texture depth of 0.001 inch and a draft angle of 1.5.degree. Here, “draft angle” refers to the amount of taper for molded or cast parts perpendicular to the mold parting line. The present invention is not limited to particular micro-texture sizing, but in certain embodiments, the micro-texture310formed on exit face210is finer than micro-texture320formed on entrance face220. In certain embodiments, laser light is applied to micro-texture310and micro-texture320to produce a laser haze across exit face210and entrance face220, respectively. Such laser light application slightly distorts the micro-texturing. Micro-texturing and laser hazing of exit face210and entrance face220provides light scattering centers on both surfaces, by which a more homogeneous lighting profile, as viewed by an observer, is produced. FIG.4is an illustration of an entrance face220of an embodiment of the present invention. As illustrated in the figure, entrance face220may have formed thereon semi-cylindrical protuberances410that act to spread the light incident thereon across the width of light guide110. In certain embodiments, protuberances410are approximately 2.0 mm wide and have a 0.3 mm radius of curvature. Protuberances410may be spaced apart at a 1.0 mm pitch. FIG.5is an exploded view of an example rear lighting assembly500by which the present invention can be embodied. Lighting apparatus500may include a light guide110, a reflector unit510and a light source unit520assembled together by suitable connection mechanisms, e.g., adhesives, screws, snap-fit connectors molded in connecting parts, etc. Lighting apparatus500is responsive to an electrical signal (LED drive current) provided through, for example, a connector530, to produce a homogeneous lighting profile at the exit face thereof. Light source unit520can be configured to provide light that is incident on light guide110, particularly at entrance face220. Light source520can include a plurality of individual solid state light sources522, e.g. light emitting diodes (LEDs), which may be implemented by organic light emitting diodes (OLEDs), polymer light emitting diodes (PLEDs), and/or monolithic LEDs, positioned along the longitudinal direction of the light guide. In certain embodiments, individual LEDs522have an active area of 0.04 cm.sup.2, are separated on 10 mm centers and generate red light (for stop and tail functions). FIG.6is a schematic diagram of lighting system500in cross-section for purposes of explaining various features of the illustrated embodiment. As discussed above, light guide110has an exit face210, an entrance face220, an outboard side wall230and an inboard side wall240. These surfaces enclose a volume of a light guide medium610, such as a polycarbonate material, that has a refractive index relative to air to cause total internal reflection at the air/light guide interface. Additionally, light guide medium610may be tuned to the wavelength of the light source, e.g., LED522, as described above. Alternatively or additionally, light guide medium610may be diffusive to produce a homogeneous lighting profile at exit face210. In one embodiment, a light dispersive agent, such as minute/microscopic beads representatively illustrated at bead612, may be distributed throughout the light guide medium610to introduce scattering centers therein. Beads612may be added in a manner by which light guide medium610is diffusive and such diffusivity is only apparent when illuminated by LEDs522(the material appears transparent to an observer otherwise, i.e., when not illuminated by LEDs522). In one embodiment, the beads addition ratio is 10%. In certain embodiments, a circular side cut620may be formed on the inboard side wall240and the exit face210and may have a radius of approximately 8 mm. This realizes a reflective surface internal to medium610by which light incident thereon is directed towards outboard side wall230. Reflector510may be pseudo-parabolic, i.e., having a cross-sectional profile similar to a parabola, yet having optical properties that differ from a true parabolic reflector. For example, as illustrated inFIG.6, light rays impinging on reflector510from LED522may be directed to converge within medium610(while still being diffused by the protuberances and texturing described above), where the light rays would be parallel in a true parabolic reflector. The light convergence by the pseudo-parabolic reflector510ameliorates dark spots that would otherwise appear along the center of light guide110. Lighting apparatus500may be electrically coupled to vehicle resources to realize lighting animation, by which various LEDs522are switched on and off with specific relative timing with the on and off switching of other LEDs522. For example, each of LEDs522may be cycled on and off sequentially by which it appears to an observer that a dark spot moves across the length of lighting apparatus500or, alternatively, a light spot moves across the length of lighting apparatus500. More sophisticated animations may also be realized by suitable programming of a controller630, such as to appear as a fluid within the light guide. Controller630may be electrically coupled to an LED driver640to control the current provided to LEDs522. Controller630and LED driver640may obtain operating power from a power source650, which may be realized by a battery, an alternator, or the like. FIG.7is a cross-sectional view of a lighting apparatus700that implements features described with reference to lighting apparatus500. Lighting apparatus700may include a light guide710, a reflector730and light source740, each of which cooperates with the others according to the principles described herein to produce a homogeneous light profile while meeting the photometric requirements for automotive lighting. Light for lighting apparatus700may be provided by light source740, which may be implemented by a plurality of LEDs742coupled to suitable circuitry on circuit board744. As is illustrated inFIG.7, light guide710may be formed or otherwise constructed in two passes of an injection molding process. In the illustrated example, light guide710may include a first shot portion712aand a second shot portion712b, where such structure may be realized by a conventional two-shot over-molding process. Here, first shot portion712aencompasses entrance face724and inboard side wall726, and second shot portion712bencompasses exit face722and outboard side wall728to include circular side cut725. In some embodiments, first shot portion712amay be formed from a clear medium, e.g., polycarbonate, and second shot portion712bmay be formed from a red medium, e.g., also the same polycarbonate but having dyes and other pigments added to tune the medium to the light source. Lighting apparatus700may include pseudo-parabolic reflector730comprising a first reflector wall732aand a second reflector wall732b. As discussed above, pseudo-parabolic reflector730may be formed or otherwise constructed to direct light from LED742towards the center of light guide710so as to eliminate a central dark line that is otherwise present at exit face722. FIG.8is a graph of wavelength versus percent-transmission of various media that can be used to realize an embodiment of the present invention. A sample LED spectrum is illustrated in the figure as well (red spectrum at 675-740 nm). As is illustrated in the figure, embodiments of the present invention (the upper transmission curve) exhibit transmission characteristics that are more transmissive to red LED light, particularly the shade of red required by Society of Automotive Engineers (SAE) and Economic Commission for Europe (ECE) standards, than that used in other systems (lower transmission curves). As used herein, the words “a”, “an”, and the like include a meaning of “one or more”, unless stated otherwise. The drawings are generally drawn not to scale unless specified otherwise or illustrating schematic structures or flowcharts. The foregoing discussion discloses and describes merely exemplary embodiments of an object of the present disclosure. As will be understood by those skilled in the art, an object of the present disclosure may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the present disclosure is intended to be illustrative, but not limiting of the scope of an object of the present disclosure as well as the claims. Numerous modifications and variations in the present disclosure are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the disclosure may be practiced otherwise than as specifically described herein. | 17,005 |
11859791 | DETAILED DESCRIPTION OF THE INVENTION An embodiment of a lighting device10of the present invention will be described with reference toFIGS.1to16. In this embodiment, the lighting device10is in the form of a desk lamp, but alternative embodiments include a floor-standing lamp and a wall-mounted light. In overview, the lighting device10comprises a body12mounted on a base14, a support16connected to the body12, and a light source18which is supported by the support16. The support16is articulated, which allows a user to move the light source18relative to the body12to allow the lighting device10to adopt a range of different configurations. With reference first toFIGS.1to3, the body12comprises a tubular housing20which in this embodiment is in the form of a pipe having a constant circular cross-section. The housing20is mounted on the base14so that the longitudinal axis of the housing20extends orthogonal to the base14, with the base14being shaped such that the housing20is vertical when the base14is located on a horizontal surface. In this embodiment, the housing20is formed from an opaque material, which may be a plastics or metallic material. The housing20includes a light permeable section in the form of a perforated section22which is extends about the longitudinal axis of the body12and at least half way along the length of the body12. In this embodiment, the body12further comprises a transparent tube24is surrounded by the perforated section22of the housing20. The transparent tube24is preferably cylindrical. As shown inFIG.9, the housing20has an open upper end26which is remote from the base14, and which defines an aperture28through which light enters the body12from the light source18. The upper end26of the housing20is located in a plane which is substantially orthogonal to the longitudinal axis of the housing20. With reference also toFIG.6, the body12includes an annular upper body joint30and a lower body joint31which connect together the housing20and the transparent tube24. The upper body joint30supports a filter32for filtering the light entering the body12from the light source18, and a transparent filter cover34. The lower body joint31is connected to a lower internal housing36of the body12, which in this embodiment houses a circuit38for providing USB charging of an external device via USB port40. The internal housing36also closes the lower end of the body12to inhibit light egress therefrom. A layer of reflective material42may be disposed on the upper end of the internal housing36to reflect incident light towards the perforated section22of the housing20. A first cable44for supplying power to the light source18extends through the body12and terminates at a cable jack46. A mains power lead47is connected to the cable jack46to a further electrical contact located on the stop30, to which a mains power supply may be connected. The cable jack46passes through a hollow shaft48of the base14. The shaft48is connected by bolts to the lower body joint31of the body12. The shaft48is mounted on a disc-shaped main body50of the base14. The main body50of the base14may include weights52which prevent the device10from toppling during use. The shaft48is mounted on the main body50of the base so that the shaft48can rotate relative to the main body50about a first axis X1, which is collinear with the longitudinal axis of the body12. This enables the body12to rotate relative to the base14about the first axis X1. During assembly, the shaft48is received by an annular central section52, which includes an inner annular flange54. A threaded cap56is then secured to the lower end of the shaft48so that the inner annular flange54becomes sandwiched between the shaft48and the cap56, which secures the body12to the base14whilst enabling the body12to rotate relative to the base14about the first axis X1. The support16is connected to the body12so that the support16extends outwardly from the body12, preferably so that the support16is orthogonal to the longitudinal axis of the body12. In this embodiment, the support16is connected to the upper end26of the body12by a collar60connected to the upper body joint30so that the support16thus rotates with the body12about the first axis X1. The support comprises a first arm62which is connected to the body12at a first end thereof. The first arm62comprises two parallel side walls64, a lower wall66located perpendicularly between the lower ends of the side walls64, and an upper wall68which is parallel to the lower wall66, and located generally midway between the upper end and lower end of the side walls64. A chamber69is located between the lower wall66and the upper wall68. The cable44extends within the chamber69towards the light source18. A first joint section70of the support16is connected to the second end of the first arm62, for example using an adhesive. The first joint section70comprises a generally cylindrical spigot72which, when the first joint section70is attached to the first arm62, has a longitudinal axis which is parallel to the longitudinal axis of the body12. A second cable jack74is housed within the spigot72. A second joint section76is mounted on the first joint section70so that the second joint section76is rotatable relative to the first joint section70about a second axis X2which is collinear with the longitudinal axis of the spigot72. The second joint section76is generally cylindrical in shape, and comprises a cylindrical recess which receives the spigot72as the second joint section76is mounted on the first joint section70. The recess houses a third cable jack78which engages the second cable jack74as the second joint section76is mounted on the first joint section70to electrically connect the first cable44to a second cable79which extends towards the light source18. A second arm80of the support16is mounted on the second joint section76so that the second arm80pivots about the second axis X2with rotation of the second joint section76about that axis. Similar to the first arm62, the second arm80comprises two parallel side walls82, a lower wall84located perpendicularly between the lower ends of the side walls82, and an upper wall86which is parallel to the lower wall84, and located generally midway between the upper end and lower end of the side walls82. The lower wall84and the upper wall86define a cylindrical recess which receives a hollow shaft88which extends outwardly from the second joint section76substantially orthogonal to the second axis X2so that the second arm80is substantially parallel to the first arm62. This also enables the second arm80to rotate relative to the second joint section76, and thus relative to the first arm62, about a third axis X3which is orthogonal to, and which preferably intersects, the second axis X2. The lower wall84and the upper wall86also define therebetween a chamber90which extends from the recess88to the second end of the second arm80. The second cable79extends from the third cable jack78towards the light source18through the hollow shaft88and chamber90. The light source18is mounted on the second end of the second arm80. With reference toFIG.7, the light source18comprises a plurality of light emitting diodes (LEDs)94centred on an optical axis O of the light source18. The LEDs94are surrounded by a reflective baffle96for directing light emitted from the LEDs94away from the light source18. The LEDs94are mounted on a board97, which is in turn mounted on a heat conductive plate98. The LEDs are connected electrically to a printed circuit board (PCB)100, to which the second cable79is electrically connected. The heat conductive plate98is mounted on a heat pipe102so that heat emitted from the LEDs94during use of the lighting device10is transferred to the heat pipe102. The heat pipe102protrudes outwardly from the light source18, and is supported by the upper wall86of the second arm80. Heat radiated from the heat pipe102during use of the lighting device10passes through an aperture located between the upper ends of the side walls82of the second arm80to enter the external environment. The second arm80is retained on the first arm62by a retaining mechanism104. With particular reference toFIGS.4and8, the retaining mechanism104comprises a detent106which is located on the upper wall68of the first arm62, and which is moveable along a rod108which extends between the first joint section70and a stop member110attached to the upper wall68. A compression spring112extending about the rod108urges the detent106away from the stop member110. The detent106is connected to a roller114by a roller support116mounted on the detent106. Under the action of the spring112, the roller114is urged against the external cylindrical surface of the second joint section76, so that the roller114enters a circular groove116extending about the second joint section76as the second joint section76is mounted on the first joint section. The engagement between the roller114and the groove116prevents the second arm from being lifted away from the first arm62during use of the lighting device10. The light source18is moveable relative to the body12to enable the lighting device10to adopt selectively either a first configuration, in which the light source18is positioned to illuminate the interior of the body12so that the external environment is illuminated by light emitted from the body12, or a second configuration in which the light source18is positioned to illuminate directly the external environment.FIGS.1to8illustrate the lighting device10in the first, or “room lighting” configuration. In this first configuration, the second arm80is oriented relative to the first arm62so that the second arm80is parallel to, and substantially overlies, the first arm62. In this configuration, the light source18is positioned directly over the open upper end26of the body12so that the optical axis O is collinear with the first axis X1. The support16is designed so that a lower annular wall120of the baffle96, which defines the aperture122through which light is emitted from the light source18into the external environment, is spaced from the open upper end26of the body12when the lighting device10is in its first configuration. To guide the light emitted from the light source18into the body12, the lighting device10includes a light guide130for guiding light emitted by the light source18into the body12. The light guide130is moveable relative to the body12between a deployed position, as shown inFIGS.1to8, to guide light emitted from the light source18into the body12when the lighting device10is in the first configuration, and a stowed position, as shown inFIGS.9to16, when the lighting device10is in a second configuration. The light guide130is supported by the body12when in its stowed position. In this embodiment, the light guide130is supported by a ledge located inside the body12, which in this embodiment is provided by the collar60which connects the support16to the body12. Alternatively, a separate supporting ledge may be provided within the body12. With particular reference toFIGS.7and13, the light guide130comprises an annular wall132which faces towards the light source18when the lighting device10is in its first configuration, and which defines an aperture134through which light emitted from the light source18passes to enter the body12. The light guide130further comprises an inner tubular wall136depending from the inner periphery of the annular wall132for guiding light into the body12. The inner surface of the inner tubular wall136may comprise a reflective surface. The light guide130also comprises an outer tubular wall138depending from the outer periphery of the annular wall132, which has an external diameter which is substantially the same as the internal diameter of the housing22of the body12, and which slides along the internal surface of the housing22as the light guide130moves between its stowed position and deployed position. As shown inFIG.13, the light guide130is preferably located substantially fully within the body12when in its stowed position, more preferably so the upper surface of the light guide130is flush with the open upper end26of the body12, so that the light guide130does not protrude from the body12when in its stowed position. However, the light guide130may protrude from the body12when in its stowed position provided that, when in its stowed position, it does not impair movement of the lighting device10between its first configuration and second configuration. However, when in its stowed position the light guide130is preferably located between the open upper end26of the body12and the perforated section24of the housing22so that it is not visible from a front, side or rear view of the body12, as illustrated inFIGS.9to16. The light guide130moves away from the collar60, and thus towards as the light source12, as its moves from its stowed position to its deployed position. When in its deployed position, the light guide130preferably engages the light source18so that there is substantially no stray light emitted from the lighting device10as it passes from the light source18and into the body12. The light is reflected by any reflective surface within the body12towards the perforated section24of the body12, from which the light is emitted into the external environment. The light guide130is preferably urged towards its deployed position as the lighting device10adopts its first configuration. In this embodiment, the upper surface of the annular wall132engages the lower annular wall120of the baffle96when the light guide is in its deployed position, as shown inFIG.7. For example, the light guide130may be magnetically attracted towards the light source18as the lighting device10adopts its first configuration. As shown inFIG.7, the light guide130compares a first pair of permanent magnets140which become attracted to a second pair of permanent magnets142carried by the light source18as the lighting device10adopts its first configuration. The strength of the magnetic field generated between the magnets140,142, is preferably such that the force of magnetic attraction between the magnets140142is greater than the weight of the light guide130so that, as the lighting device10adopts its first configuration, the light guide130rises from the supporting collar60and becomes attached to the light source18. When in its deployed position, the light guide130protrudes only partially from the body12so as to remain centred on the longitudinal axis of the body12as it moves between its stowed position and its deployed position. From the first configuration, the second arm80may be rotated manually about the second axis X2so as to move the light source18laterally away from the open upper end26of the body12, and so place the lighting device10in a second, “task lighting” configuration, in which the light emitted from the light source10can illuminate directly a work surface or other task area. By way of example,FIGS.9to13illustrate the lighting device10in a first tasking lighting configuration following a 180° rotation of the second arm80about the second axis X2, in which the first arm62and the second arm80are substantially parallel and linearly arranged, and the light source18is located furthest from the body12. When the lighting device10is in a task lighting configuration, the user may adjust the angular position of the light source18relative to the base14by rotating the body12about the first axis X1. Following a rotation of the second arm80about the second axis X2, the optical axis O of the light source18remains substantially parallel to the longitudinal axis of the body12. Such task lighting configurations are most useful for illuminating a task area on a work surface on which the lighting device10is located, and may be referred to as a downlighting configuration of the lighting device10. At other times, the user may wish to illuminate other surfaces, such as reading material held by the user, or a wall or a ceiling of the room in which the lighting device10is located. In these instances, the user may change the orientation of the optical axis O of the light source18by rotating the second arm80about the third axis X3. For example, starting from the configuration shown inFIGS.9to13, the user grasps the second arm80and rotates it about the hollow shaft88, and thus about the third axis X3, so that the optical axis O turns through 180°. As shown inFIGS.14to16, in this uplighting configuration the optical axis O is parallel to the longitudinal axis of the body12but the light source18is facing away from the work surface on which the lighting device10is located. From a second configuration, the lighting device10may be returned to the room lighting configuration by rotation of the second arm80about the second axis X2and the third axis X3, as necessary. To ensure an accurate alignment of the light source18with the body12as the lighting device10returns to its room lighting configuration, the lighting device10includes a biasing mechanism for urging the lighting device10into its room lighting configuration as the light source18approaches the body12. In this embodiment, the biasing mechanism comprises a concave recess150formed on the groove118. The recess150is positioned on the track so that the roller114is located in the recess150when the lighting device10is in its first configuration. To ensure that the first arm62and second arm80are accurately aligned as the lighting device10approaches its first configuration, and so that the optical axis O is parallel with the first axis X1, the biasing mechanism further comprises a first arm permanent magnet152connected to the first arm62, and a second arm permanent magnet154connected to the second arm80. In this embodiment, the first arm permanent magnet152is mounted on the roller114, and the second arm permanent magnet154is mounted on a support156located directly above the roller114when the lighting device is in its first configuration. As the lighting device10moves towards its first configuration, the second arm permanent magnet154is attracted towards the first arm permanent magnet152, which causes the second arm80to rotate towards the first arm62so that the first arm permanent magnet152and the second arm permanent magnet154are substantially parallel, and so the optical axis O is parallel with the first axis X1. Simultaneously, the roller114beings to enter the recess150and, under the biasing force of the spring112, urges the second joint section76to rotate about the second axis X2until the roller114has fully entered the recess150, and the lighting device10has been returned to its first configuration. When the lighting device10is subsequently moved from its first configuration to a second configuration, by rotating the second arm about the second axis X2, the second pair of permanent magnets142carried by the light source18move away from the first pair of permanent magnets140carried by the light guide130, as the movement of the light guide130is constrained along the longitudinal axis of the body12. As the pairs of magnets become spaced apart, the force of attraction between the magnets reduces so that the light guide130falls from the light source130and on to the collar60, and so returns to its stowed position. | 19,234 |
11859792 | DETAILED DESCRIPTION OF THE DRAWINGS Before any embodiments of the present invention is explained in detail, it is to be understood that the application is not limited to the details of construction and the arrangement of component part set forth in the following description or illustrated by the following drawings. Further, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting but should encompass equivalents thereof. Referring now to the drawings and more particularly to the example of the preferred embodiment depicted byFIGS.1and4, there is shown the basic component parts of the mounting plate assembly10and the displaceable adjustable spring clamp structure12. The mounting plate assembly10has a mounting plate11usually constitute by a flat metal plate provided with cut-outs and holes for attachment to an electrical junction box and providing attachment thereto of a light fixture. The mounting plate assembly10of the present invention provides additional functions compared to known mounting plates and is provided with a novel displaceably adjustable spring clamp structure12which permits the mounting of the mounting plate assembly to pre-formed holes of different sizes formed in sheet material. The displaceable spring clamp structure12can also be easily adjusted by the use of a user person's fingers without the need of tools. The mounting plate11has an aperture13to provide a passage therethrough of wiring, when mounted over an electrical junction box, or for the mounting of a light source inside a recessed housing if the light fixture is of a canister type, not shown but obvious to a person skilled in the art. A guide rail assembly14is secured to a rear face15of the mounting plate11on opposed sides of the aperture13, and as herein show, these are diametrically aligned with one another on a straight axis. Each guide rail assembly14supports an adjustable spring clamp bracket20mounted for its displacement along a pair of guide rails16. The spring clamp bracket20is connected to a displaceable base17coupled for sliding displacement along and between its associated guide rails16to position the spring clamp bracket20at a desired location. The displaceable base17is arrested at the desired location by retention means, as described herein below, to permit and the mounting of the mounting plate assembly in a pre-formed hole of a certain diameter whereby to mount a new light fixture attached to such hole. As shown in the exploded view ofFIG.4, the displaceable spring clamp structure12is described. The guide rail assembly14comprises a mounting base21to which is integrally formed the pair of spaced-apart substantially parallel guide rails16. The displaceable spring clamp bracket20is retained between the pair of parallel guide rails16for displacement therealong. The displaceable spring clamp bracket20has a spring biased clamp arm structure22secured to a torsion spring23supported at an elevated position by a horizontal bridge arm support24formed at a top end of a vertical bridge support plate25secured to the top surface26of the displaceable base17by an attachment flange28and a screw fastener29which engages in a preformed screw retention hole30in the top surface31of the displaceable base17. The torsion spring23has a helical spring section23′ retained about the bridge arm support24and its opposed ends are formed as straight arms32′ disposed parallel to one another and extending in a common plane. The free ends of the straight arms32′ are interconnected by a surface engaging pad structure33′ formed of plastics material or other material not to damage the interior surface of the gypsum board sheeting material to which it is usually spring biased against. The spring biased clamp arm structure22is spring biased in a downward direction, as illustrate by arrow27by the torsion spring23and the pad structure33′ rests in a full downward position. Therefore, to position the spring clamp structures12in a hole, it is necessary to move the spring biased clamp arms of the clamp brackets20upwardly to place then in the hole while pushing the mounting plate towards the hole. The clamp arms are release as soon as the engaging pads33′ are inside the hole, and all of this procedure is well known in the art. As herein shown, the displaceable base17is formed of a rigid metal piece of rectangular shape and defines a flat top surface31and a flat bottom surface31′. The displaceable base is also formed with opposed flange formations32which project outwardly from a bottom section of the opposed side walls33of the displaceable base17. The opposed guide rails16are formed with inwardly projecting shoulder formations34spaced above the flat top surface26of the mounting base21to form an open elongated channel35thereunder with the opening of the channel facing inwards over the flat top surface26of the mounting base21. As shown inFIG.5, these channels35have a height “h” greater than the thickness “t” of the flange formations32whereby to define a space36therebetween when said shoulders of said displaceable base is positioned thereunder, as herein illustrated. The flange formations32are elongated flat flanges of rectangular cross-section. In this particular embodiment the guide rail16is further provided with an attachment flange16′ provided with holes16″ for receiving fasteners (not shown) for securing the displaceable spring clamp structure12in u-shaped openings11′ formed in the mounting plate11on opposed sides of the aperture13. This is only one form of attachment of the displaceable clamp structure and other modifications are to be contemplated if it is to be mounted differently depending on the shape and mounting structure of different types of light fixtures. Spring biasing means is mounted in a top surface37of the flange formations32to receive a spring elements38in the form of a small compression helical spring module sized for retention in a small retention hole39formed in the top surface37of the flange formation32. The spring elements38have a friction head40to provide a smooth wear-resistant surface for displacement against an underface34′ of the shoulder formations34. As shown inFIG.5, the opposed flange formations32of the displaceable base17project under the shoulder formations34in the space36when the displaceable base is secured to the guide rail assembly14for displacement therealong. The spring elements38spring biases the bottom surface31′ of the displaceable base17against the flat top surface26of the mounting base21. With additional reference toFIG.6, which is a bottom view of the displaceable base17′, it can be seen that a retention formation, in the shape of a hole41, is formed at a predetermined position in the bottom surface31′ of the displaceable base. As shown inFIGS.3and5, retention formations in the form of rounded nipple heads42are secured to the flat top surface26of the mounting base21and disposed in predetermined spaced relationship along a straight axis which is aligned with the hole41. Accordingly, when the displaceable base17is moved over the flat top surface26of the mounting base21, and the hole41of the displaceable base is located over a nipple head41, the displaceable base is arrested by the downward spring force exerted by the spring elements38. In order to displace the displaceable base17over the flat top surface26of the mounting base21it is necessary for a user person to apply an upward pulling force on the displaceable base, to disconnect it from engagement with a nipple head, and this is accomplished by grasping the spring clamp bracket20with the fingers and pulling it upwards causing the spring elements38to compress and the displaceable base to move upwards out of its engagement. The displaceable base is then shifted toward another nipple head, see42′ inFIG.6, and released when in the vicinity of the other nipple head whereby its bottom surface36is biased against the other nipple head by the spring elements38and the hole will then clamp over the other nipple head as shown at41′ being clamped over the nipple head at42′. Accordingly, the spring clamp bracket immovably retained at a different location. As herein shown, two spaced nipple heads42are secured at predetermined locations corresponding to known hole sizes, such as holes of 4 or 6 inches. To identify the positioning of the base to place the spring clamp brackets at the proper position depending on the hole size, markings62can be printed or inscribed on the top surface of the guide rails16, as shown inFIG.4.FIG.6illustrates the base17engaged at these two positions of 4 and 6 inch spacing. With reference toFIGS.2and3, there is illustrated a mounting plate assembly45wherein the mounting plate47is of a square contour and has an LED driver module46mounted thereon. The aperture13provides access to the driver module46to connect wiring to provide operating current to LED lamps provided in a light fixture (not shown) securable to the mounting plate. Also, four displaceable spring clamp brackets12are mounted thereon and disposed in two pairs with the spring clamp brackets diametrically aligned and the pairs secured at right angles to one another. Such is desirable when supporting heavy light fixtures. As can be seen, the mounting plate47is herein provided with junction box attachment slots48and48′ disposed on two spaced-apart circumferential axes to provide a different use for the mounting plate for connection to existing junction boxes of two different diameters and connectable thereto by screw fasteners. Accordingly, when the mounting plate45with the driver module46is secured to a junction box the power leads of the junction box secured to the LED driver module46, with the module being of a small size housed within the junction box. As herein shown the LED light fixture frame49is secured to the mounting plate47by proper fasteners and its lens cover50thereafter attached to the frame49by conventional fasteners. FIGS.9and10show as similar mounting assembly to that ofFIGS.2and3but showing that the mounting plate52can be constructed of a different configuration, herein an elongated rectangular mounting plate and provided with only two displaceable clamp structure12secured in diametrical alignment. As shown, a junction box63or LED module46is mounted on the mounting plate52.FIGS.9and10further illustrates the mounting plate52being attached to an elongated LED light fixture65and wherein the mounting plate52is secured to its frame66to which is attached a lens67.FIG.10shows the LED light fixture65mounted in a hole68formed in sheeting material69with the spring biased clamp arms32spring biased over the inner surface70of the sheeting material adjacent the hole68. With reference toFIGS.7and8, there is shown a mounting plate assembly10′ similar toFIG.1, but wherein a junction box55is mounted about the aperture13which in this figure is concealed by the junction box55secured to the rear wall15′ of the mounting plate11′. The aperture13provides access to the junction box55. The mounting plate15′ may have different contour shapes, such as hexagonal as herein illustrated, or round, square or rectangular as shown inFIGS.2and9, or variations thereof. Such an embodiment is desirable when replacing an existing light fixture with additional and different light fixtures. Such is illustrated inFIG.8, wherein an old fixture56, shown in phantom line, is removed from its junction box57and replaced by a more modem LED light fixture58having its driver module59which mounts inside the junction box57and further wherein additional LED light fixtures58′ can be mounted at different locations with their power received from jumper wires60coupled to the power leads existing in the junction box57. Accordingly, such mounting plate assembly10′ permits a user person to replace an existing fixture, such as a chandelier or any type, with one or more modem LED fixtures or incandescent lamp fixtures of a different designs and such replacement can be made by a user person without the use of electricians or carpenters. The only work requirement is to remove the existing light fixture assembly and to disconnect its connecting wires from the power leads from the junction box. Holes are cut into the sheeting material at desired locations where additional replacement light fixtures58′ need to be mounted and to bring the additional wiring60from the junction box to the new mounting holes to connect to the new fixtures and to mount the new fixtures in the holes by the use of the spring clamps12′, as shown inFIG.8. Many modifications and other embodiments of the present invention as described above will come to mind to a person skilled in the art to which the invention pertains having the benefit of the teachings described herein above and the drawings. Hence, it is to be understood that the embodiments of the present invention are not to be limited to the specific examples thereof as described herein and other embodiments are intended to be included within the scope of the present invention and the appended claims. Although the foregoing descriptions and associated drawings describe example embodiments in the context of certain examples of the elements and members and/or functions, it should be understood that different combinations of elements or substitutes and/or functions may be provided by different embodiments without departing from the scope of the present invention as defined by the appended claims. Furthermore, although specific terms are employed herein, they are used in a generic and descriptive sense only and other equivalent terms are contemplated herein with respect to the items that they relate to. It is therefore within the ambit of the resent invention to encompass all obvious modifications of the examples of the preferred embodiment described herein provide such modifications fall within the scope of the appended claims. | 13,977 |
11859793 | DETAILED DESCRIPTION OF THE EMBODIMENTS For the convenience of understanding the present disclosure, the present disclosure is described more fully hereinafter with reference to the accompanying drawings. Preferable embodiments of the present disclosure are set forth in the accompanying drawings. However, the present disclosure may be embodied in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that the understanding of the present disclosure will be more thorough and complete. All technical and scientific terms used herein have the same meaning as commonly understood by skilled person in the art to which this disclosure belongs, unless otherwise defined. The terms used in the specification of the present disclosure herein are for the purpose of describing specific embodiments only and are not intended to limit the present disclosure. The term “and/or” used herein includes any and all combinations of one or more of the associated listed items. In describing positional relationships, when an element is referred to as being “on” another element, it can be directly on the other element or intermediate elements may also be present, unless otherwise specified. It is also understood that when an element is referred to as being “between” two elements, it may be the only element between the two elements, or one or more intermediate layers may also be present. In the case of using “include”, “have”, and “contain” described herein, unless explicitly defined terms such as “only”, “consist of”, etc., another component(s) may also be added. Unless mentioned to the contrary, singular terms may include plural concepts and should not be construed as having the number of one. Furthermore, the accompanying drawings are not drawn to a 1:1 scale and the relative dimensions of elements in the accompanying drawings are drawn by way of example only and not necessarily to true scale. As shown inFIGS.1and2, a lamp with integrated structure for lighting and energy storage100in an embodiment of the present disclosure includes a lamp post10, a lamp20, at least a photovoltaic panel30and an energy storage device40. The lamp post10includes at least two sub-posts, and two adjacent sub-posts are detachably connected to each other. The lamp20is detachably mounted on a sub-post on a top of the lamp post10. An interior of one of the sub-posts is provided with a receiving cavity111, and the energy storage device40is received in the receiving cavity111. The at least a photovoltaic panel30is disposed on an outer surface of at least one of the sub-posts. Therefore, in a transportation process, the lamp post10may be disassembled into a plurality of sub-posts, the photovoltaic panel30may be mounted on the outer surface of a corresponding sub-post, and the energy storage device40is mounted in the receiving chamber111of the sub-post, so that the footprint required by the lamp with integrated structure for lighting and energy storage100in the transportation process is significantly reduced, and the transportation cost is saved. In addition, conventional photovoltaic panels are generally fixed on both sides of the lamp post via a bracket, and thus has a large light-receiving area and a fixed orientation. As a result, the generating capacity varies greatly with seasons, and the wind resistance is weak. The lamp with integrated structure for lighting and energy storage100of the present disclosure has a small windward surface because the photovoltaic panel30is mounted on the outer surface of the lamp post, and the photovoltaic panel30can be mounted around a periphery of the lamp post, so that it may effectively receive light at different times without affecting the light-receiving area. In a conventional lamp with integrated structure for lighting and energy storage, an energy storage device is usually buried, suspended or integrated into a lamp base. However, when the energy storage device is buried, it is necessary to dig a battery well, which is cumbersome to construct, and is not conducive to maintenance and recycling; when the energy storage device is suspended, an overall appearance of the lamp with integrated structure for lighting and energy storage may be affected, and external wiring is also required; and when the energy storage device is integrated into the lamp base, it may cause the lamp to have a bloated volume, which also affects the attractive appearance. The lamp with integrated structure for lighting and energy storage100of the present disclosure is disposed in the lamp post100, which is convenient to be mounted and maintained, and may not affect the attractive appearance of the lamp with integrated structure for lighting and energy storage100. In a specific embodiment, the lamp post10includes two sub-posts, which are referred to as a first sub-post112and a second sub-post113, respectively, for convenience of subsequent description. Specifically, the lamp20is mounted on a top end of the first sub-post112, and the second sub-post113has a receiving cavity111for receiving the energy storage device40. Further, both the first sub-post112and the second sub-post113have a profile structure. The profile structure is convenient to be manufactured, and parameters such as specific shape, material, heat treatment state, and mechanical properties of the profile can be selected according to design requirements. In addition, profiles are also convenient to be cut to meet the requirements of the lamp post10of different heights. Preferably, both the first sub-post112and the second sub-post113are square profiles that provide a reliable receiving space for the energy storage device40on the one hand, while the photovoltaic panel30can be stably mounted without bending on the other hand. In some embodiments, the lamp post10further includes a first connection member12, and two adjacent sub-posts are detachably connected through the first connection member12. Further, as shown inFIGS.3and4, the first sub-post112and the second sub-post113are detachably connected through the first connection member12. The first connection member12is provided with a first connection portion121and a second connection portion122, which are opposite to each other. The first connection portion121is configured to cooperate with an end of the first sub-post112to limit the first sub-post112in a radial direction, and the second connection portion122is configured to cooperate with an end of the second sub-post113to limit the second sub-post133in the radial direction. In this way, the first sub-post112and the second sub-post113can be firmly connected by the first connection member12, preventing an unstable connection at the connection position caused by the first sub-post112and the second sub-post113being too long or too thin. In a preferred embodiment, the first connection portion121is provided to be recessed in the first connection member12, and an inner contour of the first connection portion121is provided to be matched with an outer contour of the first sub-post112. The second connection portion113is provided to be recessed in the first connection member12, and an inner contour of the second connection portion122is provided to be matched with an outer contour of the second sub-post113. In other embodiments, the first connection portion121is provided to protrude from the first connection member12, and an outer contour of the first connection portion121is provided to be matched with an inner contour of the first sub-post112. The second connection portion122is provided to protrude from the first connection member12, and an outer contour of the second connection portion122is provided to be matched with an inner contour of the second sub-post113. Alternatively, for other combinations, for example, the first connection portion121is provided to be recessed in the first connection member12, and the second connection portion122is provided to protrude from the first connection, member12, etc., which are not described herein again. Further, an outer diameter of the first connection portion121gradually decreases from an end close to the second connection portion122to an end away from the second connection portion122. As a result, a connection relationship between the first sub-post112and the second sub-post113is more reliable, and this reinforcing structure has an effect of preventing breakage. In some embodiments, an outer diameter of the second connection portion122is constant. As a result, the first connection portion121is more stable, so that a connection between the first sub-post112and the second sub-post113is more reliable. In some embodiments, when the first connection member portion121is provided to be recessed in the first connection member12, and/or when the second connection portion122is provided to be recessed in the first connection member12, an outer periphery of the first connection member portion121and/or the second connection portion122is provided with a reinforcing rib. The reinforcing rib is capable of reinforcing the connection between the first sub-post112and the second sub-post113. In some embodiments, two adjacent sub-posts are threadedly connected to the first connection member12. The threaded connection is simple and convenient. Specifically, threaded holes can be formed in the two sub-posts, and then a matching bolt can be used for the fixed connection. In a specific embodiment, an interior of the first connection member12is provided with a support portion123. An end of the first sub-post112abuts against the support portion123after engaging with the recessed first connection portion121. The lamp post10further includes a plurality of first bolts, and the first sub-post112is threadedly connected to the support portion123of the first connection member12through the first bolts. An end of the second sub-post113abuts against the support portion123after engaging with the recessed second connection portion122. The lamp post10further includes a plurality of second bolts, and the second sub-post113is threadedly connected to the support portion123of the first connection member12through the second bolts. Further, an outer diameter of the first sub-post112is smaller than that of the second sub-post113. The first connection member12is provided with a second threaded hole124through which the second bolt extends into the first connection portion121and the support portion123. The second bolt is threadedly connected to the second threaded hole124, so that the second sub-post113is connected to the support portion123of the first connection member12. As a result, the lamp post10is more stable without affecting the mounting positions of the first bolt and the second bolt. In some embodiments, the first connection member12may be a die cast, which is integrally formed and has a stable and high-strength structure. Referring again toFIG.3, in some embodiments, the lamp with integrated structure for lighting and energy storage100further includes a lifting ring50. The lifting ring50includes an outer frame51, an inner frame52, and a plurality of support rods53connecting the outer frame51to the inner frame52. The plurality of support rods53are arranged at intervals around a center of the lifting ring50. The inner frame52is sleeved on the lamp post10, and an upper end of the inner frame52abuts against the first connection member12. As a result, when the lifting ring50is subjected to an upward lifting force, the second connection portion122of the first connection member12provides a resistance against an upward movement of the lifting ring50. In addition, since the lifting ring50is provided at the first connection member12, and this position is convenient for operation and viewing, so that potted plants or string lights can be placed in an opening formed by two adjacent support rods53and the outer frame51and the inner frame52for decoration. Specifically, the inner frame52is sleeved on the second sub-post113, and the upper end of the inner frame52abuts on the second connection portion122of the first connection member12. Referring toFIGS.1and2again, in some embodiments, a side wall of the second sub-post113is provided with a mounting opening and a cover114covering the mounting opening. The mounting opening communicates with the receiving cavity111. By opening the cover114, it is very convenient to place the energy storage device40in the receiving cavity111and it is also convenient for subsequent maintenance. In order to facilitate the placement and fixing of the energy storage device40, two support plates may be provided in the receiving cavity111of the second sub-post113at intervals in the vertical direction. The energy storage device40is provided between the support plates. In some embodiments, a lower end of the second sub-post113is further provided with a base115. The base115is provided with a fixed through hole. The lower end of the second sub-post113is fixed in the fixed through hole. Specifically, the base115may be a flange. In some embodiments, two clamping grooves extending in the vertical direction are oppositely disposed on a side wall of the first sub-post112at intervals, and two sides of the photovoltaic panel30are clamped in the two clamping grooves, respectively. In other embodiments, the photovoltaic panel30may be fixed by other means, such as by adhesive bonding, etc. As shown inFIG.5, in some embodiments, the lamp with integrated structure for lighting and energy storage100further includes a transparent and embossed lampshade60and a light bar (not shown in the figure). The transparent and embossed lampshade60and the light bar are both mounted on the side wall of the first sub-post112, and the light bar is mounted on an edge of the transparent and embossed lampshade60. It should be appreciated that, since the transparent and embossed lampshade60is transparent, the light bar can introduce light onto the transparent and embossed lampshade60through the edge of the transparent and embossed lampshade60, so that the transparent and embossed lampshade60presents an embossed pattern. This arrangement makes the lamp with integrated structure for lighting and energy storage100more artistic. In other embodiments, the transparent and embossed lampshade60and the light bar may also be disposed on the second sub-post113. In other embodiments, the lamp with integrated structure for lighting and energy storage100further includes: a lampshade formed by the combination of a light guide plate, a lamp picture and a transparent housing; and a light bar. The lampshade and the light bar are both mounted on the side wall of the first sub-post112, and the light bar is mounted on the edge of the transparent and embossed lampshade. It should be appreciated that the light bar can introduce the light into the lampshade through the edge of the lampshade, and the light guide plate guides the light to the lamp picture and the transparent housing, so that the lampshade presents the pattern of the lamp picture. This arrangement makes the lamp with integrated structure for lighting and energy storage100more artistic. In other embodiments, the lampshade and the light bar may also be disposed on the second sub-post113. Specifically, the transparent and embossed lampshade60or the transparent housing is made of an acrylic plate. Referring toFIG.2again, in some embodiments, the lamp with integrated structure for lighting and energy storage100further includes a second connection member70through which the lamp20is detachably connected to the first sub-post112. Specifically, the second connection member70includes a connection cover plate71and a connection sleeve72. The connection cover plate71is covered at a light inlet of the first sub-post112and is detachably connected to the first sub-post112. The connection cover plate71is further provided with a through hole matched with an outer contour of the connection sleeve72. The connection sleeve72extends through the connection cover plate71and the light inlet into a light passage of the first sub-post112, and is detachably connected to the connection cover plate71. The lamp20is sleeved on and detachably connected to an end of the connection sleeve72away from the first sub-post112. It will be appreciated that the light of the lamp20enters the light passage through an interior of the connection sleeve72. Further, the lamp20and the first sub-post112are threadedly connected to the second connection member70. As shown inFIG.6, in some embodiments, the energy storage device40further includes at least one supercapacitor module, and each supercapacitor module includes a plurality of supercapacitors connected to each other. Compared with lithium batteries and lead-acid batteries, a charge-discharge process of the supercapacitor is a physical energy storage without chemical reactions. Therefore, an electron transfer speed of the supercapacitor module is fast, and the charge-discharge process is fast. In addition, a heat generated by the supercapacitor module is extremely low, and the energy storage capacity of the supercapacitor module is stronger under low light conditions. It should be noted that the plurality of supercapacitors connected to each other may be connected in series, which is not limited herein. Further, the lamp with integrated structure for lighting and energy storage100further includes at least one insulating accommodating box80disposed in the receiving cavity111, and each insulating accommodating box80accommodates a corresponding supercapacitor module. Since the lamp post10is generally made of metal materials, a short circuit may occur when the supercapacitor module is placed on the metal lamp post10without protection. Therefore, the insulating accommodating box80is provided to avoid the short circuit of the supercapacitor module, and to protect the supercapacitor module from being damaged caused by other external factors. Specifically, the insulating accommodating box80includes a box body81having an opening on a side of the box body81, and a cover body82covering at the opening. The cover body82is further provided with an electrode lead-out end83which leads out the positive and negative electrodes of the supercapacitor module. This arrangement is simple and is convenient for mounting the supercapacitor. More specifically, the electrode lead-out end83on the cover body82is a cable gland. In some embodiments, the insulating accommodating box80further includes a gasket disposed between the box body81and the cover body82for sealing the insulating accommodating box. Referring toFIGS.6and7, In some embodiments, it is provided a plurality of supercapacitor modules and a plurality of insulating accommodating boxes80. The plurality of insulating accommodating boxes80are provided to be stacked and connected to each other. The plurality of supercapacitor modules may enhance the storage capacity of the energy storage device40. By using the plurality of insulating accommodating boxes80, the space may be saved, and structures inside the lamp post10may be adapted. It should also be pointed out that the plurality of supercapacitor modules are connected to each other, and the connection method can be a series connection or other connection methods, which can be set according to the requirements. In a specific embodiment, the lamp with integrated structure for lighting and energy storage100includes three supercapacitor modules, and each supercapacitor module includes four supercapacitors. Two of the four supercapacitors are connected in parallel, and the other two are connected in series. Further, the lamp with integrated structure for lighting and energy storage100further includes a connection member90connected between two adjacent insulating accommodating boxes80. The connection member90includes a plurality of screw rods91and a plurality of nuts92matched with the screw rods91. The plurality of nuts92are fixed to the top of the insulating accommodating box80, and each screw rod91extends through the plurality of insulating accommodating boxes80and the corresponding nuts92, so that the plurality of insulating accommodating box80are stacked and connected to each other. This connection is simple, and the distance between two adjacent insulating accommodating boxes80may be controlled, so that the electrode lead-out end of each insulating accommodating box80is not affected by a stacking arrangement. Specifically, the nut92is fixed to the cover body82of the insulating accommodating box80. In a specific embodiment, it is provided four screw rod91that are respectively disposed at four diagonal corners of the insulating accommodating box80to stabilize the stacking. The lamp with integrated structure for lighting and energy storage100of the present disclosure has the following advantages over the prior art:(1) the lamp post10is disassembled into the plurality of sub-posts, the photovoltaic panel30may be mounted on the outer surface of the corresponding sub-post, and the energy storage device40is mounted in the receiving chamber111of the sub-post, so that the footprint required by the lamp with integrated structure for lighting and energy storage100in the transportation process is significantly reduced, and the transportation cost is saved;(2) the first connection portion121is configured to cooperate with the end of the first sub-post112to limit the first sub-post in the radial direction, and the second connection portion122is configured to cooperate with the end of the second sub-post113to limit the second sub-post133in the radial direction, so that the first sub-post112and the second sub-post113is firmly connected by the first connection member12, preventing an unstable connection at the connection position caused by the first sub-post112and the second sub-post113being too long or too thin;(3) the outer diameter of the first connection portion121is provided to gradually decrease from the end close to the second connection portion122to the end away from the second connection portion122, so that the connection relationship between the first sub-post112and the second sub-post113is more reliable, and this reinforcing structure has an effect of preventing breakage;(4) the first connection member12is provided as a die cast, which is integrally formed and has a stable and high-strength structure;(5) the light outlet is provided on the side wall of the first sub-post112, the acrylic lampshade is covered on the light outlet, and the first sub-post112also has a light exit passage for guiding the light of the lamp20to the light outlet, so that the side wall of the lamp post10may emit light, which enhances the aesthetic feeling of the lamp with integrated structure for lighting and energy storage100;(6) it is provided the plurality of supercapacitor modules and the plurality of insulating accommodating boxes80, the plurality of insulating accommodating boxes80are provided to be stacked and connected to each other, thereby enhancing the storage capacity of the energy storage device40. In addition, by using the plurality of insulating accommodating boxes80, the space may be saved, and the structures inside the lamp post10may be adapted. Each of the technical features of the above-mentioned embodiments may be combined arbitrarily. To simplify the description, not all the possible combinations of each of the technical features in the above embodiments are described. However, all the combinations of these technical features should be considered as within the scope of this disclosure, as long as such combinations do not contradict with each other. The above-mentioned embodiments are merely illustrative of several embodiments of the present disclosure, which are described specifically and in detail, but it cannot be understood to limit the scope of the present disclosure. It should be noted that, for those ordinary skilled in the art, several variations and improvements may be made without departing from the concept of the present disclosure, and all of which are within the protection scope of the present disclosure. Therefore, the protection scope of the present disclosure shall be defined by the appended claims. | 24,283 |
11859794 | IN THE DRAWINGS 1-base;11-base bottom shell;12-base upper shell;13-battery cover;14-control board;15-function button board;2-light-emitting assembly21-shell;22-light-emitting main body;221-housing;223-mounting piece;2231-first through hole;224-light guide column;225-ring-shaped light strip;3-rotating assembly;31-fixing piece;311-base plate;312-middle connecting column;32- rotating disc;321-clamping groove;322-second through hole;3221-mounting groove;323-cavity;33-gear;34-motor;4-lamp panel;41-mounting base;411-annular protrusion;42-LED lamp bead board;5-pattern cover;51-protrusion;6-lampshade. DETAILED DESCRIPTION In order to make objectives, technical solutions, and advantages of the embodiments of the present disclosure clear, technical solutions in the embodiments of the present disclosure will be described clearly and completely in conjunction with the accompanying drawings in the embodiments of the present disclosure. Obviously, the described embodiments are only a part of the embodiments of the present disclosure, rather than all of the embodiments. Based on the embodiments of the present disclosure, all other embodiments obtained by those of ordinary skill in the art without creative work shall fall within the protection scope of the present disclosure. FIG.1shows a rotary projection night lamp of the present disclosure according to one embodiment of the present disclosure. The rotary projection night lamp comprises a base1, a light-emitting assembly2, a rotating assembly3, a lamp panel4, a pattern cover5, and a lampshade6. The light-emitting assembly2is disposed on the base1. The rotating assembly3is disposed in the light-emitting assembly2. The lamp panel4is disposed on the rotating assembly3. The pattern cover is covers on the rotating assembly3. The pattern cover5is driven to rotate by the rotating assembly3. The lampshade6covers on the pattern cover5. The base1comprises a base bottom shell11, a base upper shell12, a battery cover13, a control board14, and a function button board15. A battery bin is disposed in the base bottom shell. The battery bin is configured to receive a battery. The battery cover13is disposed on a bottom portion of the base bottom shell11. The battery cover13is matched with the battery bin. The base upper shell12is detachably disposed on the base bottom shell11and defines button holes. The function button board15comprises buttons matched with the button holes. The buttons one-to-one pass through the button holes. The function button board15is detachably connected to the base upper shell12. The control board14is detachably disposed in the base bottom shell11. Specifically, first positioning columns are disposed in the base bottom shell11. First positioning connecting columns one-to-one corresponding to the first positioning columns are disposed on a bottom portion of the base upper shell12. The first positioning connecting columns are one-to-one connected to the first positioning columns. Optionally, the first positioning columns and the first positioning connecting columns define first screw holes. First screws respectively pass through the first positioning columns and the first positioning connecting columns to fasten the first positioning columns and the first positioning connecting columns, so as to fix the base bottom shell11to the base upper shell12. At least one second positioning column is disposed in the base bottom shell11. At least one first positioning hole corresponding to the at least one second positioning column is defined on the control board14. Optionally, the at least one second positioning column defines a second screw hole. At least one fastener passes through the at least one first positioning hole and the at least one second positioning column to fix the control board14in the base bottom shell11. At least one third positioning column is disposed on a bottom portion of the base upper shell12. At least one second positioning hole corresponding to the at least one third positioning column is defined on the function button board15. The at least one third positioning column is inserted into the at least one second positioning hole. Optionally, the at least one third positioning column defines a third screw hole, at least one second screw passes through the third screw hole to fix the function button board15to the base upper shell12. As shown inFIG.2, the light-emitting assembly2comprises a shell21and a light-emitting main body22. The shell21is disposed on the base1and the light-emitting main body22is disposed on the shell21. The base upper shell12is detachably connected to the shell21. Fourth positioning columns are disposed on a top portion of the base upper shell12. Second positioning connecting columns one-to-one corresponding to the fourth positioning columns are disposed on a bottom portion of the shell21. The second positioning connecting columns are one-to-one connected to the fourth positioning columns. Optionally, the fourth positioning columns and the second positioning connecting columns define fourth screw holes. Third screws respectively pass through the fourth positioning columns and the second positioning connecting columns to fasten the fourth positioning columns and the second positioning connecting columns, so as to fix the shell21to the base upper shell12. The light-emitting body22comprises a housing221, a mounting piece223, a light guide column224, and a ring-shaped light strip225. The housing221is detachably docked with the shell21. The housing221is connected to the shell21to define an accommodating cavity. The mounting piece223is disposed in an upper end of the housing221. A first through hole2231is defined on an center of the mounting piece223. The light guide column224is a tube structure. The light guide column224is disposed on a bottom portion of the mounting piece223. The light guide column224is communicated with the first through hole2231. The ring-shaped light strip225is disposed on a bottom portion of the light guide column224. The ring-shaped light strip225is configured as a light source for the light guide column224. The light guide column224and the ring-shaped light strip225are disposed in the accommodating cavity enclosed by the housing221and the shell21. The light guide column is a light-transmitting component and can play a lighting function. The shell21and the housing221are also the light-transmitting components, so that light is transmitted from the shell21and the housing221to outside, thereby realizing alighting function of the rotary projection night lamp. Fifth positioning columns are disposed in the shell21. Third positioning connecting columns one-to-one corresponding to the fifth positioning columns are disposed on an edge of a bottom portion of the housing. The third positioning connecting columns are one-to-one connected to the fifth positioning columns. Optionally, the fifth positioning columns and the third positioning connecting columns define fifth screw holes. Fourth screws respectively pass through the fifth positioning columns and the third positioning connecting columns to fasten the fifth positioning columns and the third positioning connecting columns, so as to fix the housing221to the shell21. Optionally, the housing221, the mounting piece223, the light guide column224, and the ring-shaped light strip225are integrally formed, which facilitates an assembly of the rotary projection night lamp and production and processing of the rotary projection night lamp. The rotating assembly3comprises a fixing piece31, a rotating disc32, a gear33, and a motor34. The fixing piece31is detachably connected to the housing221. The gear33is disposed on the fixing piece31. An output end of the motor34is connected to the gear33. The fixing piece31comprises a base plate311and a middle connecting column312. The base plate311is detachably connected to the housing221. The middle connecting column312is also the light-transmitting component and is disposed on a bottom portion of the base plate311. The middle connecting column312is coaxial with the base plate311. The middle connecting column312is sleeved with the light guide column224, which facilitates the assembly of the rotary projection night lamp and makes a structure of the rotary projection night lamp stable. Specifically, sixth positioning columns are disposed in the housing221. Fourth positioning connecting columns one-to-one corresponding to the sixth positioning columns are disposed on the bottom portion of the base plate311. The fourth positioning connecting columns are one-to-one connected to the sixth positioning columns. Optionally, the sixth positioning columns and the fourth positioning connecting columns define sixth screw holes. Fifth screws respectively pass through the sixth positioning columns and the fourth positioning connecting columns to fasten the sixth positioning columns and the fourth positioning connecting columns, so as to fix the base plate311to the housing221. Optionally, the base plate311and the middle connecting column312are integrally formed. Optionally, a receiving cavity is defined on a center of the base plate331. The lamp panel4is disposed in the receiving cavity. As shown inFIGS.3and4, a second through hole332is defined on a center of the rotating disc32of the rotating assembly3. The lamp panel4is embedded in the second through hole332. The lamp panel4comprises a mounting base41and an LED lamp bead plate42disposed on a top portion of the mounting base41. The LED lamp bead plate42comprises at least one lamp bead. The at least one lamp bead is served as the light source. Light emitted by the at least one LED lamp bead penetrates through the pattern cover5, and patterns on the pattern cover5are projected on a ceiling or a wall, so as to realize an atmosphere projection function of the rotary projection night lamp. The lamp panel4is disposed in the receiving cavity of the base plate, and the lamp panel4is embedded in the second through hole. An annular protrusion is disposed on a side wall of an upper portion of the mounting base. The annular protrusion is engaged with the mounting groove, which facilitates an assembly of the rotary projection night lamp and production and processing of the rotary projection night lamp. Optionally, a mounting groove3221is defined in the second through hole322. An annular protrusion411is disposed on a side wall of an upper portion of the mounting base41. The annular protrusion411is engaged with the mounting groove3221. Optionally, the mounting base41and the annular protrusion411are integrally formed. A cavity323coaxial with the second through hole is defined in a bottom portion of the rotating disc32. Gear teeth are disposed on an inner wall of the cavity323. The gear33is engaged with the gear teeth of the rotating disc32. The motor34drives the rotating disc32to rotate through the gear33. Clamping grooves321are defined on an edge of a top face of the rotating disc32. In the embodiment, the pattern cover5is a hollow hemispherical structure, and patterns are defined on an outer surface of the pattern cover5. The patterns are selected from stars, moons, dinosaurs, etc., which increase interest and achieve an effect of creating a romantic atmosphere. Protrusions51are disposed on an edge of a lower end of the pattern cover5. The protrusions51are matched with the clamping grooves321of the rotating disc32. The protrusions51are respectively clamped with the clamping grooves321. In the embodiment, the protrusions51are configured as convex strips, and the convex strips are engaged with the clamping grooves321. In other embodiments, the protrusions51are configured as bumps, which are not limited thereto. The rotating disc32drives the pattern cover5to rotate, and the pattern cover5is not easy to fall off when rotating, so that there is no need to use a plastic ring to fix the pattern cover5, which is convenient for the user to replace the pattern cover5having different patterns by himself/herself according to requirements and has strong practicability. The lampshade6is a hollow hemispherical structure. The lampshade6covers on the pattern cover5. A bottom edge of the lampshade6is fixed to an outer edge of the rotating disc32. The lampshade6is also the light-transmitting component. Optionally, the lampshade6is a transparent plastic component. The lampshade6not only protects the pattern cover5but also makes the light transmitted softer and less dazzling, bringing the user a good user experience. As shown inFIG.5, the control board14in the base1is electrically connected to the light-emitting assembly2and the lamp panel4. A micro control unit (MCU) is disposed on the control board14. A button signal input end of the MCU is electrically connected to the buttons disposed on the function button board15. The rotary projection night lamp further comprises a BLUETOOTH module, an audio output module, a timing module, and a light adjusting module. The BLUETOOTH module, the audio output module, the timing module, and the light adjusting module are electrically connected to the control board14. The BLUETOOTH module, the audio output module, the timing module, and the light adjusting module are electrically connected to the MCU. The audio output module is electrically connected to the BLUETOOTH module. The audio output module comprises a loudspeaker disposed on the base. The rotary projection night lamp is able to be connected to a mobile terminal such as a mobile phone, through the BLUETOOTH module to obtain audio from the mobile terminal. The audio output module is configured to process an external audio transmitted by the BLUETOOTH module and transmit the external audio to the speaker for playback. The timing module is electrically connected to the light-emitting assembly2and the lamp panel4. The rotary projection night lamp controls the light-emitting assembly2and the lamp panel4to work until the time set by the user and then automatically turn off. The light adjusting module is electrically connected to the light-emitting assembly and the lamp panel. The rotary projection night lamp controls and adjusts a brightness of the ring-shaped lamp strip225of the light-emitting assembly2and the at least one LED lamp bead of the lamp panel4. In the rotary projection night lamp of the present disclosure has the atmosphere projection function and the lighting function independent from each other. The at least one LED lamp bead disposed on the lamp panel4are turn on through the buttons, light emitted by the at least one LED lamp bead penetrates through the pattern cover5, and the patterns on the pattern cover5are projected on the ceiling or the wall. At this time, the rotary projection night lamp enters the atmosphere projection mode. The ring-shaped light strip225of the light-emitting assembly2is lit up by pressing the buttons, and light emitted by the ring-shaped light strip225penetrates through the shell21and the housing221to the outside. At this time, the rotary projection night lamp enters the lighting mode. The user is able to directly switch the atmosphere projection mode of the rotary projection night lamp to the lighting mode through pressing the buttons, which is simple and convenient to operate and brings a good user experience. Therefore, the present disclosure saves the operation of removing the pattern cover to install the ordinary lamp cover. It is convenient for the user to replace the pattern cover by himself/herself and the user is able to freely replace the patter cover5to project the patterns he/she likes, which has strong practicability. The rotary projection night lamp has the BLUETOOTH function, the music playing function, the light adjusting function, and the timing function, which is rich in functions and meets the increasing needs of the user, so that the audiences of the rotary projection night lamp are wide. The above embodiments are optional embodiments of the present disclosure, but the embodiments of the present disclosure are not limited by the foregoing embodiments, and any other changes, modifications, substitutions, combinations, and simplification made without departing from the spirit and principle of the present disclosure should be regarded as equivalent replacement manners, which are all comprised within the protection scope of the present disclosure. | 16,390 |
11859795 | DETAILED DESCRIPTION Exemplary embodiments of the present disclosure can be included, and executed, at a surface maintenance machine200. Such surface maintenance machine200can be operated in a manually driven mode, an autonomously driven mode, or interchangeably operated between a manually driven mode and an autonomously driven mode. In the manually driven mode, the surface maintenance machine200, as illustrated in the exemplary embodiments shown, can be a walk-behind machine, though in other embodiments within the scope of the present disclosure, when in the manually drive mode, the features described herein can be applied to a ride-on surface maintenance machine as well. And, both walk-behind and ride-on type surface maintenance machines can be operated in the autonomously driven mode. Such surface maintenance machines can be used to perform one or more surface maintenance operations (e.g., brushing, cleaning, polishing, striping, etc.) at various operation environments, including indoor (buildings, warehouses, garages, hallways, etc.) locations. In some operating environments, one or more obstacles (e.g., shelving, product stands, etc.) may block a direct line of sight to the surface maintenance machine200when operating. Accordingly, various embodiments disclosed herein can be configured to project light onto a ceiling surface and, thereby, help to reduce the time it takes to discern information relating to the surface maintenance machine200. For example, these embodiments that are configured to project light onto a ceiling surface can reduce the time it takes to learn the surface maintenance machine's location and/or status. By projecting light onto a ceiling surface, the surface maintenance machine's location and/or status can be discerned quickly at a glance across a distance even if one or more obstacles block a direct line of sight to the surface maintenance machine200. FIGS.1-4illustrate an exemplary embodiment of surface maintenance machine200that includes a light projection mechanism227. Specifically,FIG.1is a perspective view of surface maintenance machine200including the light projection mechanism227.FIG.2is a perspective view of surface maintenance machine200using the light projection mechanism227to project light onto a ceiling surface300.FIG.3is a plan view looking down at surface maintenance machine200.FIG.4is a block diagram of various exemplary components that can be included at surface maintenance machine200. In the illustrated embodiment here, surface maintenance machine200is a walk-behind type surface maintenance machine (e.g., for performing one or more surface maintenance tasks at a hard floor surface) that can be configured to interchangeably operate between a manually driven mode and an autonomously driven mode. In other embodiments, surface maintenance machine200can instead be a ride-on machine that can be configured to interchangeably operate between a manually driven mode and an autonomously driven mode. Embodiments of surface maintenance machine200include a body201, such as a motorized mobile body, as well as one or more components that are supported at the body201. The body201can be supported on wheels220for travel over a surface on which a surface maintenance operation is to be performed. In the illustrated embodiment, the mobile body201includes a grab handle228, a bail229, and operator controls, including a manual/autonomous mode user input mechanism226. The machine200can be powered by an on-board power source, such as one or more batteries. In the illustrated embodiment, the body201of the machine200includes a base202and a lid204, which can be attached along a side of the base202by hinges so that the lid204can pivot to provide access to the interior of the body201. The interior of the body201can include a power source for the machine200, such as one or more rechargeable battery sources, and motor, such as an electric motor (e.g., a permanent magnet alternating current (“AC”) motor), that receives power from the power source and converts that power into a motive force that is provided to one or more of the wheels220to move the machine200. The interior of the body201can also include a fluid source tank and a fluid recovery tank. The fluid source tank contains a fluid source, such as a cleaner or sanitizing fluid, that can be applied to the floor surface during one or more surface maintenance operations. The fluid recovery tank can hold recovered fluid source that has been applied to the floor surface and soiled. The base202of the body201can support a fluid recovery device222, which in the illustrated embodiment includes a vacuum squeegee224. The squeegee224is in vacuum communication with a fluid recovery tank. In operation, the squeegee224recovers soiled fluid from the floor surface and helps transport it to the recovery tank. The body201, via the base202, can further support one or more surface maintenance tools10(e.g., a cleaning head assembly). The surface maintenance tool10can be coupled to the body201and movable relative to the body201, For example, the surface maintenance tool10can be lowered away from the body201to a cleaning position, in contact with the floor surface, and raised toward the body201to a traveling position, in which the surface maintenance tool10is not in contact with the floor surface. The surface maintenance tool10can be coupled to machine200using any known mechanism, such as a suspension and lift mechanism. The surface maintenance tool10, for example, can include one or more rotatable brushes, such as disc-shaped or cylindrical scrub brushes. Alternatively, the surface maintenance tool10can include other cleaning tools such as a sweeping brush, or polishing, burnishing or buffing pads. The brushes or pads are held by a driver (e.g., a brush driver or a pad driver respectively) that, together with the brush or pad, is detachable from a hub of the surface maintenance tool10. In certain embodiments, the surface maintenance tool10includes a magnetic coupling system that allows for touch-free attachment and aligning between the pad driver or brush driver and the hub. When the machine200is operated in a manually driven mode, the grab handle228and the bail229can be configured to cause the machine200to move along a surface at which a surface maintenance task is desired to be performed. To begin moving the machine200, the user can grasp the grab handle228and actuate the bail229to cause a motive force to be applied at the machine200. For example, the bail229can be configured to be actuated via a user applying a pull force at the bail229(e.g., to move the bail229toward the grab handle228). A first actuation (e.g., a user applied pull force at the bail229) of the bail229can activate application of the motive force at the machine200, and a second actuation (e.g., a user releasing, and thus terminating the pull force at, the bail229) of the bail229can terminate application of the motive force at the machine200. The grab handle228can provide a surface at which a user of the machine200can grasp the machine200during manual operation and apply desired user user-originated forces. For instance, in the manually driven mode, the grab handle228can be grasped and used by a user to apply user forces at the machine200in different directions to cause the machine200to move forward, move rearward, and turn in various directions. The machine200can include a controller230(illustrated atFIG.4). The controller230can include processing circuitry and be supported at the body201, and the controller230can be configured, via the processing circuitry, to execute one or more of the various features disclosed herein. The controller230can be, for example, a programmable processor that is configured to execute non-transitory computer-readable instructions stored in a non-transitory memory component (e.g., at the controller230). Execution of the non-transitory computer-readable instructions at the controller230can cause the machine200to perform one or more various features disclosed herein. The manual/autonomous mode user input mechanism226can be coupled to the controller230, such as via a line231, as shown inFIG.4. The manual/autonomous mode user input mechanism226can receive one or more inputs thereat from the user of the machine200and, as a result, send one or more corresponding input signals to the controller230via the line231. For example, the manual/autonomous mode user input mechanism226can be configured, when actuated, to send a mode control signal to the controller230corresponding to one of a manual mode command and an autonomous mode command. For instance, a first actuation of the manual/autonomous mode user input mechanism226can cause the manual/autonomous mode user input mechanism226to send a manual mode control signal to the controller230, and a second, different actuation of the manual/autonomous mode user input mechanism226can cause the manual/autonomous mode user input mechanism226to send an autonomous mode control signal to the controller230. As illustrative examples, the first actuation of the manual/autonomous mode user input mechanism226can be a user providing a manual mode selection at the manual/autonomous mode user input mechanism226(e.g., via a manual mode button at the manual/autonomous mode user input mechanism226) and the second actuation of the manual/autonomous mode user input mechanism226can be a user providing an autonomous mode selection at the manual/autonomous mode user input mechanism226(e.g., via an autonomous mode button at the manual/autonomous mode user input mechanism226). When the controller230receives the manual mode command from the manual/autonomous mode user input mechanism226, the controller230can, in response, execute non-transitory computer-readable instructions to cause the machine200to be configured for operation in a manually driven mode. Likewise, when the controller230receives the autonomous mode command from the manual/autonomous mode user input mechanism226, the controller230can, in response, execute non-transitory computer-readable instructions to cause the machine200to be configured for operation in an autonomously driven mode. As such, in one embodiment the machine200can be switched between manually driven and autonomously driven modes (e.g., via actuation of the manual/autonomous mode user input mechanism226). In another embodiment, the machine200can be solely an autonomously driven machine without a manually driven mode. And, in yet another embodiment, the machine200can be solely a manually driven machine without an autonomously driven mode. In embodiments where the surface maintenance machine200is configured to operate in the autonomously driven mode, to facilitate operation of the machine200in the autonomously driven mode, the machine200can include onboard at the body201one or more vision sensors139. The vision sensor139can be coupled to the controller130, such as via a line131(shown inFIG.4). The vision sensor139can be configured to scan and detect features in the ambient environment of the machine200. In some embodiments, the vision sensor139can include one or more of visible light and/or thermal (infrared) vision cameras, LIDAR sensors, laser beacons, ultrasound sensors, and the like to detect features of the environment (such as physical boundaries and the like). In some embodiments, the vision sensors139can be provided at various, spaced apart locations on the machine200(e.g., front, lateral sides, rear, and the like) so as to obtain data corresponding to areas at different locations around the machine200over a relatively wide field of view. In some particular embodiments, the field of view of the vision sensors139can correspond to an angle of between about 200 degrees and about 300 degrees, and a radius of between about 50 feet and 150 feet. In one yet more particular embodiment, the field of view of the vision sensors139can be approximately 240 degrees and a radius of approximately 90 feet. In certain embodiments, also to help facilitate operation of the surface maintenance machine200in the autonomously driven mode, the machine200can also include a location sensor128. The location sensor128can be coupled to the controller130, such as via a line129(shown inFIG.4), and the location sensor128can include a wireless transceiver configured to output a wireless signal and receive a wireless signal. The location sensor128can permit ascertaining localization the machine200, such as before, during, or after mapping of a location at which the machine200is to operate autonomously. In some embodiments, the location sensor128can include a Global Positioning System (“GPS”) sensor. Alternatively, or in addition, the location sensor128can include an inertial measurement unit (e.g., compass, accelerometer, gyroscope, magnetometer and the like). In addition, additional components such as wireless communication beacons (e.g., WiFi or Bluetooth) can be provided at the location sensor128to improve accuracy of localization. To further assist operation of the surface maintenance machine200in the autonomously driven mode, the machine200can include a mapping system. The mapping system can, for instance, be executed at the controller130, such as via a mapping processor and mapping computer-executable instructions at the controller130. The mapping processor can have one or more integrated circuits that can be in electrical communication with an on-board or a remote non-transitory memory component. The memory component can store mapping instructions in the form of a mapping software program that can be executed by the mapping processor to generate a map for use by the machine200to navigate a location in the autonomously drive mode. The mapping processor can be coupled (e.g., via the controller130) to the one or more vision sensors139and/or location sensor128. For instance, the mapping processor can be coupled (e.g., via electrical circuits provided on the machine200) to the vision sensors139and/or location sensor128such that data collected by vision sensors139(e.g., electrical signals representative thereof) and/or the location sensor128can be transmitted to the mapping processor via the electrical circuits. The mapping processor can also send control signals to initiate data collection at the vision sensors139and/or the location sensor128. In some examples, the mapping system can also include a visualization processor. The visualization processor can be provided as a part of the controller130(e.g., GPU component at the controller130) at the surface maintenance machine200. The visualization processor can have one or more integrated circuits that can be in electrical communication with the mapping processor. Additionally, the visualization processor can be in electrical communication with the on-board and/or remote memory component. The memory can store computer-readable visualization instructions in the form of a visualization software program that can be executed by the visualization processor to generate a map of the location at which the machine200is to be autonomously operated. The controller130can then execute the generated map to provide control signals to the motor of the machine200. FIG.2shows the surface maintenance machine200using the light projection mechanism227to project light304onto a ceiling surface300. As noted, when the surface maintenance machine200is deployed in an operating environment, for instance in the autonomously driven mode, the light projection mechanism227can help facilitate ascertaining information relating to the surface maintenance machine200in a quick and convenient manner. In particular, when the surface maintenance machine200is operating in an environment with one or more obstacles, such as shelving301shown inFIG.2, the light projection mechanism227can be configured to project light onto the ceiling surface300to convey information, such as location and/or status condition of the machine200, even though the shelving301, or other obstacle, blocks a direct line of sight to the machine200. Accordingly, the light projection mechanism227can be configured to project light onto the ceiling surface300that is above a floor surface302along which the machine200is configured to perform the surface maintenance task using the surface maintenance tool10. In this way, a direct line of sight, over the one of more obstacles, such as the shelving301, to the light projected onto the ceiling surface300via the light projection mechanism227can be provided and, thereby, allow for quick and convenient information conveyance relating to the machine200. As will be discussed in further detail later with respect to the figures showing various embodiments of the light projection mechanism227, the light projection mechanism227can include a light emitting element (e.g., a light emitting diode, or “LED”)241within a light housing242and a projection lens243that is configured to focus light emanating from the light emitting element241. The light emitting element241can have a light intensity, and the projection lens242can have a light focus. Other embodiments within the scope of the present disclosure can include a reflector member, in addition to or as an alternative to the projection lens243. For example, the reflector member can be adjacent to and surround (e.g., circumferentially) at least a portion, or all (e.g., surround circumferentially at three hundred and sixty degrees), of the light emitting element241. As one specific example, the reflector member can include a central aperture though which the light emitting element241extends and the reflector member can extend around the light emitting element241and up in elevation (e.g., at an increasing width, or diameter, as defined between opposite wall members of the reflector member) from the light emitting element241. The light intensity, of the light emitting element241, and the light focus, of the projection lens242can be configured such that the light projection mechanism227is configured to project light onto the ceiling surface300at a predetermined distance D, as shown inFIG.2, from the light projection mechanism227. The predetermined distance D at which the light projection mechanism227is configured to project light onto the ceiling surface300can be a distance sufficient to extend above typical obstacles present in the operating environment of the surface maintenance machine200. For example, in some embodiments, the predetermined distance at which the light projection mechanism227is configured to project light onto the ceiling surface300can be at least ten feet from the light projection mechanism227, at least fifteen feet from the light projection mechanism227, at least twenty feet from the light projection mechanism227, at least twenty five feet from the light projection mechanism227, or at least thirty feet from the light projection mechanism227. As additional examples, to facilitate light projection at the predetermined distance D from the light projection mechanism227, the light intensity of the light emitting element241can be, for instance, greater than 3,000 candela, greater than 4,000 candela, greater than 5,000 candela, greater than 6,000 candela, or greater than 7,000 candela. Likewise, as further additional examples, to facilitate light projection at the predetermined distance D from the light projection mechanism227, the projection lens242can have, for instance, a lens focal angle that produces the output light emission at beam angle less than eight degrees, less than ten degrees, or less than twelve degrees. Notably, the inventors have discovered that light intensity values for the light emitting element241and light focus values for the projection lens242within the noted ranges can act to help facilitate projection of light onto the ceiling surface300at the noted predetermined distances D, such as at least fifteen feet. These noted value ranges have been discovered by the inventors to help synergistically balance the need to project light at the predetermined distance D sufficient to clear beyond obstacles in typical surface maintenance machine operating environments while maintaining the projected light at the ceiling surface300at a sufficient focus so as to be clearly discernible by an observer at line of sight distances typical in these same operating environments. The light304projected by the light projection mechanism227onto the ceiling surface300can define a ceiling projected light area305at the ceiling surface300. As shown in the example ofFIG.2, the light304projected by the light projection mechanism227extends the predetermined distance D beyond the top end of the shelving301and, at the same time, results in a ceiling projected light area305at the ceiling surface300having a sufficient focus to allow for a clear visualization of the projected light at the ceiling surface300by an observer at relatively distance locations elsewhere in the operating environment. The noted ranges for the light intensity value, of the light emitting element241, and the light focus value, of the projection lens242, can facilitate this relatively clear focus of the ceiling projected light area305at the ceiling surface300at the predetermined distance D extending beyond, and clearing, the top of obstacles adjacent the surface maintenance machine200. In the illustrated example, the ceiling projected light area305is a generally circular, though in other embodiments within the scope of this disclosure the ceiling projected light area305can be other shapes, including elliptical, a half ellipse, oval, square, and rectangular. Indeed, in some embodiments, the light projection mechanism227can be configured to project light onto the ceiling surface300to create multiple, different shapes of the ceiling projected light area305. For instance, the light projection mechanism227can be configured to change the shape of the ceiling projected light area305at the ceiling surface300from one shape to another different shape as a means for communicating information relating to the surface maintenance machine200, such as a change in a condition at the surface maintenance machine200. As best seen inFIG.3, in certain embodiments, the light projection mechanism227can be configured such that the light projected onto the ceiling surface300has the ceiling projected light area305that is within an envelope310defined by the body201of the surface maintenance machine200. The envelope310, of the body201, can be an area defined by a maximum body width311and a maximum body length312. For example, the body201of the surface maintenance machine200can define a central longitudinal axis313. The body201can include the maximum body width311defined in a first direction perpendicular to the central longitudinal axis313, and the body210can include the maximum body length312defined in a second direction parallel to the central longitudinal axis313. As various examples, depending on the specific model of the surface maintenance machine200, the maximum body width311can, in some cases, range from fifteen inches to sixty-five inches, and the maximum body length312can, in some cases, range from eighteen inches to 110 inches. As shown inFIG.3, the ceiling projected light area305, present on the ceiling surface300, can be within this envelope310defined by the body201of the surface maintenance machine200. As examples, the light projection mechanism227can be configured such that the light projected onto the ceiling surface300has the ceiling projected light area305of at least thirty-six square inches and no more than 1,296 square inches, of at least sixty-four square inches and no more than 900 square inches, or of at least 100 square inches and no more than 625 square inches. The inventors have discovered that the ceiling projected light area305within the noted ranges can be within the envelope310and yet provide the ceiling projected light area305sufficiently large enough to be seen across various distances within typical surface maintenance machine operating environments. As noted, the surface maintenance machine200can be configured to operate in a manually drive mode or an autonomously driven mode (or interchangeable between the manually and autonomously driven modes). Though the light projection mechanism227can be particularly useful when the surface maintenance machine200is configured to operate in the autonomously driven mode. This can be the case since in the autonomously driven mode there may not be an operator, or other personnel, in a direct line of sight to the surface maintenance machine200when it is operating, and, accordingly, the light projection mechanism227can be useful in conveying information, via the light projected onto the ceiling surface300, relating to the surface maintenance machine200at a location—on the ceiling surface300—that is within a direct line of sight of an appropriate observer. Thus, in some embodiments where the surface maintenance machine200is configured to be operate in the autonomously driven mode, the light projection mechanism227can be configured such that the light emitting element241can be in an enabled state when the surface maintenance machine200is in the autonomously driven mode. When the light emitting element241is in the enabled state, the light emitting element241can emit light as discussed elsewhere herein or can be ready to emit light upon receiving a light on command from the processing circuitry of the light projection mechanism227and/or the controller of the surface maintenance machine200. The surface maintenance machine200, as previously noted, can include the manual/autonomous mode user input mechanism226. The manual/autonomous mode user input mechanism226can be coupled to the light projection mechanism227such that actuation of the manual/autonomous mode user input mechanism226can be communicated to the light projection mechanism227. For example, when the manual/autonomous mode user input mechanism226is actuated to transition the surface maintenance machine from a manually driven mode to the autonomously driven mode, the light projection mechanism227can be configured to transition (e.g., transition the light emitting element241) from a disabled state to the enabled state. The light projection mechanism227can be configured to project light onto the ceiling surface300at different light states as a means for conveying different types of information relating to the surface maintenance machine200. For example, the light projection mechanism227can be configured to project light onto the ceiling surface300in a first light state when the surface maintenance machine200is in a first autonomously driven mode condition. And, the light projection mechanism227can be configured to project light onto the ceiling surface300in a second light state when the surface maintenance machine200is in a second autonomously driven mode condition, where the first autonomously driven mode condition is different than the second autonomously driven mode condition and the first light state is different than the second light state. In this way, an observer of the ceiling projected light area305on the ceiling surface300can see the particular light state of the ceiling projected light area305and, based on the particular light state corresponding to a particular autonomously driven mode condition of the surface maintenance machine200, discern a current status condition of the surface maintenance machine200despite the observer potentially lacking a direct line of sight to the surface maintenance machine200. As to the first and second different autonomously drive mode conditions, the first autonomously driven mode condition can be a warning of an upcoming error state, or an indication of the presence of a current error state, at the surface maintenance machine, while the second autonomously driven mode condition can be a normal operational state (e.g., operating as preprogrammed) of the surface maintenance machine200. For instance, the first autonomously driven mode condition can be selected from the group consisting of: low surface maintenance machine fluid level, low surface maintenance machine battery level, and surface maintenance machine mobility deviation from a previously selected course of travel (e.g., the surface maintenance machine200is not moving according to its preprogrammed path of travel, for instance, because it is stuck at a location in the operating environment). Also, for instance, the second autonomously driven mode condition can be an indication that the surface maintenance machine200is currently operating as preprogrammed and no current condition exists at the surface maintenance machine that needs near-term attention. As to the various light states, for instance, the first light state can be a first color and the second light state can be a second, different color. Additionally or alternatively, the first light state can be one of a steady state light projection and a flashing light projection while the second light state can be the other of the steady state light projection and a flashing light projection. As noted, the different first and second light states can correspond respectively to the different first and second autonomously driven mode conditions. In this way, the different light states can serve to provide a visual cue, at the ceiling surface300, as to the current state of the surface maintenance machine200. FIG.4illustrates a block diagram of an exemplary embodiment of various components that can be included at the surface maintenance machine200for executing functions, including those disclosed herein, at the surface maintenance machine200. The surface maintenance machine200can include the controller230, which itself can include processing circuitry, for receiving one or more inputs and, based on the one or more inputs, providing one or more resulting outputs, such as one or more control signals corresponding to the received one or more inputs. As illustrated atFIG.4, the light projection mechanism227can be coupled to the processing circuitry at the controller230via a line255. In some embodiments, the light projection mechanism227can include light projection processing circuitry232that is configured to receive one or more control inputs from the controller230and, based on the one or more inputs received from the controller230, provide one or more corresponding outputs (e.g., an output control signal) to one or more components at the light projection mechanism227, such as to the light emitting element241to enable the light emitting element241at a predetermined light state and/or change the light state of the light emitting element241. In this way, the controller230of the surface maintenance machine200can act to control the operation of the light projection mechanism227, for instance enabling/disabling and/or changing a light state of the light projection mechanism227, based on information the controller230receives from one or more other components at the surface maintenance machine200. For example, as shown for the embodiment illustrated atFIG.4, the controller230can be coupled to various components of the surface maintenance machine200in addition to the light projection mechanism227. For instance, the controller230can be coupled to the manual/autonomous mode user input mechanism226, via the line231, and, upon the controller230receiving an input signal from the manual/autonomous mode user input mechanism226(e.g., an input signal corresponding to user input at the manual/autonomous mode user input mechanism226to operate in the autonomously driven mode), the controller230can output a corresponding control signal to the light projection mechanism227(e.g., to enable the light emitting element241at a corresponding predetermined light state). The controller230can also be coupled to one or more sensor(s) that are on-board the surface maintenance machine200, such as location sensor128, vision sensor(s)139, fluid tank fluid level sensor(s), and/or temperature sensor, via the line(s)129,131or other line(s) connecting other various sensors to the controller230. And, upon the controller230receiving an input signal from one or more of the sensor(s) (e.g., an input signal from the one or more sensor(s) corresponding to a predetermined sensed state at the respective sensor associated component), the controller230can output a corresponding control signal to the light projection mechanism227(e.g., to change the light state at the light emitting element241, such as from the second light state, that for instance can be output when the machine200begins operating in the autonomously driven mode, to the first, different light state described previously). Similarly, the controller230can further be coupled to the motor233of the surface maintenance machine200via a line234, and, upon the controller230receiving an input signal from the motor233(e.g., an input signal from the motor233corresponding to a predetermined sensed state currently present at the motor233, such as a motor current level or torque level being different than a preset level for operation), the controller230can output a corresponding control signal to the light projection mechanism227(e.g., to change the light state at the light emitting element241). Finally, with respect toFIG.4, the controller230can further be coupled to the surface maintenance tool(s)10of the surface maintenance machine200via a line235, and, upon the controller230receiving an input signal from the surface maintenance tool(s)10(e.g., an input signal from the surface maintenance tool(s)10corresponding to a predetermined sensed state currently present at the surface maintenance tool(s)10, such as a surface maintenance tool rotational speed, torque, temperature, or position being different than that preset for operation), the controller230can output a corresponding control signal to the light projection mechanism227(e.g., to change the light state at the light emitting element241). FIGS.5-7illustrate different exemplary embodiments of the light projection mechanism227that can be used at the surface maintenance machine200as described herein. As such, each of the light projection mechanism embodiments illustrated atFIGS.5-7can include one or more of the same (e.g., each of the same), or similar, features described previously herein with respect to the light projection mechanism227. FIG.5is a side elevational, cross-sectional view of one exemplary embodiment of a light projection mechanism500that can serve as the light projection mechanism used at the surface maintenance machine as described elsewhere herein. The light projection mechanism500includes a light housing501, light projection processing circuitry502supported at the light housing501, a light emitting element503within the light housing501and coupled to the light projection processing circuitry502, and a projection lens504supported at the light housing501. The light projection processing circuitry502can include an input240(shown atFIG.4) that is configured to couple to the surface maintenance machine controller and, thereby, receive an output, such as a control signal, from the controller as described elsewhere herein. For instance, the input240of the light projection processing circuitry502can be configured to receive, from the surface maintenance machine controller, an enable state command corresponding to an autonomously driven mode of the surface maintenance machine, and, in response to receiving the enable state command, the light projection processing circuitry502can be configured to transition the light emitting element503from a disabled state to the enabled state. The light emitting element503can be, for instance, a light emitting diode (“LED”) positioned within the light housing501adjacent the projection lens504. The projection lens504can be configured to focus light emanating from the light emitting element503. For example, the projection lens504can be positioned at a distance505from the light emitting element502, and this distance can be in the range of 0.5 inches to 6 inches, 1 inch to 5 inches, or 2 inches to 4 inches, from the light emitting element502. The light projection mechanism500can be configured to project light304onto the ceiling surface at the predetermined distance D from the light projection mechanism500, as described previously. For instance, as described previously, the light intensity, of the light emitting element503, and the light focus, of the projection lens504, can be configured such that the light projection mechanism500is configured to project light onto the ceiling surface at the predetermined distance D from the light projection mechanism500. FIG.6is a side elevational, cross-sectional view of another exemplary embodiment of a light projection mechanism600that can serve as the light projection mechanism used at the surface maintenance machine as described elsewhere herein. The light projection mechanism600can be the same as, or similar to, that described with respect to the light projection mechanism500ofFIG.5. Namely, similar to or the same as that described for the same termed components of the light projection mechanism500ofFIG.5, the light projection mechanism600can include a light housing601, a light projection processing circuitry602supported at the light housing601, a light emitting element603within the light housing601and coupled to the light projection processing circuitry602, and a projection lens604supported at the light housing601. And, the projection lens604can be positioned at a distance605from the light emitting element602. However, the light projection mechanism600can differ from the light projection mechanism500in that the light projection mechanism600additionally includes a light diffuser606. The light diffuser606can be positioned to receive light emanating from the light emitting element603. The light diffuser606can include a diffuser housing607. The diffuser housing607can include a first diffuser housing end608, a second diffuser housing end609that is opposite the first diffuser housing end608, and one or more side walls610extending between the first diffuser housing end608and the second diffuser housing end609. The diffuser housing607can additionally define a channel613extending from the first diffuser housing end608to the second diffuser housing end609. The first diffuser housing end608can be positioned adjacent the projection lens604, and the second diffuser housing end609can include an opening614defined in the diffuser housing607such that at least a portion of light611breceived from the light emitting element603at the light diffuser606passes (e.g., generally vertically) through the channel613and out the opening614. The one or more side walls610can include a translucent or transparent material through which light611a, received from the light emitting element603at the light diffuser606, is output radially (e.g., in a direction generally perpendicular to a central longitudinal axis612of the light housing602) from the light diffuser housing607. Accordingly, the light diffuser606can be configured such of the light received from the might emitting element603at the diffuser housing607, a portion of this light611bpasses through the channel613and out the opening614while a portion of this light611apasses into the channel613and out the one or more side walls610generally radially before reaching the opening614. Thus, the light diffuser housing607can be configured to output light received from the light emitting element603both generally radially, via the translucent or transparent material at the one or more side walls610, and generally vertically, via the channel613and the opening614. FIG.7is a perspective, cross-sectional view of a further exemplary embodiment of a light projection mechanism700that can serve as the light projection mechanism used at the surface maintenance machine as described elsewhere herein. The light projection mechanism700can be the same as, or similar to, that described with respect to the light projection mechanism600ofFIG.6except that the light projection mechanism700includes multiple light emitting elements—a first light emitting element703A and a second light emitting element703B—as well as multiple projection lenses—a first projection lens704A and a second projection lens704B. The first projection lens704A can be aligned with, and correspond to, the first light emitting element703A, and the second projection lens704B can be aligned with, and correspond to, the second light emitting element704B. The inclusion of multiple light emitting elements703A,703B as in the embodiment of the light projection mechanism700illustrated atFIG.7can be useful for certain light projection functions that may be desired for implementation at the light projection mechanism700. As one example, the inclusion of multiple light emitting elements703A,703B can be useful in projecting light from the light projection mechanism700onto the ceiling surface in different light states. In particular, the first light emitting element703A can be configured to emanate light at a first light state (e.g., a first color) while the second light emitting element703B can be configured to emanate light at a second, different light state (e.g., a second, different color). In this case, the first light emitting element703A can be enabled in response to a first status condition at the surface maintenance machine (e.g., the first autonomously driven mode condition), and the second light emitting element703B can be enabled in response to a second, different status condition at the surface maintenance machine (e.g., the second autonomously driven mode condition). Other than as described above for, and illustrated different at,FIG.7, the light projection mechanism700can be similar to or the same, and operate similar to, or the same as, that described for the same termed components of the light projection mechanism500ofFIG.5. Namely, the light projection mechanism700can include a light housing701, a light projection processing circuitry702supported at the light housing601, the light emitting elements703A,703B within the light housing701and coupled to the light projection processing circuitry702, the projection lenses704A,704B supported at the light housing701and positioned, respectively, at the distances705A,705B from the corresponding light emitting elements703A,703B, a light diffuser706including a diffuser housing707. The diffuser housing707can include a first diffuser housing end708, a second diffuser housing end709that is opposite the first diffuser housing end708, and one or more side walls710extending between the first diffuser housing end708and the second diffuser housing end709. The diffuser housing707can additionally define a channel713extending from the first diffuser housing end708to the second diffuser housing end709. The channel713in the illustrated embodiment of the diffuser housing707is a single channel aligned with each of the light emitting elements703A,703B so as to receive light from each light emitting element703A,703B at the common, single channel. Though in other embodiments within the scope of the present disclosure, the diffuser housing can define two separate channels—one channel aligned with one of the light emitting elements703A,703B and the other channel aligned with the other of the light emitting elements703A,703B. The first diffuser housing end708can be positioned adjacent the projection lens704, and the second diffuser housing end709can include an opening714at the diffuser housing707. FIG.8is a flow diagram of an exemplary embodiment of a method800of operating a light projection mechanism. At step810, the method800includes enabling a light projection mechanism. This step can include, for example, turning on the light projection mechanism, such as turning on a light emitting element located within a light housing of the light projection mechanism. When the light projection mechanism is enabled at step810, the light emitting element of the light projection mechanism can emit light energy at a first light state, such as a first color, a first steady state light emission, or a first flashing light state. The first light state can be projected from the light projection mechanism onto a ceiling surface to form a ceiling projected light area. In some cases, the light projection mechanism can be enabled, and in the first light state, at step810in response to a control signal from a controller, of a surface maintenance machine, to which the light projection mechanism is coupled. The control signal can be output from the controller to the light projection mechanism as a result of the presence of a first status condition at the surface maintenance machine. As one example, the first autonomously driven mode condition could include the surface maintenance machine being powered and in configured to operate in an autonomously driven mode. At step820, the method800includes detecting a surface maintenance machine condition. As one example, detecting a surface maintenance machine condition at step820can include, for instance, detecting, such as at the surface maintenance machine controller, a change from the first status condition at the surface maintenance machine present at step810(e.g., the surface maintenance machine is not operating as programmed initially at the start of a surface maintenance task operation). Such a change from the first status condition at the surface maintenance machine can include, as examples, a warning of an upcoming error state or an indication of the presence of a current error state at the surface maintenance machine. Specific such examples can include low surface maintenance machine fluid level, low surface maintenance machine battery level, and surface maintenance machine mobility deviation from a previously selected course of travel (e.g., the surface maintenance machine is not moving according to its preprogrammed path of travel, for instance, because it is stuck at a location in the operating environment). At step830, the method800includes changing the light state at the light projection mechanism. Changing the light state at the light projection mechanism at step830can include changing the light state at the light projection mechanism in response to detecting the surface maintenance machine condition at step820. For example, prior to detecting the surface maintenance machine condition at step820, the light emitting element at the light projection mechanism can be in the first light state as noted at step810. Then, in response to detecting the surface maintenance machine condition at step820, the light state at the light projection mechanism can be changed at step830to a second light state that is different than the first light state. The second light state can be projected from the light projection mechanism onto the ceiling surface to form the ceiling projected light area. As one particular example, the light projection mechanism can be in the first light state in the form of a first color and/or first light emission pattern (e.g., steady state light emission or flashing light emission) (at step810), the surface maintenance machine condition, such as noted above the warning of an upcoming error state or an indication of the presence of a current error state at the surface maintenance machine, can be detected (at step820), and, in response to detecting the surface maintenance machine condition, the light state at the light projection mechanism can be changed from the first light state to a second, different light state in the form of a second, different color and/or second, different light emission pattern (e.g., the other of steady state light emission of flashing light emission). Various non-limiting exemplary embodiments have been described. It will be appreciated that suitable alternatives are possible without departing from the scope of the examples described herein. | 48,081 |
11859796 | DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS The following description of exemplary embodiments refers to the attached drawings, in which like numerals indicate like elements throughout the several figures.FIG.1is an elevational top view of hanger bars105, a plaster frame110, a can-shaped receptacle for housing a light source (a “can”)115, and a junction box120of a recessed lighting fixture100, according to certain exemplary embodiments.FIG.2is an elevational cross-sectional side view of the hanger bars105, plaster frame110, can115, and junction box120of the recessed lighting fixture100ofFIG.1, in accordance with certain exemplary embodiments. With reference toFIGS.1and2, the hanger bars105are configured to be mounted between spaced supports or joists (not shown) within a ceiling (not shown). For example, ends of the hanger bars105can be fastened to vertical faces of the supports or joists by nailing or other means. In certain exemplary embodiments, the hanger bars105can include integral fasteners for attaching the hanger bars105to the supports or joists, substantially as described in co-pending U.S. patent application Ser. No. 10/090,654, titled “Hanger Bar for Recessed Luminaires with Integral Nail,” and U.S. patent application Ser. No. 12/122,945, titled “Hanger Bar for Recessed Luminaires with Integral Nail,” the complete disclosures of which are hereby fully incorporated herein by reference. The distance between the supports or joists can vary to a considerable degree. Therefore, in certain exemplary embodiments, the hanger bars105can have adjustable lengths. Each hanger bar105includes two inter-fitting members105aand105bthat are configured to slide in a telescoping manner to provide a desired length of the hanger bar105. A person of ordinary skill in the art having the benefit of the present disclosure will recognize that many other suitable means exist for providing adjustable length hanger bars105. For example, in certain alternative exemplary embodiments, one or more of the hanger bars described in U.S. Pat. No. 6,105,918, titled “Single Piece Adjustable Hanger Bar for Lighting Fixtures,” the complete disclosure of which is hereby fully incorporated herein, may be utilized in the lighting fixture100ofFIG.1. The plaster frame110extends between the hanger bars105and includes a generally rectangular, flat plate110awith upturned edges110b. For example, the flat plate110acan rest on a top surface of the ceiling. The junction box120is mounted to a top surface110aaof the flat plate110a. The junction box120is a box-shaped metallic container that typically includes insulated wiring terminals and knock-outs for connecting external wiring (not shown) to an LED driver (not shown) disposed within the can115of the light fixture100or elsewhere within the light fixture100. In certain exemplary embodiments, the plaster frame110includes a generally circular-shaped aperture110csized for receiving at least a portion of the can115therethrough. The can115typically includes a substantially dome-shaped member configured to receive an LED module (not shown) that includes at least one LED light source (not shown). The aperture110cprovides an illumination pathway for the LED light source. A person of ordinary skill in the art having the benefit of the present disclosure will recognize that, in certain alternative exemplary embodiments, the aperture110ccan have another, non-circular shape that corresponds to an outer profile of the can115. FIGS.3-8illustrate an exemplary LED module300of the recessed lighting fixture100ofFIG.1. The exemplary LED module300can be configured for installation within the can115of the lighting fixture100ofFIG.1. The LED module300includes an LED package305mounted to a heat sink310. The LED package305may be mounted directly to the heat sink310or with one or more other components mounted in-between the LED package305and the heat sink310. The LED package305includes one or more LEDs mounted to a common substrate306. The substrate306includes one or more sheets of ceramic, metal, laminate, circuit board, mylar, or another material. Each LED includes a chip of semi-conductive material that is treated to create a positive-negative (“p-n”) junction. When the LED package305is electrically coupled to a power source, such as a driver315, current flows from the positive side to the negative side of each junction, causing charge carriers to release energy in the form of incoherent light. The wavelength or color of the emitted light depends on the materials used to make the LED package305. For example, a blue or ultraviolet LED can include gallium nitride (“GaN”) or indium gallium nitride (“InGaN”), a red LED can include aluminum gallium arsenide (“AlGaAs”), and a green LED can include aluminum gallium phosphide (“AlGaP”). Each of the LEDs in the LED package305can produce the same or a distinct color of light. For example, the LED package305can include one or more white LED's and one or more non-white LEDs, such as red, yellow, amber, or blue LEDs, for adjusting the color temperature output of the light emitted from the fixture100. A yellow or multi-chromatic phosphor may coat or otherwise be used in a blue or ultraviolet LED to create blue and red-shifted light that essentially matches blackbody radiation. The emitted light approximates or emulates “white,” incandescent light to a human observer. In certain exemplary embodiments, the emitted light includes substantially white light that seems slightly blue, green, red, yellow, orange, or some other color or tint. In certain exemplary embodiments, the light emitted from the LEDs in the LED package305has a color temperature between 2500 and 5000 degrees Kelvin. In certain exemplary embodiments, an optically transmissive or clear material (not shown) encapsulates at least a portion of the LED package305and/or each LED therein. This encapsulating material provides environmental protection while transmitting light from the LEDs. For example, the encapsulating material can include a conformal coating, a silicone gel, a cured/curable polymer, an adhesive, or some other material known to a person of ordinary skill in the art having the benefit of the present disclosure. In certain exemplary embodiments, phosphors are coated onto or dispersed in the encapsulating material for creating white light. In certain exemplary embodiments, the white light has a color temperature between 2500 and 5000 degrees Kelvin. In certain exemplary embodiments, the LED package305includes one or more arrays of LEDs that are collectively configured to produce a lumen output from 1 lumen to 5000 lumens in an area having less than two inches in diameter or in an area having less than two inches in length and less than two inches in width. In certain exemplary embodiments, the LED package305is a CL-L220 package, CL-L230 package, CL-L240 package, CL-L102 package, or CL-L190 package manufactured by Citizen Electronics Co., Ltd. By using a single, relatively compact LED package305, the LED module300has one light source that produces a lumen output that is equivalent to a variety of lamp types, such as incandescent lamps, in a source that takes up a smaller volume within the fixture. Although illustrated inFIGS.7and8as including LEDs arranged in a substantially square geometry, a person of ordinary skill in the art having the benefit of the present disclosure will recognize that the LEDs can be arranged in any geometry. For example, the LEDs can be arranged in circular or rectangular geometries in certain alternative exemplary embodiments. The LEDs in the LED package305are attached to the substrate306by one or more solder joints, plugs, epoxy or bonding lines, and/or other means for mounting an electrical/optical device on a surface. Similarly, the substrate306is mounted to a bottom surface310aof the heat sink310by one or more solder joints, plugs, epoxy or bonding lines, and/or other means for mounting an electrical/optical device on a surface. For example, the substrate306can be mounted to the heat sink310by a two-part arctic silver epoxy. The substrate306is electrically connected to support circuitry (not shown) and/or the driver315for supplying electrical power and control to the LED package305. For example, one or more wires (not shown) can couple opposite ends of the substrate306to the driver315, thereby completing a circuit between the driver315, substrate306, and LEDs. In certain exemplary embodiments, the driver315is configured to separately control one or more portions of the LEDs to adjust light color or intensity. As a byproduct of converting electricity into light, LEDs generate a substantial amount of heat that raises the operating temperature of the LEDs if allowed to accumulate. This can result in efficiency degradation and premature failure of the LEDs. The heat sink310is configured to manage heat output by the LEDs in the LED package305. In particular, the heat sink310is configured to conduct heat away from the LEDs even when the lighting fixture100is installed in an insulated ceiling environment. The heat sink310is composed of any material configured to conduct and/or convect heat, such as die cast metal. FIG.9is an elevational cross-sectional top view of the exemplary heat sink310.FIG.10illustrates a thermal scan of the exemplary heat sink310in operation. With reference toFIGS.3-10, the bottom surface310aof the heat sink310includes a substantially round member310bwith a protruding center member310con which the LED package305is mounted. In certain exemplary embodiments, the center member310cincludes two notches310dthat provide a pathway for wires (not shown) that extend between the driver315and the ends of the substrate306. In certain alternative exemplary embodiments, three or more notches310dmay be included to provide pathways for wires. In certain alternative exemplary embodiments, the bottom surface310amay include only a single, relatively flat member without any protruding center member310c. Fins311extend substantially perpendicular from the bottom surface310a, towards a top end310eof the heat sink310. The fins311are spaced around a substantially central core905of the heat sink310. The core905is a member that is at least partially composed of a conductive material. The core905can have any of a number of different shapes and configurations. For example, the core905can be a solid or non-solid member having a substantially cylindrical or other shape. Each fin311includes a curved, radial portion311aand a substantially straight portion311b. In certain exemplary embodiments, the radial portions311aare substantially symmetrical to one another and extend directly from the core905. In certain alternative exemplary embodiments, the radial portions311aare not symmetrical to one another. Each straight portion311bextends from its corresponding radial portion311a, towards an outer edge310fof the heat sink310, substantially along a tangent of the radial portion311a. The radius and length of the radial portion311aand the length of the straight portion311bcan vary based on the size of the heat sink310, the size of the LED module300, and the heat dissipation requirements of the LED module300. By way of example only, one exemplary embodiment of the heat sink310can include fins311having a radial portion311awith a radius of 1.25 inches and a length of 2 inches, and a straight portion311bwith a length of 1 inch. In certain alternative exemplary embodiments, some or all of the fins311may not include both a radial portion311aand a straight portion311b. For example, the fins311may be entirely straight or entirely radial. In certain additional alternative exemplary embodiments, the bottom surface310aof the heat sink310may not include the round member310b. In these embodiments, the LED package305is coupled directly to the core905, rather than to the round member310b. As illustrated inFIG.10, the heat sink310is configured to dissipate heat from the LED package305along a heat-transfer path that extends from the LED package305, through the bottom surface310aof the heat sink, and to the fins311via the core905. The fins311receive the conducted heat and transfer the conducted heat to the surrounding environment (typically air in the can115of the lighting fixture100) via convection. For example, heat from the LEDs can be transferred along a path from the LED package305to the core905, from the core905to the radial portions311aof the fins311, from the radial portions311aof the fins311to their corresponding straight portions311b, and from the corresponding straight portions311bto a surrounding environment. Heat also can be transferred by convection directly from the core905and/or the fins311to one or more gaps between the fins311. In certain exemplary embodiments, a reflector housing320is coupled to the bottom surface310aof the heat sink310. A person of ordinary skill in the art will recognize that the reflector housing320can be coupled to another portion of the LED module300or the lighting fixture100in certain alternative exemplary embodiments.FIG.11illustrates the exemplary reflector housing320. With reference toFIGS.3-8and11, the reflector housing320includes a substantially round member320ahaving a top end320band a bottom end320c. Each end320band320cincludes an aperture320baand320ca, respectively. A channel320dextends through the reflector housing320and connects the apertures320baand320ca. The top end320bincludes a substantially round top surface320bbdisposed around at least a portion of the channel320d. The top surface320bbincludes one or more holes320bccapable of receiving fasteners that secure the reflector housing320to the heat sink310. Each fastener includes a screw, nail, snap, clip, pin, or other fastening device known to a person of ordinary skill in the art having the benefit of the present disclosure. In certain alternative exemplary embodiments, the reflector housing320does not include the holes320bc. In those embodiments, the reflector housing320is formed integrally with the heat sink310or is secured to the heat sink310via means, such as glue or adhesive, that do not require holes for fastening. In certain exemplary embodiments, the reflector housing320is configured to act as a secondary heat sink for conducting heat away from the LEDs. For example, the reflector housing320can assist with heat dissipation by convecting cool air from the bottom of the light fixture100towards the LED package305via one or more ridges321. The reflector housing320is configured to receive a reflector1205(FIG.12) composed of a material for reflecting, refracting, transmitting, or diffusing light emitted by the LED package305. The term “reflector” is used herein to refer to any material configured to serve as an optic in a light fixture, including any material configured to reflect, refract, transmit, or diffuse light.FIG.12is a perspective side view of the exemplary reflector1205being inserted in the channel320dof the reflector housing320, in accordance with certain exemplary embodiments. With reference toFIGS.3-8,11, and12, when the reflector1205is installed in the reflector housing320, outer side surfaces1205aof the reflector1205are disposed along corresponding interior surfaces320eof the reflector housing320. In certain exemplary embodiments, a top end1205bof the reflector1205abuts an edge surface330aof an optic coupler330, which is mounted to a bottom edge310aof the top surface320bb. The reflector1205is described in more detail below with reference toFIG.20. The optic coupler330includes a member configured to cover the electrical connections at the substrate306, to allow a geometric tolerance between the LED package305and the reflector1205, and to guide light emitted by the LED package305. The optic coupler330and/or a material applied to the optic coupler330can be optically refractive, reflective, transmissive, specular, semi-specular, or diffuse. The optic coupler330is described in more detail below with reference toFIGS.17-19. The bottom end320cof the reflector housing320includes a bottom surface320cathat extends away from the channel320d, forming a substantially annular ring around the channel320d. The surface320caincludes slots320cbthat are each configured to receive a corresponding tab1305afrom a trim ring1305(FIG.13).FIG.13illustrates a portion of the trim ring1305aligned for installation with the reflector housing320. With reference toFIGS.3-8and11-13, proximate each slot320cb, the surface320caincludes a ramped surface320ccthat enables installation of the trim ring1305on the reflector housing320via a twisting maneuver. Specifically, the trim ring1305can be installed on the reflector housing320by aligning each tab1305awith its corresponding slot320cband twisting the trim ring1305relative to the reflector housing320so that each tab1305atravels up its corresponding ramped surface320ccto a higher position along the bottom surface320ca. Each ramped surface320cchas a height that slowly rises along the perimeter of the housing320. The trim ring1305provides an aesthetically pleasing frame for the lighting fixture100. The trim ring1305may have any of a number of colors, shapes, textures, and configurations. For example, the trim ring1305may be white, black, metallic, or another color and may also have a thin profile, a thick profile, or a medium profile. The trim ring1305retains the reflector1205within the reflector housing320. In particular, when the reflector1205and trim ring1305are installed in the light fixture100, at least a portion of a bottom end1205bof the reflector1205rests on a top surface1305bof the trim ring1305. Referring now toFIGS.3-8, a bracket325couples torsion springs340to opposite side surfaces310fof the heat sink310. The bracket325includes a top member325aand opposing, elongated side members325bthat extend substantially perpendicularly from the top member325a, towards the bottom end320cof the reflector housing320c. The bracket325is coupled to the heat sink310via one or more screws, nails, snaps, clips, pins, and/or other fastening devices known to a person of ordinary skill in the art having the benefit of the present disclosure. Each side member325bincludes an aperture325cconfigured to receive a rivet325dor other fastening device for mounting one of the torsion springs340to the heat sink310. Each torsion spring340includes opposing bracket ends340athat are inserted inside corresponding slots (not shown) in the can115of the light fixture100. To install the LED module300in the can115, the bracket ends340aare squeezed together, the LED module300is slid into the can115, and the bracket ends340aare aligned with the slots and then released such that the bracket ends340aenter the slots. A mounting bracket335is coupled to the top member325aand/or the top end of heat sink310via one or more screws, nails, snaps, clips, pins, and/or other fastening devices known to a person of ordinary skill in the art having the benefit of the present disclosure. The mounting bracket335includes a substantially round top member335aand protruding side members335bthat extend substantially perpendicular from the top member335a, towards the bottom end320cof the reflector housing320. In certain exemplary embodiments, the mounting bracket335has a profile that substantially corresponds to an interior profile of the can115. This profile allows the mounting bracket335to create a junction box (or “j-box”) in the can115when the LED module300is installed in the light fixture100. In particular, as described in more detail below with reference toFIG.14, electrical junctions between the light fixture100and the electrical system (not shown) at the installation site may be disposed within the substantially enclosed space between the mounting bracket335and the top of the can115(the junction box), when the LED module300is installed. In certain exemplary embodiments, the driver315and an Edison base socket bracket345are mounted to a top surface350cof the top member350aof the mounting bracket335. Alternatively, the driver315can be disposed in another location in or remote from the light fixture100. As set forth above, the driver315supplies electrical power and control to the LED package305. As described in more detail below with reference toFIGS.14-16, the Edison base socket bracket345is a bracket that is configured to receive an Edison base socket1505(FIGS.15-16) and an Edison base adapter1520(FIGS.15-16) in a retrofit installation of the LED module300in an existing, non-LED fixture. This bracket345allows the LED module300to be installed in both new construction and retrofit applications. In certain alternative exemplary embodiments, the bracket345may be removed for a new construction installation. FIG.14is a flow chart diagram illustrating a method1400for installing the LED module300in an existing, non-LED fixture, in accordance with certain exemplary embodiments.FIGS.15and16are views of an exemplary Edison base adapter1520and of the LED module being300connected to an Edison base socket1505of the existing, non-LED fixture via the Edison base adapter1520. The exemplary method1400is illustrative and, in alternative embodiments of the invention, certain steps can be performed in a different order, in parallel with one another, or omitted entirely, and/or certain additional steps can be performed without departing from the scope and spirit of the invention. The method1400is described below with reference toFIGS.3-8and14-16. In step1410, an inquiry is conducted to determine whether the installation of the LED module300in the existing fixture will be compliant with Title 24 of the California Code of Regulations, titled “The Energy Efficiency Standards for Residential and Nonresidential Buildings,” dated Oct. 1, 2005. Title 24 compliant installations require removal of the Edison base socket1505in the existing fixture. An installation that does not need to be Title 24 compliant does not require removal of the Edison base socket1505. If the installation will not be Title 24 compliant, then the “no” branch is followed to step1415. In step1415, the Edison base socket1505from the existing fixture is released. For example, a person can release the Edison base socket1505by removing the socket1505from a plate of the existing fixture. In step1420, the person screws the Edison base adapter1520into the Edison base socket1505. The Edison base adapter1520electrically couples the driver315of the LED module300to the power source of the existing fixture via the socket1505of the existing fixture and/or via wires connected to the socket1505, as described below, with reference to steps1455-1460. In step1425, the person plugs wiring1530from the LED module300into the Edison base adapter1520. For example, the person can plug one or more quick-connect or plug connectors350from the driver315into the Edison base adapter1520. Alternatively, the person may connect wires without connectors from the driver to the Edison base adapter1520. In step1430, the person mounts the Edison base adapter1520and the socket1505to the mounting bracket335on the LED module300. For example, the person can snap, slide, or twist the Edison base adapter1520and socket1505onto the Edison base socket bracket345on the mounting bracket335, and/or the person can use one or more screws, nails, snaps, clips, pins, and/or other fastening devices to mount the Edison base adapter1520and socket1505to the Edison base socket bracket345and/or mounting bracket335. In step1435, the person squeezes the torsion springs340so that the bracket ends340aof each torsion spring340move towards one another. The person slides the LED module300into a can115of the existing light fixture, aligns the bracket ends340awith slots in the can115, and releases the bracket ends340ato install the bracket ends340awithin the can115, in step1440. In step1445, the person routes any exposed wires (not shown) into the existing fixture and pushes the LED module300flush to a ceiling surface. Returning to step1410, if the installation will be Title 24 compliant, then the “yes” branch is followed to step1450, where the person cuts wires in the existing fixture to remove the Edison base, including the Edison base socket1505, from the existing fixture. In step1455, the person cuts wires1520aon the Edison base adapter1520to remove an Edison screw-in plug1520bon the adapter1520. The person connects the wires1520afrom the Edison base adapter1520to wires (not shown) in the existing fixture, and plugs wiring1530from the LED module300into a connector1520con the adapter1520, in step1460. These connections complete an electrical circuit between a power source at the installation site, the Edison base adapter1520, and the LED module300, without using an Edison base socket1505. In step1465, the person mounts the Edison base adapter1520to the mounting bracket335on the LED module300, substantially as described above in connection with step1430. As set forth above, the mounting bracket335has a profile that substantially corresponds to an interior profile of the can115. This profile allows the mounting bracket335to create a junction box (or “j-box”) in the can115when the LED module300is installed in the light fixture100by substantially enclosing the space between the mounting bracket335and the top of the can115. In particular, the electrical junctions between the wires1530, the driver315, the Edison base adapter1520, and, depending on whether the installation is Title 24 compliant, the socket1505, may be disposed within the substantially enclosed space between the mounting bracket335and the top of the can115when the LED module300is installed. FIGS.17and18are views of the optic coupler330of the LED module300, in accordance with certain exemplary embodiments. With reference toFIGS.17and18, the optic coupler330includes a refractive, reflective, transmissive, specular, semi-specular, or diffuse member that covers the electrical connections at the substrate306, to allow a geometric tolerance between the reflector1205and the LEDs in the LED package305, and to guide light emitted by the LEDs. In certain exemplary embodiments, the optic coupler330includes a center member330bhaving a top surface330baand a bottom surface330bb. Each surface330baand330bbincludes an aperture330caand330cb, respectively. The apertures330caand330cbare parallel to one another and are substantially centrally disposed in the center member330b. A side member330bcdefines a channel330dthat extends through the center member330band connects the apertures330caand330cb. In certain exemplary embodiments, the side member330bcextends out in a substantially perpendicular direction from the top surface330ba. Alternatively, the side member330bccan be angled in a conical, semi-conical, or pyramidal fashion. When the optic coupler330is installed in the LED module300, the apertures330caand330cbare aligned with the LEDs of the LED package305so that all of the LEDs are visible through the channel330d. In certain exemplary embodiments, the geometry of the side member330bcand/or one or both of the apertures330caand330cbsubstantially corresponds to the geometry of the LEDs. For example, if the LEDs are arranged in a substantially square geometry, as shown inFIGS.7and8, the side member330bcand the apertures330caand330cbcan have substantially square geometries, as shown inFIGS.17and18. Similarly, if the LEDs are arranged in a substantially round geometry, the side member330bcand/or one or both of the apertures330caand330cbcan have a substantially round geometry. In certain exemplary embodiments, the optic coupler330dis configured to guide light emitted by the LED package305. For example, the emitted light can travel through the channel330dand be reflected, refracted, diffused, and/or transmitted by the side member330bcand/or the bottom surface330bbof the center member330b. A side wall member330eextends substantially perpendicularly from the top surface330baof the optic coupler330. The side wall member330econnects the center member330band an edge member330fthat includes the edge surface330aof the optic coupler330. The side wall member330ehas a substantially round geometry that defines a ring around the center member330b. The edge member330fextends substantially perpendicularly from a top end330eaof the side wall member330e. The edge member330fis substantially parallel to the center member330b. The side wall member330eand center member330bdefine an interior region330gof the optic coupler330. The interior region330gincludes a space around the aperture330cathat is configured to house the electrical connections at the substrate306. In particular, when the optic coupler330is installed within the LED module300, the optic coupler330covers the electrical connections on the substrate306by housing at least a portion of the connections in the interior region330g. Thus, the electrical connections are not visible when the LED module300is installed. FIG.19is a perspective top view of an optic coupler1900of the LED module300, in accordance with certain alternative exemplary embodiments. The optic coupler1900is substantially similar to the optic coupler330, except that the optic coupler1900has a wider edge member1900fand a narrower center member1900bthat has a substantially conical or frusto-conical geometry. In particular, a bottom surface1900baof the center member1900bhas a larger radius than a top surface1900bbof the center member1900b. Each surface1900baand1900bbincludes an aperture1900caand1900cb, respectively, that connects a channel1900dextending through the center member1900b. The bottom surface1900bahas a substantially angled profile that bows outward from the channel1900d, defining the substantially conical or frusto-conical geometry of the center member1900b. In certain exemplary embodiments, the geometry of the center member1900bcan reduce undesirable shadowing from the optic coupler1900. In particular, the center member1900bdoes not include sharp angled edges that could obstruct light from the LED package305. AlthoughFIGS.17-18and19illustrate center members330band1900bwith square and conical geometries, respectively, a person of ordinary skill in the art having the benefit of the present disclosure will recognize that the center members330band1900bcan include any geometry. For example, in certain alternative exemplary embodiments, the optic coupler300or1900can include a center member that incorporates a hemispherical or cylindrical geometry. FIG.20is an exaggerated depiction of a cross-sectional profile of the reflector1205, in accordance with certain exemplary embodiments. The profile includes a first region2005at the top of the reflector1205and a second region2010at the bottom of the reflector1205. The second region2010is more diverging than the first region2005. The regions2005and2010define a curve that resembles the shape of a side of a bell. As is well known to a person of ordinary skill in the art having the benefit of the present disclosure, reflectors within a downlight need to create a specific light pattern that is pleasing to the eye, taking into account human visual perception. Most visually appealing downlights are designed such that the reflected image of the source light begins at the top of the reflector and works its way downward as an observer walks toward the fixture. This effect is sometimes referred to as “top down flash.” It is generally accepted that people prefer light distributions that are more or less uniform, with smooth rather than abrupt gradients. Abrupt gradients are perceived as bright or dark bands in the light pattern. Traditional reflector designs for downlights with large sources, such as incandescent or compact fluorescent lamps, are fairly straightforward. A parabolic or nearly parabolic section created from the edge rays or tangents from the light source will create a top down flash with the widest distribution possible with given perception constraints. With respect to the light pattern on a nearby surface, such as a floor, the light pattern is generally smooth due to the fact that the large source is reflected into a large, angular zone. Designing a reflector for a small light source, such as an LED, is not as straightforward. In particular, it has traditionally been difficult to create a smooth light pattern when using an LED source. The reflector for a small source downlight, such as an LED downlight100, needs to be more diverging than is typical with downlights having larger sources. The reflected portion of the light, nearest nadir, or the point directly below the light fixture, is the most critical area for a small source downlight. If the transition between the reflector image and the bare source alone is abrupt in the downlight, a bright or dark ring will be perceived in the light pattern. To compensate, the reflector1205of the present invention becomes radically diverging near this zone to better blend the transition area. In particular, the bell-shape of the profile of the reflector1205defines at least one smooth curve with a substantially centrally disposed inflection point. A top portion of the curve (the first region2005), reflects light in a more concentrated manner to achieve desired light at higher angles. For example, the top portion of the curve can reflect light near the top of the reflector1205starting at about 50 degrees. A bottom portion of the curve (the second region2010) is more diverging than the top portion and reflects light over a large angular zone (down to zero degrees), blending out what would otherwise be a hard visible line in the light pattern. This shape has been shown to meet the requirement of a top-down flash while also creating a smooth, blended light pattern in the LED downlight fixture100. Although particularly useful for LED downlights, a person of ordinary skill in the art having the benefit of the present disclosure will recognize that the design of the reflector1205may be used in any type of fixture, whether LED-based or not. The precise shape of the reflector1205can depend on a variety of factors, including the size and shape of the light source, the size and shape of the aperture opening, and the desired photometric distribution. In certain exemplary embodiments, the shape of the reflector1205can be determined by defining a number of vertices and drawing a spline through the vertices, thereby creating a smooth, continuous curve that extends through the vertices. Although it might be possible to approximate this curve with an equation, the equation would change depending on a given set of variables. In one exemplary reflector1205, the vertices of the spline were determined in a trial and error methodology with optical analysis software to achieve a desired photometric distribution. The variables set at the onset of the design were: the diameter of the aperture (5 inches), the viewing angle an observer can first see the light source or interior of the optical coupler through the aperture as measured from nadir, directly below the fixture (50 degrees), and the cutoff angle of the reflected light from the reflector as measured from nadir, directly below the fixture (50 degrees). Although specific embodiments of the invention have been described above in detail, the description is merely for purposes of illustration. It should be appreciated, therefore, that many aspects of the invention were described above by way of example only and are not intended as required or essential elements of the invention unless explicitly stated otherwise. Various modifications of, and equivalent steps corresponding to, the disclosed aspects of the exemplary embodiments, in addition to those described above, can be made by a person of ordinary skill in the art, having the benefit of this disclosure, without departing from the spirit and scope of the invention defined in the following claims, the scope of which is to be accorded the broadest interpretation so as to encompass such modifications and equivalent structures. | 36,105 |
11859797 | Components are included inFIG.1toFIG.9: 1, lamp holder shell;2, shell main body; 21, lamp holder installation hole;22, main body installation part; 23, wire placing groove;24, first installation groove; 242, first elastic sheet locating groove;251, second installation groove; 252, second elastic sheet locating groove;26, main body buckling hole; 3, lamp holder top cover;31, top cover wire pressing part; 32, top cover buckling tongue;33, fixed hanging ring; 34, wire hiding hole;35, fixed hook; 4, first conductive elastic sheet;41, first elastic sheet tip; 42, first elastic sheet fixing part;43, first elastic sheet elastic contact part; 5, second conductive elastic sheet;51, second elastic sheet tip; 52, second elastic sheet fixing part; and53, second elastic sheet elastic contact part; 6, waterproof sealing rubber coating layer. DESCRIPTION OF EMBODIMENTS The present disclosure is described below in combination with specific embodiments. As shown inFIG.1toFIG.5, a novel lamp holder structure comprises a lamp holder shell1, the lamp holder shell1comprises a shell main body2and a lamp holder top cover3arranged at the upper end of the shell main body2, and the shell main body2and the lamp holder top cover3are hard plastic parts respectively. Wherein, a bulb installation hole21with a downward opening is formed in the shell main body2, a main body installation part22located above the bulb installation hole21is arranged at the upper end of the shell main body2, and the main body installation part22and the shell main body2are of an integrated structure; a wire placing groove23which is opened upwards and completely penetrates left and right is formed in the middle of the main body installation part22of the shell main body2, a first installation groove241and a second installation groove251which communicate with the bulb installation hole21respectively are formed in the bottom surface of the wire placing groove, the first installation groove241and the second installation groove251are arranged at intervals, a first conductive elastic sheet4is embedded in the first installation groove241, a second conductive elastic sheet5is embedded in the second installation groove251, and the lower ends of the first conductive elastic sheet4and the second conductive elastic sheet5stretch into the bulb installation hole21respectively; the upper end of the first conductive elastic sheet4is provided with a first elastic sheet tip41which protrudes upwards and extends into the wire placing groove23, and the upper end of the second conductive elastic sheet5is provided with a second elastic sheet tip51which protrudes upwards and extends into the wire placing groove23. Preferably, the first conductive elastic sheet4and the second conductive elastic sheet5are copper elastic sheets respectively; and certainly, the above copper materials do not limit the present disclosure, namely the first conductive elastic sheet4and the second conductive elastic sheet5of the present disclosure can also be made of other conductive metal materials. Further, a top cover wire pressing part31which protrudes downwards and is aligned with the wire placing groove23is arranged in the middle of the lamp holder top cover3, and the top cover wire pressing part31and the lamp holder top cover3are of an integrated structure. It needs be pointed out that when the novel lamp holder structure is used for wiring, two wires are located and placed in the wire placing groove23of the main body installation part22, the top cover wire pressing part31of the lamp holder top cover3presses the two wires downwards, the first elastic sheet tip41of the first conductive elastic sheet4pierces through an insulating layer of one wire and is electrically in contact with a wire core of the wire, and the second elastic sheet tip51of the second conductive elastic sheet5pierces through an insulating layer of the other wire and is electrically in contact with a wire core of the other wire. It needs to be explained that the first conductive elastic sheet4comprises a first elastic sheet fixing part42and a first elastic sheet elastic contact part43arranged at the lower end of the first elastic sheet fixing part42, the first elastic sheet tip41is arranged at the upper end of the first elastic sheet fixing part42, the first elastic sheet elastic contact part43stretches into the bulb installation hole21, and the first elastic sheet fixing part42, the first elastic sheet elastic contact part43and the first elastic sheet tip41are of an integrated structure; and a first elastic sheet locating groove242is formed in the inner wall of the first installation groove241, and the edge part of the first elastic sheet fixing part42of the first conductive elastic sheet4is embedded in the first elastic sheet locating groove242. In the process that the first conductive elastic sheet4is installed on the main body installation part22, the first conductive elastic sheet4is embedded in the first installation groove241of the main body installation part22, and the edge part of the first elastic sheet fixing part42is embedded in the first elastic sheet locating groove242. According to the present disclosure, the first conductive elastic sheet4can be rapidly installed and located through the cooperation of the first elastic sheet locating groove242and the edge part of the first elastic sheet fixing part42; and during installation, the first conductive elastic sheet4can be installed only by aligning the edge part of the first elastic sheet fixing part42and inserting the edge part of the first elastic sheet fixing part42into the first elastic sheet locating groove242, and the installation is convenient and rapid. Similarly, the second conductive elastic sheet5comprises a second elastic sheet fixing part52and a second elastic sheet elastic contact part53arranged at the lower end of the second elastic sheet fixing part52, the second elastic sheet tip51is arranged at the upper end of the second elastic sheet fixing part52, the second elastic sheet elastic contact part53stretches into the bulb installation hole21, and the second elastic sheet fixing part52, the second elastic sheet elastic contact part53and the second elastic sheet tip51are of an integrated structure; and a second elastic sheet locating groove252is formed in the inner wall of the second installation groove251, and the edge part of the second elastic sheet fixing part52of the second conductive elastic sheet5is embedded in the second elastic sheet locating groove252. In the process that the second conductive elastic sheet5is installed on the main body installation part22, the second conductive elastic sheet5is embedded in the second installation groove251of the main body installation part22, and the edge part of the second elastic sheet fixing part52is embedded in the second elastic sheet locating groove252. According to the present disclosure, the second conductive elastic sheet5can be rapidly installed and located through the cooperation of the second elastic sheet locating groove252and the edge part of the second elastic sheet fixing part52; and during installation, the second conductive elastic sheet4can be installed only by aligning the edge part of the second elastic sheet fixing part52and inserting the edge part of the second elastic sheet fixing part52into the second elastic sheet locating groove252, and the installation is convenient and rapid. In addition, a lamp holder and a lamp cover can be fixedly arranged at the upper end of the shell main body2in a buckling or screwing mode. Wherein, for the lamp holder top cover3assembled in a buckling mode, the following structural design can be adopted, specifically, as shown inFIG.2,FIG.3andFIG.5, the lamp holder top cover3is provided with two top cover buckling tongues32which protrude and extend downwards respectively, each top cover buckling tongue32and the lamp holder top cover3are of an integrated structure, and the two top cover buckling tongues32are arranged at intervals oppositely; the main body installation part22is provided with main body buckling holes26corresponding to the top cover buckling tongues32, and the top cover buckling tongues32are buckled and clamped in the corresponding main body buckling holes26. As a preferred embodiment, as shown inFIG.1toFIG.4, a fixed hanging ring33is arranged on the upper surface of the lamp holder top cover3, and the fixed hanging ring33and the lamp holder top cover3are of an integrated structure. For the fixed hanging ring33, the lamp holder shell1can be conveniently hung, so that the installation of the present disclosure is improved. It needs to be further explained that the novel lamp holder structure of the present disclosure adopts the following method to realize wiring installation, specifically comprising the following steps: sep a, aligning and inserting the edge part of the first elastic sheet fixing part42into the first elastic sheet locating groove242so as to realize the installation of the first conductive elastic sheet4; sep b, aligning and inserting the edge part of the second elastic sheet fixing part52into the second elastic sheet locating groove252so as to realize the installation of the second conductive elastic sheet5; step c, locating and placing two wires in the wire placing groove23of the main body installation part22; and step d, installing and fastening the lamp holder top cover3, pressing the two wires by the top cover wire pressing part31of the lamp holder top cover3downwards, and enabling the first elastic sheet tip41of the first conductive elastic sheet4to pierce through an insulating layer of one wire and to be electrically in contact with a wire core of the wire, and enabling the second elastic sheet tip51of the second conductive elastic sheet5to pierce through an insulating layer of the other wire and to be electrically in contact with a wire core of the other wire. In the bulb installation process, the upper end of a bulb is inserted into the bulb installation hole21of the shell main body2, one electrode of the bulb makes elastic contact with the first elastic sheet elastic contact part43of the first conductive elastic sheet4, the other electrode of the bulb makes elastic contact with the second elastic sheet elastic contact part53of the second conductive elastic sheet5, and then the bulb is powered on. It needs to be further explained that the novel lamp holder structure can be a screw lamp holder structure or a buckle lamp holder structure; wherein, as shown inFIG.3andFIG.4, the inner wall of the bulb installation hole21of the shell main body2is provided with a threaded structure, and the threaded structure of the inner wall of the bulb installation hole21can be designed into two half-tooth structures. In these circumstances, by means of the structural design, the present disclosure has the advantages of being novel in design, simple in structure and convenient and fast to wire. As a preferred embodiment, as shown in theFIG.6, the lamp holder top cover3is provided with a wire hiding hole34in the bottom surface of the top cover wire pressing part. When the novel lamp holder structure is applied to string lamps, a plurality of novel lamp holder structures are sequentially connected to a wire; and for the novel lamp holder structure serving as the tail end of the wire, the tail end of the wire can be inserted and hidden in the wire hiding hole34. As a preferred mode of execution, as shown inFIG.7, a fixed hook35is arranged on the edge part of the lamp holder top cover3; and in the installation of the present disclosure, the present disclosure can be hooked at the corresponding installation position through the fixed hook35. As a preferred mode of execution, as shown inFIG.8andFIG.9, the periphery of the lamp holder shell1is coated with a waterproof sealing rubber coating layer6; and for the waterproof sealing rubber coating layer, on one hand, rubber coating sealing waterproof performance of a wire inlet end and a wire outlet end can be realized, and on the other hand, close contact with the surface of the bulb is achieved when the bulb is installed and the waterproof sealing of the bulb installation position is realized. The foregoing is merely a preferred embodiment of the present disclosure, those skilled in the art can make various modifications in terms of specific embodiments and scope of application in accordance with the thoughts of the present disclosure, and the details of the description should not interpreted as the limitation of the present disclosure. | 12,611 |
11859798 | The figures depict embodiments of the present invention for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the invention described herein. DETAILED DESCRIPTION I. UPRIGHT CONFIGURATION FIG.1is an illustration of a portable lighting device100in an upright configuration according to an embodiment. The portable lighting device100includes an upper structure having a top side and a bottom side. The upper structure includes two or more horizontal beams coupled to each other. The embodiment shown inFIG.1includes a first horizontal beam102and a second horizontal beam104that are parallel to each other. A lighting component160is coupled to the bottom side of the upper structure. In some embodiments, the lighting component160is rigidly coupled to one or more of the horizontal beams using bolts or other suitable types of fasteners known to one skilled in the art. The position of the lighting component160can also be adjustable, e.g., fixed to one of multiple positions. Light from the lighting component160is directed to a workspace area underneath the upper structure when the portable lighting device100is in the upright configuration. In some use cases, the workspace area can be the surface of a workbench. Since the portable lighting device100is portable, the workspace area can also be a different surface such as the ground or on another object. Example users of the portable lighting device100include different types of tradespersons and hobbyists. A tradesperson such as an electrician or mechanic can use the portable lighting device100to illuminate an object being built or repaired by the tradesperson. A hobbyist can use the portable lighting device100to illuminate an object such as a radio-controlled (RC) car, or a device that needs electrical or hardware repairs. The portable lighting device100can be used in both industrial or commercial workspaces (e.g., a machine shop or electronics shop), or residential workspaces (e.g., garage or basement workstation). The portable lighting device100can be used indoors or outdoors. In some embodiments, the portable lighting device100is up to twenty inches tall in the upright configuration and up to forty-eight inches wide (i.e., the longer length of the upper structure); these dimensions may vary in other embodiments. In some embodiments, the portable lighting device100weighs less than five pounds. Thus, the compact nature of the portable lighting device100—which is described in further detail below with respect to the folded configuration—allows a user to conveniently transport the portable lighting device100between different workspaces or storage. The lighting component160can be a LED light or any other suitable type of light known to one skilled in the art. The lighting component160includes a cable162to a power source such as a standard electrical outlet. In other embodiments, the lighting component160is battery powered and does not include a cable162. In some embodiments, the lighting component160includes multiple lighting sub-elements. In some embodiments, multiple lighting components160are electrically coupled together. For example, two or more portable lighting devices100are positioned adjacent to each other, and the lighting component160of each portable lighting device100are coupled to the same power source. As a result, this set up of portable lighting devices100provides increased lighting for a larger workspace area. The upper structure includes of lugs110configured to hold one or more objects on the top side of the upper structure. This helps increase the available workspace area of the portable lighting device100. For example, the lugs110are positioned to hold a RC car. The distance between the lugs110are customized to the dimensions of the RC car (e.g., chassis dimensions) such that the RC car fits snugly and does not shift when placed on the lugs110. In some embodiments, a user can adjust the position of the lugs110based on a specific use case for the portable lighting device100. For example, the lugs110help secure tools or a toolbox while a user works on an object in the workspace area under the lighting component160. In this way, the tools are readily available to the user and also not obstructing the workspace area under the lighting component160when the user is not actively using the tools. The portable lighting device100includes a first set of legs coupled to one side of the upper structure. In the embodiment shown inFIG.1, the first set of legs includes a first leg120and second leg122. In other embodiments, the first set of legs includes a different number of legs. The first set of legs is coupled to the upper structure at a first pivot point and includes a first hard stop106. The first set of legs can rotate at the first pivot point, about an axis of rotation142, until the first hard stop106contacts the top side of the upper structure in the upright configuration of the portable lighting device. The portable lighting device100includes a first pivot mechanism140at the first pivot point. As illustrated inFIG.1, when the first hard stop106contacts the top side of the upper structure, the first set of legs is perpendicular, or approximately perpendicular, to the first horizontal beam102and second horizontal beam104. The portable lighting device100includes a second set of legs coupled to another side of the upper structure opposite of the first side and at a second pivot point. In the embodiment shown inFIG.1, the second set of legs includes a first leg124and second leg126. In other embodiments, the second set of legs includes a different number of legs, which may be different than the number of legs in the first set of legs. The second set of legs can rotate at the second pivot point, about an axis of rotation152, until the second set of legs contacts a second hard stop108coupled to the top side of the upper structure. The portable lighting device100includes a second pivot mechanism150at the second pivot point. As illustrated inFIG.1, in the upright configuration when the second set of legs contacts the second hard stop108, the second set of legs is perpendicular, or approximately perpendicular, to the first horizontal beam102and second horizontal beam104. In some embodiments, the first set of legs and the second set of legs include feet130to support the portable lighting device100in the upright configuration. In the embodiment shown inFIG.1, each leg of the first and second set of legs includes an “L” shaped bracket as one of the feet130, which increases the surface area of contact between the legs and the workspace surface area, and thus improves the stability of the portable lighting device100. The bottom portion of the feet130contacting the workspace may comprise rubber or another type of material to provide greater friction with to the workspace surface area. In other embodiments, the feet130have a different form factor. The feet130can have variations (e.g., different size or shape) across the legs, and some legs may not include feet in some embodiments. In some embodiments, the first set of legs, second set of legs, and upper structure are formed with one or more segments of metal extrusions, e.g., aluminum extrusions or an alloy. This provides a strong yet lightweight material for the portable lighting device100. In other embodiments, one or more of these structural components are formed with other types of material such as carbon fiber. In the example shown inFIG.1, the first horizontal beam102and second horizontal beam104are each formed with a metal extrusion. The first horizontal beam102and second horizontal beam104are coupled together at both ends with additional metal extrusions that are perpendicular to the horizontal beams. The first hard stop106and second hard stop108are also each formed with a metal extrusion. These metal extrusions can be welded together or rigidly coupled using one or more types of fasteners such as nuts and bolts. In embodiments with fasteners, the dimensions of the portable lighting device100may be adjusted by interchanging the metal extrusions to smaller or larger sizes, in order to customize the device for a specific use case. II. FOLDED CONFIGURATION FIG.2is an illustration of the portable lighting device100shown inFIG.1transitioning from the upright configuration to a folded configuration according to an embodiment. As shown in the side view ofFIG.2, the second set of legs (124and126) are partially folded inward toward the lighting component160. FIG.3is an illustration of the portable lighting device shown100inFIG.1in the folded configuration according to an embodiment. As shown inFIG.3, the second set of legs (124and126) are folded to be approximately parallel to the first horizontal beam102and second horizontal beam104of the upper structure. And the first set of legs (120and122) are folded to be approximately parallel to the first horizontal beam102and second horizontal beam104of the upper structure. The first set of legs and second set of legs can be folded without interfering with each other because these sets of legs have asymmetric spacing. As shown inFIG.3, the first set of legs and second set of legs are secured in offset positions in the folded configuration. Specifically, the first set of legs are secured above the upper structure, while the second set of legs are secured below the upper structure. As a result, the first set of legs do not interfere with the second set of legs even though the sum of the lengths of the first set of legs and second set of legs is greater than the length of the upper structure. The asymmetric spacing accommodates this partial overlap of the lengths of the legs, while still maintaining a folded configuration that is compact for storage. In other embodiments, the length of the legs may be shorter or longer than the lengths shown inFIG.3. Regardless of the length of the legs, the asymmetric spacing prevents the legs from interfering with each other in the folded configuration. In some embodiments, the distance between the first leg120and second leg122(of the first set of legs) is the same as the distance between the first leg124and second leg126(of the second set of legs). Without the asymmetric spacing described above, the legs may interfere with each other when folded if the distances between the two sets of legs are equal. Thus, the asymmetric spacing of the legs is advantageous for this additional reason. FIG.4is an illustration of a pivot mechanism of the portable lighting device100according to an embodiment. As previously discussed with reference toFIG.1, the portable lighting device100includes a first pivot mechanism140and second pivot mechanism150. The first pivot mechanism140secures rotation of the first set of legs about the first pivot point. The second pivot mechanism150secures rotation of the second set of legs about the second pivot point. InFIG.4, the upper diagram400illustrates the second pivot mechanism150in a secured configuration, and the bottom diagram410illustrates the second pivot mechanism150in a released configuration. When the pivot mechanisms are in the secured configuration, the portable lighting device100is secured in either the upright configuration or folded configuration, such that the legs cannot rotate. When the pivot mechanisms are in the released configuration, a user can rotate the legs to transition the portable lighting device100from the upright configuration to the folded configuration, or vice versa. The pivot mechanism includes a lever to secure and release the legs for rotation. A user manually operates the lever. In some embodiments, the pivot mechanism includes a greased bearing, which mitigates wear and tear on the pivot mechanism over repeated rotations. In some embodiments, the pivot mechanism includes a rubber-on-rubber bushing to avoid metal-on-metal contact, which may result in greater wear and tear. V. ADDITIONAL CONSIDERATIONS The foregoing description of the embodiments of the invention has been presented for the purpose of illustration; it is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Persons skilled in the relevant art can appreciate that many modifications and variations are possible in light of the above disclosure. The language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter. It is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based hereon. Accordingly, the disclosure of the embodiments of the invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims. | 13,051 |
11859799 | DETAILED DESCRIPTION Reference will now be made in detail to the embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Connection Assembly With reference toFIGS.1-7, the present disclosure may be embodied as a connection assembly100that includes a stem200and two connectors300,700.FIG.1Aillustrates a connection assembly100in an assembled state, which may comprise a downward facing light fixture400suspended from a ceiling (not shown) via the stem200. In some embodiments, the two connectors300,700constitute a bottom connector300and a top connector700. As illustrated inFIGS.1B-1C and4B, at least one connector300may be configured to engage the stem200. The two connectors300,700may be configured to couple, directly or indirectly, to a light fixture shade500. Stem Referring toFIGS.2A-2B, the stem200may contain a longitudinal stem-bore201and an end-portion202. The end-portion202may define a stem-opening203that extends from the longitudinal stem-bore201. The end-portion202of the stem200may comprise a cylindrical wall204with an internal threaded-stem segment205. The internal threaded-stem segment205may have a single-thread diameter206, and may traverse the end-portion202of the longitudinal stem-bore201. Bottom Connector As shown inFIGS.3A-3D, an embodiment may contain a bottom connector300comprising a top-end portion302, a nut320, and a bottom ring330. The bottom connector300may comprise a longitudinal connector-bore301, which may traverse an entire axial-length of the bottom connector300. An external surface of the top-end portion302may comprise an external threaded-connector segment310. Referring back toFIG.1C, the bottom connector300may be configured to engage the stem200. The external threaded-connector segment310may be configured to engage the internal threaded-stem segment205of the stem200. In some embodiments, the external threaded-connector segment310may comprise a bottom-segment311and a top-segment312. As illustrated inFIGS.3A and3D, the bottom-segment311and the top-segment312may have the same diameter. This diameter may correspond to the single-thread diameter206of the internal threaded-stem segment205of the stem200to facilitate the engagement of the stem200with the top-segment312of the external threaded-connector segment310of the bottom connector300, as shown inFIG.1C. An internal threaded-connector segment701of a top connector700, which is described in detail below, may be adapted to engage the bottom-segment311of the external threaded-connector segment310of the bottom connector300. In certain embodiments, as illustrated inFIG.4A-4C, the bottom-segment311and the top-segment312may have different diameters. The diameter of the top-segment312may correspond to the single-thread diameter206of the internal threaded-stem segment205of the stem200to facilitate the engagement of the bottom connector300with the stem200. The diameter of the bottom-segment311may correspond to the diameter of the internal threaded-connector segment701of a top connector700to facilitate the engagement of the bottom connector300with the top connector700. Accordingly, the bottom-segment311may engage an internal threaded-connector segment701of a top connector700, and the top-segment312may engage the internal threaded-stem segment205of the stem200. In embodiment, the size and type of the threading for the bottom-segment311and the top-segment312may match. In some embodiments, where the bottom-segment311and the top-segment312have different diameters, the threading may be different. The threading of the bottom-segment311and the top-segment312may be in the same direction. In certain embodiments, the threading of the bottom-segment311and the top-segment312may be in opposite directions. The opposing direction of the threads may facilitate improved assembly of the connection assembly100. Such an embodiment may allow for tighter engagement of the bottom connector300with the top connector700and with the stem200. In some embodiments, use of O-rings, gaskets, or the like may further improve the engagements. Referring toFIGS.1C and4B, an O-ring104may facilitate coupling of the top connector700with the light fixture shade500. A rubber gasket105may facilitate coupling of the bottom connector300with the light fixture shade500. The O-ring104and gasket105may facilitate this engagement by preventing unintentional rotation of components of the connection assembly100. The nut320of the bottom connector300may be located adjacent to the external threaded-connector segment310. The nut320may have two external diameters. The first external-diameter321may be the distance between two diametrically opposite sides, and the second external-diameter322may be the distance between two diametrically opposite vertices. Accordingly, the first external-diameter321may be less than the second external-diameter322. Various shapes may be suitable for the configuration of the nut320, including hexagons, pentagons, squares, and other shapes known in the art. Such shapes may enable engagement of the nut320by a wrench, socket driver, pliers, or other torsional tool to effectuate threaded engagement of the bottom connector300with the stem200. The nut320may be configured to engage an aperture501in the light fixture shade500. The nut320may have a shape that corresponds to the shape of the aperture501in the light fixture shade500. The top-end portion302of the bottom connector300may pass through the aperture501in the light fixture shade500, allowing engagement of the top-end portion302with the top connector700and the stem200above the light fixture shade500. The bottom ring330of the bottom connector300may be located adjacent to the nut320. The bottom ring330may have a diameter greater than the second external-diameter322of the nut320. The bottom ring330may have an upper surface332configured for coupling to an interior surface502of the light fixture shade500adjacent to the aperture501. In some embodiments, this coupling may be direct, while in other embodiments the coupling may be indirect such as through the use of an intervening element such as a gasket105. The bottom ring330may further have a bottom opening333configured to extend into a cavity503within the light fixture shade500. In some embodiments, this bottom opening333may facilitate the passing of electrical components, such as wiring106, through the bottom connector300. In some embodiments, the bottom connector300may have a bottom-end portion303adjacent to the bottom ring330. As illustrated inFIG.6, the bottom-end portion303may comprise a housing340defining a cylindrical cavity. The housing340may have a top-opening coupled to the bottom-opening333of the bottom ring330. The housing340may be configured to receive electrical wiring106from the longitudinal stem-bore201of the stem200. The electrical wiring106may be adapted to connect to a light source (not shown) within the cavity503of the light fixture shade500. Top Connector Referring toFIGS.7A-7C, a connection assembly100may include a top connector700. In some embodiments, the top connector700may engage the bottom connecter300. The top connector700may have an internal threaded-connector segment701. The internal threaded-connector segment701may be configured to couple to at least a portion of the external threaded-connector segment310of the bottom connector300, as illustrated inFIG.1C. The top connector700may further include a bottom-side702configured for coupling to an exterior surface504of the light fixture shade500adjacent to the aperture501in the light fixture shade500. In some embodiments, the coupling may be direct, while in other embodiments the coupling may be indirect such as through the use of an intervening element such as an O-ring105. The top connector700may have a top-side703configured for coupling to the stem-opening203of the stem200. In some embodiments, this coupling may be direct, while in other embodiments the coupling may be indirect such as through the use of an intervening element such as an O-ring or gasket. Use of the Connection Assembly In some embodiments, upon operative engagement of the stem200with the bottom connector300, the longitudinal stem-bore201of the stem200and the longitudinal connector-bore301of the bottom connector300may define a hollow passage101, as illustrated inFIG.1C. Upon operative engagement of the top connector700with the bottom connector300, a seal102may form between the top connector700and the light fixture shade500. In some embodiments, enhancement of the seal102may occur with addition of an intervening component, such as an O-ring104or another component that would be obvious to one of ordinary skill in the art. In certain embodiments, the hollow passage101may be adapted to house electrical wiring106, and the seal102may be adapted to reduce water-leakage into the hollow passage101. In an embodiment, the electrical wiring106may be adapted to connect to a light source within the cavity503of the light fixture shade500. In some embodiments, the light fixture shade500may be configured to enable projection of light from the light source in a downward direction. The stem200may be adapted for mounting such a downward facing light fixture shade500. The connection assembly100may be adapted to mount the light fixture shade500on a ceiling (not shown) where the stem200has a tube or cylindrical shape (e.g., as illustrated inFIG.1A) in a vertical position. The connection assembly100may be adapted to mount the light fixture shade500on a vertical wall (not shown) where the stem200has a stem-segment having a gooseneck shape, as illustrated inFIG.12. In certain embodiments, a bottom seal103may form between the bottom connector300and the light fixture shade500, in addition to the seal102between the top connector700and the light fixture shade500. In such embodiments, the seal102and the bottom seal103may be located adjacent to the aperture501in the light fixture shade500. The seal102and the bottom seal103may clamp and support the light fixture shade500. In some embodiments, an intervening component (such as an O-ring104or another component that would be obvious to one of ordinary skill in the art) may enhance the seal102. An intervening component, such as a rubber gasket105or another component that would be obvious to one of ordinary skill in the art, may enhance the bottom seal103. Such sealing mechanisms may further reduce water leakage in the hollow passage101and the housing340that contain the electrical wiring106. Similar mechanisms may be implemented to seal the bottom-opening333of the bottom ring330with the housing340for the light source within the cavity503of the light fixture shade500. Alternative Connection Assembly FIGS.8-11illustrate an alternative connection assembly800comprising the stem200described above, as well as two alternative connectors. An alternative top connector900may be configured to engage the stem200and an alternative bottom connector1000, which may be configured to engage the alternative top connector900. The alternative top connector900and the alternative bottom connector1000may couple, directly or indirectly, to the light fixture shade500. Alternative Top Connector Referring toFIGS.8C and9A-9C, the alternative top connector900may have an external threaded-connector segment901configured to engage the internal threaded-stem segment205of the stem200. The alternative top connector900also contains a bottom-side902configured to couple to the exterior surface504of the light fixture shade500adjacent to the aperture501in the light fixture shade500. In some embodiments, this coupling may be direct, while in other embodiments the coupling may be indirect such as through the use of an intervening element such as an O-ring104. The alternative top connector900may have an internal threaded-connector segment903, which may be configured to engage an external threaded-connector segment1010of the alternative bottom connector1000. In certain embodiments, the alternative connection assembly800may provide the benefit of an improved sealing mechanism from water leakage and additional protection for the electrical wiring106. In some embodiments, the alternative top connector900may contain a hollow-bore904. The hollow-bore904may traverse an entire axial length of the alternative top connector900. In an embodiment, the hollow-bore904may differ in width throughout. The internal threaded-connector segment903may traverse a portion of the hollow-bore904. The top portion of the external threaded-connector segment1010of the alternative bottom connector1000may be configured to access the bottom portion of the hollow-bore904in order to facilitate the engagement of the external threaded-connector segment1010with the internal threaded-connector segment903of the alternative top connector900. In certain embodiments, this engagement of the alternative top connector900housing a portion of the alternative bottom connector1000may provide the benefit of an improved sealing mechanism to reduce water leakage into the cavity503within the light fixture shade500and may provide additional protection for the electrical wiring106within the housing1040. Alternative Bottom Connector Referring toFIGS.10A-10D, the alternative bottom connector1000may have a top-end portion1002, a nut1020, and a bottom ring1030. As described in the preceding paragraph, the alternative bottom connector1000may be configured to engage the alternative top connector900. The alternative bottom connector1000may comprise a longitudinal connector-bore1001, which may traverse an entire axial-length of the alternative bottom connector1000. An external surface of the alternative top-end portion1002may comprise an external threaded-connector segment1010. Referring back toFIG.8C, the external threaded-connector segment1010of the alternative bottom connector1000may engage the internal threaded-connector segment903of the alternative top connector900. The threading of the external threaded-connector segment1010of the alternative bottom connector1000and the internal threaded-connector-segment903of the alternative top connector900may be in the same direction, or in a different direction, as the threading of the internal threaded-stem segment205of the stem200and the external threaded-connector segment901of the alternative top connector900. The opposing direction of the threads may facilitate improved assembly of the connection assembly800. Such an embodiment may allow for a tighter engagement of the alternative bottom connector1000with the alternative top connector900, and a tighter engagement of the alternative top connector900with the stem200. In some embodiments, use of O-rings, gaskets, or the like may further improve the engagements. Referring toFIG.8C, an O-ring104may facilitate coupling of the alternative top connector1000with the light fixture shade500. A rubber gasket105may facilitate coupling of the alternative bottom connector900with the light fixture shade500. The O-ring104and the gasket105may facilitate this engagement by preventing unintentional rotation of the components of the alternative connection assembly800. The nut1020of the alternative bottom connector1000may be located adjacent to the external threaded-connector segment1010. The nut1020may have various shapes and two external diameters, similar to the first external-diameter321and the second external-diameter322described above. Such shapes may enable engagement of the nut1020by a wrench, socket driver, pliers, or other torsional tool to effectuate threaded engagement of the alternative bottom connector1000with the alternative top connector900. The nut1020may be configured to engage the aperture501in the light fixture shade500. The nut1020may have a shape that corresponds to the shape of the aperture501in the light fixture shade500. The top-end portion1002of the bottom connector1000may pass through the aperture501in the light fixture shade500, allowing engagement of the top-end portion1002with the alternative top connector900above the light fixture shade500. The bottom ring1030of the alternative bottom connector1000may be located adjacent to the nut1020. The bottom ring1030may have a diameter greater than the larger of the two external diameters of the nut1020. The bottom ring1030may have an upper surface1032configured for coupling to the interior surface502of the light fixture shade500adjacent to the aperture501in the light fixture shade500. In some embodiments, the coupling may be direct, while in other embodiments the coupling may be indirect such as through the use of an intervening element such as a gasket105. The bottom ring1030may have a bottom opening1033configured to extend into the cavity503within the light fixture shade500. In some embodiments, this bottom opening1033may facilitate the passing of electrical components, such as electrical wiring106, through the alternative bottom connector1030. In some embodiments, the alternative bottom connector1000may have a bottom-end portion1003adjacent to the bottom ring1030. As illustrated inFIG.11, the bottom-end portion1003may comprise a housing1040defining a cylindrical cavity. The housing1040may have a top-opening coupled to the bottom-opening1033of the bottom ring1030. The housing1040may be configured to receive electrical wiring106from the longitudinal stem-bore201of the stem200. The electrical wiring106may be adapted to connect to a light source (not shown) within the cavity503of the light fixture shade500. Use of the Alternative Connection Assembly In some embodiments, upon operative engagement of the stem200with the alternative top connector900and the operative engagement of the alternative top connector900with the alternative bottom connector1000, a hollow passage801is defined as illustrated inFIG.8Cby the longitudinal stem-bore201of the stem200, the hollow-bore904of the alternative top connector900, and the longitudinal connector-bore1001of the alternative bottom connector1000. Upon operative engagement of the alternative top connector900with the alternative bottom connector1000, a seal802may form between the alternative top connector900and the light fixture shade500. In some embodiments, enhancement of the seal802may occur with addition of an intervening component, such as an O-ring, gasket, or another component that would be obvious to one of ordinary skill in the art. In some embodiments, the hollow passage801may be adapted to house electrical wiring106, and the seal802may be adapted to reduce water-leakage into the hollow passage801. In an embodiment, the bottom-opening1033of the bottom ring1030of the alternative bottom connector1000may be configured to receive electrical wiring106adapted to connect to a light source (not shown). In some embodiments, the cavity503within the light fixture shade500may be adapted to house the light source. The light fixture shade500may be configured to enable projection of light from the light source in a downward direction. The stem200may be adapted for mounting such a downward facing light fixture shade500. The alternative connection assembly800may be adapted to mount the light fixture shade500on a ceiling (not shown) where the stem200has a tube or cylindrical shape (e.g., as illustrated inFIG.8A) in a vertical position. The alternative connection assembly800may be adapted to mount the light fixture shade500on a vertical wall (not shown) where the stem200has a stem-segment having a gooseneck shape, as illustrated inFIG.12. In certain embodiments, a bottom seal803may form between the alternative bottom connector1000and the light fixture shade500, in addition to the seal802between the alternative top connector900and the light fixture shade500. In such embodiments, the seal802and the bottom seal803may be located adjacent to the aperture501in the light fixture shade500. The seal802and the bottom seal803may clamp and support the light fixture shade500. In some embodiments, an intervening component (such as an O-ring104or another component that would be obvious to one of ordinary skill in the art) may enhance the seal802. An intervening component, such as a rubber gasket105or another component that would be obvious to one of ordinary skill in the art, may enhance the bottom seal803. Such sealing mechanisms may further reduce water leakage in the hollow passage801and the housing1040that contain the electrical wiring106. Similar mechanisms may be implemented to seal the bottom-opening1033of the bottom ring1030with the housing1040for the light source within the cavity503of the light fixture shade500. While the present disclosure has been particularly shown and described with reference to an embodiment thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present disclosure. Although some embodiments are specifically mentioned, others will be apparent to those of ordinary skill in the art and so do not present an exhaustive list of alternatives. | 21,095 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.