U.S. patent application number 13/478964 was filed with the patent office on 2013-11-28 for temperature control system for a machine and methods of operating same.
The applicant listed for this patent is Mark John DeBlock, Michael John Douglass, William Dwight Gerstler, Ilia Oxman, Olivier Pellerin, Jeremy Daniel Van Dam. Invention is credited to Mark John DeBlock, Michael John Douglass, William Dwight Gerstler, Ilia Oxman, Olivier Pellerin, Jeremy Daniel Van Dam.
Application Number | 20130315755 13/478964 |
Document ID | / |
Family ID | 48607011 |
Filed Date | 2013-11-28 |
United States Patent
Application |
20130315755 |
Kind Code |
A1 |
Oxman; Ilia ; et
al. |
November 28, 2013 |
TEMPERATURE CONTROL SYSTEM FOR A MACHINE AND METHODS OF OPERATING
SAME
Abstract
A temperature control system for an electrical machine and a
method of operating the system is provided. The machine includes a
housing enclosing a motor and a compressor, the housing includes a
suction pipeline in flow communication with the compressor. The
suction pipeline is configured to channel fluid into the housing. A
temperature control system assembly includes a fluid mover coupled
to at least one of the rotor shaft and the compressor shaft and in
flow communication with the suction pipeline upstream from the
compressor. The fluid mover is configured to channel the fluid from
the suction pipeline and across at least one of the motor and the
compressor. Temperature control system includes a distribution
header coupled to the housing and in flow communication with the
fluid mover, the distribution header includes a first outlet
coupled in flow communication to the motor to channel the fluid
across the motor.
Inventors: |
Oxman; Ilia; (Toronto,
CA) ; Gerstler; William Dwight; (Niskayuna, NY)
; DeBlock; Mark John; (Peterborough, CA) ; Van
Dam; Jeremy Daniel; (West Coxsackie, NY) ; Douglass;
Michael John; (Amsterdam, NY) ; Pellerin;
Olivier; (Le Cruesot, FR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Oxman; Ilia
Gerstler; William Dwight
DeBlock; Mark John
Van Dam; Jeremy Daniel
Douglass; Michael John
Pellerin; Olivier |
Toronto
Niskayuna
Peterborough
West Coxsackie
Amsterdam
Le Cruesot |
NY
NY
NY |
CA
US
CA
US
US
FR |
|
|
Family ID: |
48607011 |
Appl. No.: |
13/478964 |
Filed: |
May 23, 2012 |
Current U.S.
Class: |
417/368 |
Current CPC
Class: |
F04D 25/06 20130101;
F04D 29/5806 20130101 |
Class at
Publication: |
417/368 |
International
Class: |
F04D 29/58 20060101
F04D029/58; F04D 13/06 20060101 F04D013/06 |
Claims
1. An electrical machine comprising: a motor comprising a stator
and a rotor, said rotor comprising a rotor shaft; a compressor
rotatably coupled to said motor and comprising a compressor shaft;
a housing enclosing said motor and said compressor, said housing
comprising a suction pipeline in flow communication with said
compressor, said suction pipeline configured to channel a fluid
into said housing; and a temperature control assembly coupled in
flow communication to said housing, said temperature control
assembly comprising: a fluid mover coupled to at least one of said
rotor shaft and said compressor shaft and in flow communication
with said suction pipeline upstream from said compressor to channel
the fluid from said suction pipeline and across at least one of
said motor and said compressor; and a distribution header coupled
to said housing and in flow communication with said fluid mover,
said distribution header comprising a first outlet coupled in flow
communication to said motor to channel the fluid across said
motor.
2. The electrical machine of claim 1, wherein said housing
comprises a return pipeline coupled in flow communication to said
suction pipeline.
3. The electrical machine of claim 1, further comprising a motor
opposite drive end bearing and a motor drive end bearing coupled to
said rotor shaft, said fluid mover is configured to channel the
fluid across at least one of said motor bearings, said rotor, and
said stator.
4. The electrical machine of claim 1, further comprising a shaft
coupler coupled to said rotor shaft and said compressor shaft in
flow communication with said distribution header.
5. The electrical machine of claim 4, comprising a compressor
opposite drive end bearing coupled to said compressor shaft wherein
said first outlet is configured to channel fluid across at least
one of said compressor bearing, said shaft coupler, and said
compressor.
6. The electrical machine of claim 1, further comprising a motor
bearing coupled to said rotor shaft in flow communication with said
first outlet and a compressor opposite drive end bearing coupled to
said compressor shaft in flow communication with said first
outlet.
7. The electrical machine of claim 1, further comprising a second
outlet coupled in flow communication to said compressor to channel
the fluid across said compressor.
8. The electrical machine of claim 1, wherein said temperature
control assembly comprises a discharge pipeline and a heat
exchanger coupled to said discharge pipeline and between said
housing and said fluid mover.
9. The electrical machine of claim 8, wherein said heat exchanger
is in flow communication with said fluid mover.
10. The electrical machine of claim 8, further comprising a
normally open valve coupled to said suction pipeline and to said
housing in flow communication with said fluid mover and a normally
closed valve coupled to said heat exchanger and said housing in
flow communication with said fluid mover.
11. A temperature control system for use in cooling an electrical
machine, said system comprising: a housing having a motor portion,
a compressor portion and a suction pipeline, said motor portion,
said compressor portion and said suction pipeline configured in
flow communication; a temperature control assembly coupled to said
housing and comprising a distribution header coupled in flow
communication to said motor portion and said compressor portion;
and a fluid mover coupled to said motor portion and in flow
communication with said suction pipeline upstream from said
compressor portion, said fluid mover configured to channel a fluid
from said suction pipeline and within said motor portion, said
compressor portion and said distribution header.
12. The temperature control system of claim 11, wherein said
distribution header is coupled to said housing in flow
communication with a shaft coupler of the electrical machine.
13. The temperature control system of claim 11, wherein said
distribution header comprises a first outlet coupled in flow
communication to said motor portion and a second outlet coupled to
said housing in flow communication to said compressor portion.
14. The temperature control system of claim 11, wherein said
temperature control assembly comprises a motor return pipe and a
compressor return pipe coupled in flow communication to said
suction pipeline upstream from said compressor portion.
15. The temperature control system of claim 11, wherein said
distribution header couples to said housing in flow communication
with a motor bearing and a compressor bearing of the electrical
machine.
16. The temperature control system of claim 11, wherein said
compressor portion includes a first compressor portion and a second
compressor portion which are coupled in flow communication with
said distribution header.
17. The temperature control system of claim 11, further comprising
a heat exchanger coupled in flow communication to said housing and
to said fluid mover.
18. A temperature control system for use in cooling an electrical
machine, said system comprising: a housing having a motor portion,
a compressor portion and a suction pipeline, said motor portion,
said compressor portion and said suction pipeline configured in
flow communication; a temperature control assembly coupled to said
housing and comprising a distribution header coupled in flow
communication to said motor portion and said compressor portion; a
fluid mover coupled to said motor portion and in flow communication
with said suction pipeline upstream from said compressor portion,
said fluid mover configured to channel a fluid from said suction
pipeline and within said motor portion, said compressor portion and
said distribution header; and a heat exchanger coupled in flow
communication to said housing and to said fluid mover.
19. The temperature control system of claim 8, wherein said heat
exchanger is in flow communication with said fluid mover.
20. The temperature control system of claim 8, further comprising a
normally open valve coupled to said suction pipeline and to said
housing in flow communication with said fluid mover and a normally
closed valve coupled to said heat exchanger and said housing in
flow communication with said fluid mover.
Description
BACKGROUND
[0001] The present disclosure relates to electrical machines and,
more particularly, to methods and systems for use in temperature
control of the electrical machine.
[0002] Electrical machines, such as integrated motor-driven
compressors, generate heat during operation as a result of both
electrical and mechanical losses. Components in both the motor and
the compressor of the integrated motor-driven compressor require
temperature control in order to maintain temperatures within
allowable operating ranges. An excessively high motor temperature,
for example, may result in motor bearing failure and/or damage to
the stator winding insulation, power connectors, or
instrumentation. Maintaining optimal temperature range for
temperature sensitive components of electrical machines results in
enhanced performance efficiency and extending service life.
[0003] Electrical drives may be advantageous over mechanical drives
(i.e., gas turbines) in operational flexibility (attaining constant
torque at variable speed for example), maintainability, lower
capital cost and lower operational cost, better efficiency, and
environmental compatibility. Additionally, electric drives are
generally simpler in construction than mechanical drives, generally
require a smaller foot print, may be easier to integrate with a
temperature control system, may eliminate the need for a gearbox,
and/or may be more energy efficient and reliable than mechanical
drives.
[0004] At least some known electrical machines use temperature
control systems that include separate cooling systems for both the
motor and the compressor. However, multiple cooling systems may
increase manufacturing, installation, operation, and/or maintenance
costs. Further, within at least some known electric drives,
compressor and drive components are cooled using high pressure gas
bled from the compressor. However, bleeding significant flow of
partly or fully compressed gas from the compressor to provide for
motor cooling needs reduces compression efficiency and may also
cause additional stress, vibration, and fatigue of the compressor
components. In some cases, the pressure of the fluid available from
the compressor is far higher than the pressure required for cooling
flow and must be throttled, which represents an efficiency loss.
Further, in some cases, the fluid being transported may have
aggressive constituents or impurities entrained therein that may
adversely affect service life of the components being used.
BRIEF DESCRIPTION
[0005] In one aspect, an electrical machine is provided. The
electrical machine includes a motor having a stator, a rotor, and a
rotor shaft, wherein a compressor is rotatably coupled to the motor
and includes a compressor shaft. The machine further includes a
housing enclosing the motor and the compressor, wherein the housing
includes a suction pipeline in flow communication with the
compressor. The suction pipeline is configured to channel fluid
into the housing. A temperature control system assembly is coupled
in flow communication to the housing. The temperature control
system assembly includes a fluid mover coupled to at least one of
the rotor shaft and the compressor shaft and in flow communication
with the suction pipeline upstream from the compressor. The fluid
mover is configured to channel the fluid from the suction pipeline
and across at least one of the motor and the compressor. The
temperature control system further includes a distribution header
coupled to the housing and in flow communication with the fluid
mover, wherein the distribution header includes a first outlet
coupled in flow communication to the motor to channel the fluid
across the motor.
[0006] In another aspect, a temperature control system for use in
cooling an electrical machine. The system includes a housing having
a motor portion, and a compressor portion, wherein the motor
portion and the compressor portion are configured in flow
communication. The system further includes a temperature control
system coupled to the housing and includes an inlet coupled to the
motor portion and includes a distribution header coupled to the
motor portion and the compressor portion. A fluid mover is coupled
to the motor portion and configured to channel a fluid from the
inlet and within the motor portion and the distribution header.
[0007] In a further aspect, a method of operating an electrical
machine having a motor, a compressor and a suction pipeline is
provided. The method includes moving a fluid from the suction
pipeline and into a housing having a motor portion disposed about
the motor and a compressor portion disposed about the compressor.
The fluid is moved within the motor portion and across the motor
and within the compressor portion and across the compressor. The
method includes moving the fluid within a distribution header in
flow communication with the motor portion and the compressor
portion, and then discharging the fluid from the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a cross-sectional schematic view of an exemplary
temperature control system that may be used with an electrical
machine.
[0009] FIG. 2 is a cross-sectional schematic view of an alternative
temperature control system that may be used with an electrical
machine.
[0010] FIG. 3 is a cross-sectional schematic view of an alternative
temperature control system that may be used with an electrical
machine.
[0011] FIG. 4 is a cross-sectional schematic view of an alternative
temperature control system that may be used with an electrical
machine.
[0012] FIG. 5 is a cross-sectional schematic view of an alternative
temperature control system that may be used with an electrical
machine.
[0013] FIG. 6 is a flowchart of an exemplary method of operating a
temperature control system in an integrated motor-compressor
electrical machine.
DETAILED DESCRIPTION
[0014] FIG. 1 is a cross-sectional schematic view of an exemplary
temperature control system 10 for use with an electrical machine
12. In the exemplary embodiment, machine 12 includes an integrated
motor-compressor assembly 14. Temperature control system 10
facilitates temperature control, such as cooling and/or heating,
for temperature-sensitive components of assembly 14. In the
exemplary embodiment, machine 12 includes a multi-stage compressor
16 that is rotatably coupled to an electric drive motor 18.
[0015] Temperature control system 10 includes a single common
housing 20 that encloses motor 18, compressor 16, forming a
leak-tight pressure vessel. In the exemplary embodiment, static
components of motor 18 and compressor 16 are fixedly coupled within
housing 20. Motor 18 is positioned within a motor portion 22 of
housing 20 and compressor 16 is positioned within a compressor
portion 24 of housing 20. Housing 20 includes a compressor suction
port 26 that is coupled in flow communication to compressor portion
24. Compressor suction port 26 is also coupled to an inlet suction
pipeline 28 that is coupled to a fluid source 29 containing
compressible fluid 30 at an initial pressure. Fluid source 29
includes structures such as, but not limited to, storage tanks,
process or distribution pipelines, natural gas wells, etc. Fluid 30
includes a medium such as, but not limited to, gas, air and various
other compressible gaseous media. In the exemplary embodiment,
fluid 30 includes a mixture of flammable gases termed "natural
gas". Fluid 30 may be obtained directly from various mineral
resources or produced by an engineered, biological or chemical
process.
[0016] In the exemplary embodiment, temperature control system 10
also includes a compressor end piece 32 that is coupled to housing
20. End piece 32 facilitates enclosing compressor 16 within
assembly 14 subsequent to insertion of compressor 16 into housing
20 and includes a compressor discharge outlet 34 that is coupled in
flow communication to a compressor outlet pipeline 36. Compressor
outlet pipeline 36 may couple to other systems (not shown) and/or
to fluid source 29. In addition, a motor end cover 38 is coupled to
housing 20. End cover 38 facilitates enclosing motor 18 within
assembly 14 subsequent to insertion of motor 18 into housing 20. As
illustrated, housing 20 encloses motor 18 and compressor 16 to
define an interior 40 that facilitates flow communication within
and between motor portion 22 and compressor portion 24. In this
embodiment, housing 20 can be constructed with one or both of the
side covers 32 and 38 which are removable, for convenient assembly
and maintenance. Alternatively, housing 20 may include other
constructions (not shown) such as, but not limited to, a
construction with a horizontal split.
[0017] Motor 16 includes a rotor 42 fabricated from magnetically
conductive materials, a plurality of permanent magnets (not shown)
that are coupled to rotor 42, and a stator 44 that are positioned
such that a gap 46 is defined between rotor 42 and stator 44. The
permanent magnets induce a magnetic field around rotor 42. When
stator 44 is powered, an electromagnetic field is induced within
motor 16. Gap 46 facilitates magnetic coupling of rotor 42 and
stator 44 to generate a torque that induces rotation in rotor 42.
Alternatively, motor 16 may include any configuration that provides
for an electro-magnetic coupling between rotor 42 and stator
44.
[0018] A shaft 48 extends through rotor 42, and defines a motor
axis of rotation 50. Motor axis 50 may be a center axis for housing
20, rotor 42, and stator 44. Shaft 48 may be fixed to rotor 42 such
that as rotor 42 rotates, rotor 42 drives shaft 48. Likewise, when
shaft 48 rotates, shaft 48 may drive rotor 42. Bearings 52 support
shaft 48 within housing 20. In the exemplary embodiment, bearings
52 include an opposite drive end motor bearing 54 and a drive end
motor bearing 56. Alternatively, bearings 52 (not shown) may be
housed in separate enclosures to facilitate replacement without
interference with other components at system 10.
[0019] Compressor 16 includes a rotatable compressor shaft 58 that
is coupled to rotor 42. In the exemplary embodiment, a shaft
coupler 60 is configured to rotatably couple rotor shaft 48 to
compressor shaft 58. Coupler 60 includes a rotating coupling
element (not shown). Coupler 60 may include any mechanical contact
coupling (not shown) or non-contacting electro-magnetic coupling
(not shown). Alternatively, rotor shaft 48 and compressor shaft 58
may be integral (not shown) and free from any coupling element.
Rotor shaft 48 and compressor shaft 58 are rotatable about motor
axis of rotation 50. In the exemplary embodiment, compressor 16
includes a plurality of compressor stages 62. Alternatively,
compressor 16 may include only one stage (not shown). Compressor
shaft 58 is supported by radial bearings 64 and 66, and an axial
bearing 68. Location of the radial bearings 64 and 66 and thrust
bearing 68 within compressor portion 24 may vary depending on
design requirements; wherein bearings 64, 66, or 68 may be located
opposite of the compressor portion 24 and enclosed in their own
separate housings (not shown).
[0020] In the exemplary embodiment, temperature control system 10
includes a temperature control assembly 70 and a fluid mover 72.
Temperature control assembly 70 includes a supply pipeline 76, a
return pipeline 78 and a distribution header 80 coupled to housing
20 and in flow communication with supply pipeline 76 and return
pipeline 78. As illustrated in FIG. 1, motor 18 with its associated
shaft 48 and bearings 54 and 56, shaft coupler 60 and compressor 16
with its associated shaft 58 and bearings 64, 66 and 68, are in
flow communication with distribution header 80.
[0021] Supply pipeline 76, return pipeline 78 and distribution
header 80 are coupled to housing 20 and in flow communication with
interior 40 of housing 20. More particularly, supply pipeline 76 is
coupled in flow communication with inlet suction pipeline 28 and
motor end cover 38. More particularly, supply pipeline 76 is
coupled in flow communication with inlet suction pipeline 28
upstream from suction port 26 Return pipeline 78 is coupled in flow
communication to housing 20 and inlet suction pipeline 28.
Connection of return pipeline 78 to inlet suction pipeline 28 is
downstream of the connection point of supply pipeline 76 to inlet
suction pipeline 28. Pipelines 76 and 78 may be fabricated of
metal, rubber, polyvinylchloride (PVC), or any material that
attains predetermined operational parameters associated with fluid
30 being transported and the location of assembly 14. Pipelines 76
and 78 are sized to facilitate initial filling, and subsequently
facilitate maintaining fluid pressure within housing 20 at
pre-determined operating pressures.
[0022] In the exemplary embodiment, supply pipeline 76 includes a
flow control device 82 such as, but not limited to, a regulating
valve, for example, a throttling-type valve that is adjusted to
predetermined open positions to facilitate channeling a
predetermined flow of fluid 30 from fluid source 29 and through
housing 20 as well as a predetermined rate of pressurization of
housing 20. Flow control device 82 may be, but not be limited to, a
needle valve. Other types of regulating valves may also be used
that enables functionality of the temperature control system 10 as
described herein. Moreover, flow control device 82 may include flow
control orifices.
[0023] Motor end cover 38 includes a fluid supply passage 84
defined within motor end cover 38 that is coupled in flow
communication with supply pipeline 76. Fluid supply passage 84 is
sized to facilitate initial filling of, and subsequently facilitate
maintaining fluid pressure within housing 20 at pre-determined
operating pressures. Passage 84 also facilitates creating optimal
inlet flow pattern for fluid mover 72 and controlling a rate of
pressurization of housing 20 to a predetermined rate.
[0024] Return pipeline 78 includes a motor return pipeline section
86 and a compressor return pipeline section 88. Motor return
pipeline section 86 is coupled in flow communication to motor
portion 22 and to inlet suction pipeline 28. Motor return pipeline
section 86 includes a flow control device 90 located between
housing 20 and inlet suction pipeline 28. Compressor return
pipeline section 88 is coupled in flow communication to compressor
portion 24 and inlet suction pipeline 28. Compressor return
pipeline section 88 includes a flow control device 92 located
between housing 20 and inlet suction pipeline 28. Motor return
pipeline 86 and compressor return pipeline 88 are coupled to
suction pipeline 28 downstream of supply pipeline 76 and upstream
from suction port 26. The return flow of fluid 30 through motor
return pipeline 86 and compressor return pipeline 88 can be mixed
with fluid 30 within inlet suction pipeline 28 to facilitate closed
temperature operations for control system 10.
[0025] Distribution header 80 includes a first outlet 94, a second
outlet 96, and a distribution channel 98 between first outlet 94
and second outlet 96. Alternatively, distribution header 80 may
have a single outlet or more than three outlets in flow
communication with housing 20. In the exemplary embodiment,
distribution header 80 is configured external of housing 20.
Alternatively, distribution header 80 can be positioned within
housing 20. More particularly, distribution header 80 can be
positioned within at least one of motor portion 22 and compressor
portion 24.
[0026] First outlet 94 is coupled to housing 20 and in flow
communication with motor portion 22. More particularly, first
outlet 94 is in flow communication with motor portion 22 adjacent
shaft coupler 60. Distribution header 80 includes a flow control
device 100 located between first outlet 94 and distribution channel
98. Second outlet 96 is coupled to housing 20 and in flow
communication with compressor portion 24. Second outlet 96 is flow
communication with compressor portion 24 adjacent opposite drive
end compressor bearing 64. Distribution header 80 further includes
a flow control device 102 located between second outlet 96 and
distribution channel 98. Flow control devices 82, 90, 92, 100, 102
may be manually and/or electronically controlled. In the exemplary
embodiment, a controller 104 is coupled to flow control devices via
control circuits 106 to facilitate electronic operation of flow
control devices. For simplicity, FIG. 1 illustrates control circuit
106 coupling flow control device 92 to controller 104. Any type of
controller 104 such as, but not limited to, a central processing
unit or microprocessor may be used that enables temperature control
system 10 and electrical machine 12 to function as described
herein.
[0027] Fluid mover 72 is coupled to at least one of rotor shaft 48
and compressor shaft 58. In the exemplary embodiment, fluid mover
72 is a fan coupled to an opposite drive end portion of motor shaft
48 to rotate with rotor shaft 48. Fluid mover 72 is dimensioned and
positioned to facilitate fluid flow from suction pipeline 28,
through supply pipeline 76 and within housing 20, motor portion 22,
and compressor portion 24 to facilitate temperature control of
temperature sensitive components therein. Moreover, fluid mover 72
is dimensioned and positioned to facilitate fluid flow within
distribution header 80. Alternatively, fluid mover 72 may include,
but not be limited to, a pump or compressor or any device that
attains predetermined parameters associated with fluid 30 being
transported within housing 20. Moreover, fluid mover 72 may be
positioned within interior 40 of housing 20 wherever predetermined
operational parameters are attained. In an alternative embodiment
(not shown), fluid mover 72 is coupled to compressor shaft 58.
Using a low compression ratio fluid mover 72 to facilitate fluid
flow across compressor 16 and motor 18 is more economical than
diverting a portion of high pressure gas obtained inside or
downstream of known compressors (not shown) for temperature control
of compressor components.
[0028] In operation, fluid 30 being transported by temperature
control system 10 is used to facilitate temperature control of at
least motor 18, coupler 60, and compressor 16 along with associated
shafts 48 and 58 and bearings 54, 56 and 64, 66 and 68 as
illustrated with arrows in FIG. 1. Prior to electrically powering
stator 44 and starting motor 18, housing 20 is filled with fluid 30
and attains a pressure substantially similar to that of inlet
suction pipeline 28. Moreover, motor portion 22 and compressor
portion 24 are filled with fluid 30 and are also in substantial
pressure equilibrium.
[0029] During operation, a power source (not shown) supplies
multi-phase alternating current to stator 44 at pre-determined
voltages and frequencies. A rotating electromagnetic field is
generated in stator 44. At any given speed, a relative strength of
the magnetic field generated is proportional to the voltage
supplied by power source. As the electromagnetic field induced in
stator 44 rotates, the magnetic field of rotor 42 interacts with
the electromagnetic field of stator 44 through gap 46. The
interaction of the two magnetic fields induces torque, and
subsequently, rotation of rotor 42 and rotor shaft 48. Compressor
shaft 58 is rotated via coupler 60 to power compressor 16.
[0030] Fluid 30 is channeled from fluid source 29 and into inlet
suction pipeline 28 due to low suction pressure created in the
compressor inlet 26 as a result of rotation of rotor 42 and/or
rotor shaft 48. A portion of fluid 30 is channeled into compressor
16, where its pressure is increased to a required value. During
process of compression in compressor 16, fluid 30 is heated. Heated
fluid 30 from compressor 16 is discharged through compressor
discharge outlet 34 and through compressor outlet pipeline 36.
Discharged fluid 30 from compressor outlet pipeline 36 can be
re-circulated with fluid source 29.
[0031] In operation, a portion of fluid 30 is channeled from inlet
suction pipeline 28, through supply pipeline 76 and towards motor
end cover 38 as the associated arrows illustrate. Fluid 30 is
channeled through motor portion 22, compressor portion 24, and
distribution header 80, and subsequently channeled to suction port
26 via return pipeline 78. More particularly, once motor 18 is
powered and rotor 42 is rotating, fluid mover 72 forms a low
pressure region locally in the vicinity of the region wherein
passage 84 couples in flow communication to motor portion 22 and
also forms a local high pressure region within motor portion 22.
Fluid 30 is channeled by fluid mover 72 from inlet suction pipeline
28, through supply pipeline 76, and into passage 84. The fluid 30
is further channeled within motor portion 22 and across opposite
motor drive end bearing 54, motor 18, and motor drive end bearing
56. As fluid 30 is channeled through motor portion 22, fluid 30
removes heat from motor 18 and bearings 56 and 58. Heated fluid 30
from motor portion 22 is discharged through motor return pipeline
86, where heated fluid 30 is mixed with fluid 30 in inlet suction
pipeline 28.
[0032] A portion of fluid 30 that is moved by fluid mover 72 is
channeled into distribution header 80 and through at least one
first outlet 94 and second outlet 96. A portion of fluid 30 flows
from header 80, through first outlet 94 and within motor portion
22. More particularly, a portion of fluid 30 flows across coupler
60, motor drive end bearing 56, and opposite drive end compressor
bearing 66. As fluid 30 is channeled through first outlet 94, fluid
removes heat from coupler 60 and motor bearing 56 and compressor
bearing 66. Portions of fluid 30 from housing 20, which houses
coupler 60, is directed through bearings 56 and then is channeled
through motor return pipeline 86, where the heated fluid 30 is
mixed with fluid 30 in inlet suction pipeline 28. Other portions of
fluid 30 are channeled from shaft coupler 60 through the compressor
bearing 66 and then mixed with suction flow of the compressor
16.
[0033] A portion of fluid 30 flows through header 80 and into
second outlet 96, within compressor 16, and through the opposite
drive end compressor bearing 64 and thrust bearing 68. As fluid 30
is channeled through second outlet 96, fluid 30 removes heat from
bearings 64 and 68. Heated fluid 30 from bearings 64 and 68 is
channeled through compressor return pipeline 88, where the heated
fluid 30 is mixed with fluid 30 in inlet suction pipeline 28.
Controller 104 and regulating flow control devices facilitate
optimizing fluid supply to various areas of temperature control
system 10 over a range of temperatures, rotating speeds, and motor
loads.
[0034] During operation of temperature control system 10, fluid
mover 72 is coupled to rotor shaft 48 and fluid 30 at low pressure
is taken from inlet suction pipeline 28 upstream from compressor
16, wherein fluid pressure is then increased by fluid mover 72 and
the flow of compressed cooling fluid 30 is directed to the various
components in motor portion 22 and compressor portion 24 to
facilitate simultaneously maintaining temperatures within a
pre-determined range. Temperature control system 10 uses the same
source of pressurized fluid and the same fluid source 29 for
various sub-systems located in motor portion 22 and compressor
portion 24, where the source of pressurized fluid, i.e., fluid
mover 72 is coupled to rotor shaft 48. Cost reduction is achieved
by using single temperature control system 10 for cooling motor
portion 22 and compressor portion 24. Moreover, fluid heat-up prior
to channeling fluid 30 after compression by fluid mover 72 is
minimal, since any temperature rise in fluid mover 72 and fluid 30
that is channeled to distribution header 80 can be made acceptably
small due to low compression ratio of fluid mover 72, such as a
fan, and by design of the components in contact with fluid 30.
[0035] Temperature control system 10 can also be used for heating
of motor portion 22 and/or compressor portion 24 when appropriate
amount of heating fluid 30 is provided. For example, components of
motor 18 and/or compressor 16 may require pre-heating prior to cold
start of integrated motor-compressor assembly 14 and/or to perform
diagnostic testing.
[0036] FIG. 2 is a cross-sectional schematic view of an alternative
temperature control system 108. Moreover, in FIG. 2, the same
reference numerals are used to indicate identical components
previously described. Motor 18 further includes at least one
magnetic bearing 56 coupled to motor rotor shaft 48 to support
rotor shaft 48. Compressor 16 also includes at least one magnetic
bearing 66 coupled to compressor shaft 58 to support compressor
shaft 58. Magnetic bearing 56 is sealed from the motor inner space
with a seal 110 and magnetic bearing 66 is sealed from the
compressor inner space with a seal 112. In the exemplary, seals 110
and 112 include non-contact labyrinth seals 130 to facilitate
operation of bearings 56 and 66.
[0037] Magnetic bearings 56 and 66 facilitate radial positioning of
motor rotor shaft 48 and compressor shaft 58. In the exemplary
embodiment, magnetic bearings 56 and 66 are configured to be an
active-type of magnetic bearing. More specifically, a control
sub-system (not shown) is used in conjunction with magnetic
bearings 56 and 66 to determine the radial position of the
rotational bearing component (not shown) relative to the fixed
component (not shown) at any given time, and facilitate magnetic
adjustments to correct any deviations at any given angular
position. Magnetic bearings 56 and 66 facilitate operation of motor
rotor shaft 48 and compressor shaft 58 at the high speeds
associated with exemplary motor 18 and compressor 16.
Alternatively, non-magnetic bearings (not shown) may be used that
include, but not be limited to including, roller bearings, for
example, that attain predetermined parameters, that include, but
are not limited to, mitigating vibration and friction losses. At
least one rundown bearing (not shown) may be positioned within
motor 18 and/or compressor 16 to facilitate radial support to rotor
shaft 48 and/or compressor shaft 58 in the event of magnetic
bearing failure. Furthermore, at least one axial bearing 68 may be
coupled to compressor 16 to facilitate mitigating the effects of
axial thrust of motor shaft 48 and compressor shaft 58.
[0038] In the exemplary embodiment, first outlet 94 of distribution
header 80 is in flow communication with a motor inlet 114 and
outlet 95 of header 80 is in flow communication with a compressor
inlet 116. Distribution header 80 further includes a flow control
device 118 between motor inlet 114 and distribution channel 98, and
includes a flow control device 120 between compressor inlet 116 and
distribution channel 98. Moreover, return pipeline 78 includes a
first return pipeline 122 and a second return pipeline 124 that are
in flow communication with suction pipeline 28. In the exemplary
embodiment, first return pipeline 122 includes a flow control
device 126 between housing 20 and inlet suction pipeline 28, while
second return pipeline 124 includes a flow control device 128
between housing 16 and inlet suction pipeline 28.
[0039] During operation, fluid 30 is channeled into and through
distribution header 80 as previously described. A portion of fluid
30 is channeled through motor inlet 114 and into housing 20. More
particularly, fluid 30 is channeled into housing 20 between
magnetic bearing 56 and seal 110, fitted with non-contact labyrinth
seal 130. Fluid 30 is channeled through and out of labyrinth seal
130 into housing 20 and across bearing 56 and coupler 60 to
facilitate cooling of bearing 56 and coupler 60. Heated fluid 30,
after passing through labyrinth 130, is mixed with heated fluid 30
from motor 18 and channeled out of housing 20 through the first
return pipeline 122. Heated fluid 30 from bearing 56 and coupler 60
is channeled through second return pipeline 124, where heated fluid
30 is mixed with fluid 30 in inlet suction pipeline 28 and
transferred to compressor suction port 26.
[0040] A portion of fluid 30 is channeled through outlet 95 of
distribution header 80 to compressor inlet 116 and into housing 20.
More particularly, fluid 30 is channeled into housing 20 between
magnetic bearing 60 and seal 112, which is fitted with non-contact
labyrinth seal 130. Fluid 30 is channeled through and out of
labyrinth 130 into housing 20 and across bearing 66 and coupler 60
to facilitate cooling of bearing 66 and coupler 60. Heated fluid 30
from bearing 66 and coupler 60 is channeled through second return
pipeline 124, where the heated fluid 30 is mixed with fluid in
suction pipeline 28 and transferred to compressor suction port 26.
During operation, flow control devices 118, 120 and 126, 128 are
coupled to controller 104 through temperature control circuits 166
to facilitate regulating fluid flow rates.
[0041] FIG. 3 is a cross-sectional schematic view of an alternative
fluid system 132. Moreover, in FIG. 3, the same reference numerals
are used to indicate identical components previously described.
Fluid system 132 includes suction pipeline 28, supply pipeline 76,
return pipeline 78, and distribution header 80 coupled to housing
20 and in flow communication with supply pipeline 76 and return
pipeline 78 as previously described. Moreover, fluid system 132
includes a heat exchanger 134, a regulator 136, a flow control
device 138, a heat exchange return pipeline 140, and a filter
142.
[0042] Supply pipeline 76, return pipeline 78, and distribution
header 80 are coupled to housing 20 and in flow communication with
interior 40 of housing 20. More particularly, supply pipeline 76 is
coupled in flow communication with inlet suction pipeline 28 and
motor end cover 38. Flow control device 82 is coupled to inlet
suction pipeline 28 between supply pipeline 76 and motor end cover
38. During normal operation, flow control device 28 is open. Filter
142 is coupled in flow communication to supply pipeline 76. Filter
142 is configured to mitigate and/or prevent introduction of
contaminants present in fluid 30 into housing 20. Supply pipeline
76 is coupled in flow communication with compressor portion 24 via
inlet 144.
[0043] Return pipeline 78 is coupled in flow communication to
housing 20 and supply pipeline 76. Pipelines 76 and 78 may be
fabricated of metal, rubber, polyvinylchloride (PVC), or any
material that attains predetermined operational parameters
associated with the fluid being transported and the location of
assembly 14. Pipelines 76 and 78 are sized to facilitate initial
filling, and subsequently facilitate maintaining fluid pressure
within housing 20 at a pre-determined operating pressure.
[0044] Return pipeline 78 includes motor return pipeline 86 and
compressor return pipeline 88. Motor return pipeline 86 is coupled
in flow communication to motor portion 22 and to supply pipeline
76. Motor return pipeline 86 includes flow control device 90
located between housing 20 and supply pipeline 76. Compressor
return pipeline 88 is coupled in flow communication to compressor
portion 24 and to heat exchanger 134. Compressor return pipeline 88
includes flow control device 92 located between housing 20 and
heart exchanger 134.
[0045] Distribution header 80 includes first outlet 94, second
outlet 96 and third outlet 97 and distribution channel 98 located
between first and second outlets 94 and 96. In the exemplary
embodiment, first outlet 94 of distribution header 80 includes
motor inlet 114 and third outlet 97 includes compressor inlet 116.
Distribution header 80 further includes a flow control device 118
between motor inlet 114 and distribution channel 98, and includes
flow control device 120 between compressor inlet 116 and
distribution channel 98. Moreover, temperature control system 10
includes a flow direction device 101 that is coupled to housing 20
and in flow communication with compressor inlet 116. Flow direction
device 101 is configured to channel fluid 30 from compressor inlet
116 and across at least one of bearing 66 and coupler 60. Flow
direction device 101 is configured to facilitate directing fluid 30
from header 80 and toward bearing 66 and coupler 60 because
compressor inlet 166 is positioned adjacent to high pressure area
of compressor 16. In the exemplary embodiment, flow control device
101 includes a seal such as, but not limited to, a labyrinth seal
which may includes a non-contacting seal and/or a contact seal. Any
structure for enabling fluid flow may be used that enables
temperature control system 10 and electrical machine 12 to function
as described herein.
[0046] Heat exchanger 134 is coupled to housing 20 and in flow
communication with motor portion 22. In the exemplary embodiment,
heat exchanger 134 is coupled to and in flow communication with
compressor return pipeline 88. Moreover, heat exchanger 134 is
coupled and in flow communication with return pipeline 140.
Regulator 136 is coupled to and in flow communication with heat
exchanger 134. Regulator 136 is controlled by controller 104 based
on pre-determined operating characteristics such as, but not
limited to, motor temperature and compressor temperatures. Heat
exchanger return pipeline 140 is coupled to supply pipeline 76 and
in flow communication with motor portion 22 via motor end cover 38.
Return pipeline 140 includes flow control device 138 such as, but
not limited to, a check valve that is configured to facilitate
maintaining a predetermined rate of fluid flow and a predetermined
rate of pressurization of housing 20. During normal operation of
system 10, flow control device 138 is normally closed to facilitate
fluid flow from heater exchanger 134 to other systems (not
shown).
[0047] In the exemplary embodiment, heat exchanger 134 is located
at predetermined distances from housing 20 to facilitate conductive
heat transfer from heat exchanger 134 to an environment 148
external to housing 20. Alternatively, configurations (not shown)
for heat exchanger 134 may include, but not be limited to, heat
exchanger 134 positioned in contact with housing 20 and/or heat
exchanger 134 being configured to be integral with portions of
housing 20 and/or internal to housing 20. Heat exchanger 134 may be
positioned in environments 148 wherein external temperatures on
housing 20, or the temperature of the fluid 30 within housing 20,
are such that effective conductive heat transfer using the methods
and apparatus of the exemplary embodiments as discussed above may
not be fully facilitated.
[0048] During operation, fluid 30 is channeled from suction
pipeline 28 and into supply pipeline 76. During normal operation,
flow control device 82 is normally open to facilitate channeling
fluid 30 from supply pipeline 76 through passageway 84 and in flow
communication with fluid mover 72. Fluid 30 is channeled into and
through motor portion, compressor portion and distribution header
80 as previously described. A portion of fluid 30 is channeled
through motor inlet 114 and into motor portion 22 and through
compressor inlet 116 and inlet compressor portion 24. Moreover, a
portion of fluid 30 is channeled through second outlet 96 and into
compressor portion 24. In the exemplary embodiment, fluid 30 is
channeled through housing 20 via supply pipeline 76 and heat is
removed from motor portion 22 and/or compressor portion 24 as in
the exemplary embodiments and then fluid 30 is channeled through
heat exchanger 134, wherein heat is transferred from fluid 30 and
to environment 148 external to housing 20.
[0049] During other operations such as start up of electrical
machine 12 and/or adding another electrical machine (not shown) to
work in combination with electrical machine 12, increased
temperature of fluid 30 may be required for electrical machine 12.
During operations for increased fluid temperature, controller 104
is configured to close normally open flow control device 82 and to
open normally closed flow control device 138. Fluid 30 is channeled
from heat exchanger 134, through heat exchange return pipeline 140
and to supply pipeline 76 and subsequently to fluid mover 72 for
flow through housing 20.
[0050] FIG. 4 is a cross-sectional schematic view of an alternative
fluid temperature control system 150 used with an electrical
machine 152. Moreover, in FIG. 4, the same reference numerals are
used to indicate identical components previously described. Fluid
system 150 further includes supply pipeline 76, return pipelines
78, distribution header 80, and compressor outlet pipeline 36 as
previously described. In the exemplary embodiment, electrical
machine 152 includes a plurality of compressors 16 such as, but not
limited to, a first compressor 154 and a second compressor 156
located on opposite sides of motor 18. First and second compressors
154 and 156 are in fluid communication with motor 18 within housing
20. Couplers 60 are configured to couple first and second
compressors 154 and 156 to motor shaft 48. Electrical machine 152
with two compressors 154 and 156 driven by single motor 18
facilitates reducing axial thrust and increasing flow rates as
compared to known compressors (not shown). Fluid system 150
includes fluid mover 72 such as, but not limited to a fan, that is
coupled to motor shaft 48. Fluid mover 72 is configured to channel
fluid 30 across electrical machine 152 and across first and second
compressors 154 and 156 and associated bearings (not shown) and
couplers 60.
[0051] FIG. 5 is a cross-sectional schematic view of an alternative
fluid temperature control system 158 used with an electrical
machine 160. Moreover, in FIG. 5, the same reference numerals are
used to indicate identical components previously described in FIG.
4. For electrical machine 154, couplers 60 are exposed to ambient
environment 148 to facilitate heat transfer from couplers 60.
[0052] FIG. 6 is a flowchart illustrating an exemplary method 200
of applying thermal controls for operating a compressor driven by
an electric motor, for example machine 12 (shown in FIG. 1). Method
200 includes moving 210 a fluid, such as fluid 30 (shown in FIG.
1), from a low pressure side of machine, such as inlet suction
pipeline 28 and into a housing, for example housing 20 (shown in
FIG. 1). The housing includes a motor portion, such as motor
portion 22 (shown in FIG. 1), disposed about the motor, for example
motor 18 (shown in FIG. 1) and a compressor portion, such as
compressor portion 24 (shown in FIG. 1), and disposed about the
compressor, for example compressor 16 (shown in FIG. 1). Fluid, for
example fluid 30 (shown in FIG. 1), is moved 220 within motor
portion and across the motor and moved within the compressor
portion via compression by fluid mover mechanically coupled to
motor or/and compressor shaft, such as cooling fan 72 (shown in
FIG. 1). Method 200 includes directing 230 fluid across temperature
sensitive elements in motor and compressor, such as but not limited
to bearings 54, 56, 66 and 68 and shaft coupler 60 (as shown in
FIG. 1) within a distribution header, such as distribution header
80 (shown in FIG. 1), which is in flow communication with locations
of the temperature sensitive elements. Method 200 further includes
channeling fluid across motor temperature sensitive components such
as, but not limited to stator windings, electrical connection plugs
and rings, air gaps between rotor and stator. Fluid is then
discharged from housing and into suction port of the compressor.
The discharged fluid is mixed with fluid in suction pipeline 28,
upstream of the compressor. In the exemplary embodiment, fluid 30
is discharged through a heat exchanger such as heat exchanger 134
(shown in FIG. 3).
[0053] The embodiments described herein provide an integral
temperature control system for thermal treatment of an electrical
machine. The electrical machine can include a turbo-generator which
can include a turbine section and electric machine section, a
housing a turbine rotor that is rotatably coupled to an electric
machine rotor. The fluid mover can be rotatably coupled to the
turbine and/or an electrical machine rotor. The temperature control
system thermally treats, such as cooling and/or heating, a motor
portion and a compressor portion of the machine, wherein the motor
portion and compressor portion are in fluid communication. The
temperature control systems can include a single source of
pressurized fluid and a single supply assembly to thermally treat
various components and/or sub-systems with the motor portion and
the compressor portion. The system channels fluid from a low
pressure side of the machine and upstream from the compressor to
facilitate heat transfer of the motor portion and compressor
portion using a single, integrated temperature control assembly.
The temperature control systems include flow controls for
optimizing fluid supply to various points in the motor portion and
the compressor portion. Flow control devices may be, but not be
limited to, a valves and flow orifices. Any type of valve or
orifice may be used that enables electrical machine to function as
described herein. The temperature control systems described herein
provide efficiency, reliability, and reduced maintenance costs and
outages.
[0054] Parameters associated with the materials used to fabricate
components of the electrical machine and temperature control system
include, but are not limited to, having sufficient heat transfer
properties to facilitate conductive heat transfer, and having
sufficient strength and corrosion resistance to mitigate distortion
and corrosion during operation. Properties associated with the
materials used to fabricate assembly and fluid system include, but
are not limited to having sufficient strength and corrosion
resistance to mitigate wall distortion and corrosion during
operation as well as sufficient flexibility to facilitate pressure
equalization as described above during dynamic conditions may also
include properties that facilitate conductive heat transfer.
Assembly and fluid system may be fabricated from materials that
include, but are not limited to metals, plastics and ceramic
composites.
[0055] The embodiments described herein provide a shaft-powered,
fluid mover such as a fan that facilitates enhanced cooling and
heat dissipation by using the motor shaft as a fluid mover. The
shaft mounted fan is configured to facilitate heat transfer of the
motor, the compressor, the bearings and the coupler between the
motor and the compressor together by branching a portion of the
suction fluid flow and returning the fluid to the compressor
suction line. Moreover, by using a fan with predefined operating
characteristics, the fan can be selected based at least on motor
resistance so as to operate the fan at its best efficiency
performance and with minimum noise. With better cooling and heat
dissipation more power can be supplied by the motor and with better
efficiency. Thus, motor output power can be increased with less
electrical and mechanical frictional losses. Fan performance
depends on its own operating characteristics. Therefore, the fan is
designed for best performance in terms of efficiency, flow rate and
noise.
[0056] Exemplary embodiments of systems and methods for using a
temperature control system are described above in detail. The
systems and methods are not limited to the specific embodiments
described herein, but rather, components of systems and/or steps of
the method may be utilized independently and separately from other
components and/or steps described herein. Each component and each
method step may also be used in combination with other components
and/or method steps. Although specific features of various
embodiments may be shown in some drawings and not in others, this
is for convenience only. Any feature of a drawing may be referenced
and/or claimed in combination with any feature of any other
drawing.
[0057] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they have structural elements that do not differ
from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal languages of the claims.
* * * * *