Patent Application
20190128260
The subject matter disclosed herein relates generally to fluid machines, and more specifically, to fluid machines, such as compressors, having helically lobed rotors.
It has been determined that commonly used refrigerants, such as R-410A in one non-limiting example, have unacceptable global warming potential (GWP) such that their use will cease for many HVAC&R applications. Non-flammable, low GWP refrigerants are replacing existing refrigerants in many applications, but have lower density and do not possess the same cooling capacity as existing refrigerants. Replacement refrigerants require a compressor capable of providing a significantly greater displacement, such as a screw compressor.
Existing screw compressors typically utilize roller, ball, or other rolling element bearings to precisely position the rotors and minimize friction during high speed operation. However, for typical HVAC&R applications, existing screw compressors with roller element bearings result in an unacceptably large and costly fluid machine.
Therefore, there exists a need in the art for an appropriately sized and cost effective fluid machine that minimizes friction while allowing precise positioning and alignment of the rotors.
According to one aspect, a fluid machine includes a first rotor rotatable about a first axis. The first rotor has a first portion and a second portion. A second rotor is rotatable about a second axis. The second rotor includes a first portion and a second portion. At least one spacer is associated with the first rotor and the second rotor to limit intermeshing engagement between the first rotor and the second rotor.
In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one spacer is positioned between the first portion and the second portion of at least one of the first rotor and the second rotor to prevent the first portion of the second rotor from engaging the second portion of the first rotor.
In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one spacer is positioned between the first portion and second portion of the second rotor to prevent the first portion of the second rotor from engaging the second portion of the first rotor.
In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one spacer is positioned between the first portion and second portion of the first rotor to prevent the first portion of the first rotor from engaging the second portion of the second rotor.
In addition to one or more of the features described above, or as an alternative, in further embodiments including a casing, a first shaft for supporting the first rotor relative to the casing, and a second shaft for supporting the second rotor relative to the casing. The at least one spacer is mounted concentrically with at least one of the first shaft and the second shaft.
In addition to one or more of the features described above, or as an alternative, in further embodiments the first portion of the first rotor has a first upper rotor length M1, the second portion of the first rotor has a first lower rotor length M2, the first portion of the second rotor has a second upper rotor length F1, the second portion of the second rotor has a second lower rotor length F2, a first upper rotor axial clearance C1 is formed between the first portion of the first rotor and the casing, a first lower rotor axial clearance C2 is formed between the second portion of the first rotor and the casing, a second upper rotor axial clearance D1 is formed between the first portion of the second rotor and the casing, and a second lower rotor axial clearance D2 is formed between the second portion of the second rotor and the casing.
In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one spacer has an axial thickness such that the first upper rotor axial clearance C1 is equal to the second upper rotor axial clearance D1 and the first lower rotor axial clearance C2 is equal to the second lower rotor axial clearance D2.
In addition to one or more of the features described above, or as an alternative, in further embodiments an axial thickness of the at least one spacer is selected based on an arrangement of the first rotor and second rotor.
In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one spacer is positioned between the first portion and the second portion of the first rotor, and an axial thickness of the spacer is greater than a summation of the second upper rotor length F1, the second upper rotor axial clearance D1 and the second lower rotor axial clearance D2 minus the first upper rotor length M1.
In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one spacer is positioned between the first portion and the second portion of the first rotor, and an axial thickness of the spacer is greater than a summation of the second lower rotor length F2, the second upper rotor axial clearance D1 and the second lower rotor axial clearance D2 minus the first lower rotor length M2.
In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one spacer is positioned between the first portion and the second portion of the second rotor, and an axial thickness of the spacer is greater than a summation of the first lower rotor length M2, the first upper rotor axial clearance C1 and the first lower rotor axial clearance C2 minus the second lower rotor length F2.
In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one spacer is positioned between the first portion and the second portion of the second rotor, and an axial thickness of the spacer is greater than a summation of the first upper rotor length M1, the first upper rotor axial clearance C1 and the first lower rotor axial clearance C2 minus the second upper rotor length F1.
According to another aspect, a fluid machine includes a first rotor rotatable about a first axis, a second rotor rotatable about a second axis, at least one spacer associated with the first rotor and the second rotor to limit intermeshing engagement between the first rotor and the second rotor, a motor for driving rotation of at least one of the first rotor and the second rotor, and a casing for rotatably supporting at least one of the first rotor and the second rotor.
In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one spacer is mounted concentrically with at least one of the first shaft and the second shaft.
In addition to one or more of the features described above, or as an alternative, in further embodiments the first rotor includes a first portion and a second portion and the second rotor includes a first portion and a second portion.
In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one spacer is positioned between the first portion and second portion of the second rotor to prevent the first portion of the second rotor from engaging the second portion of the first rotor.
In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one spacer is positioned between the first portion and second portion of the first rotor to prevent the first portion of the first rotor from engaging the second portion of the second rotor.
In addition to one or more of the features described above, or as an alternative, in further embodiments the at least one spacer includes a first spacer positioned between the first portion and second portion of the first rotor and a second spacer positioned between the first portion and second portion of the second rotor, the first spacer having a first thickness and the second spacer having a second thickness different from the first thickness.
In addition to one or more of the features described above, or as an alternative, in further embodiments a clearance between the first rotor and the casing is equal to a clearance between the second rotor and the casing.
The subject matter, which is regarded as the disclosure, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the disclosure are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
The detailed description explains embodiments of the disclosure, together with advantages and features, by way of example with reference to the drawings.
Referring now to the
The fluid machine 20 includes a first shaft 38 fixed for rotation with the first rotor 22. The fluid machine 20 further include a casing 40 rotatably supporting the first shaft 38 and at least partially enclosing the first rotor 22 and the second rotor 24. A first end 42 and a second end 44 of the casing 40 are configured to rotatably support the first shaft 38. The first shaft 38 of the illustrated embodiments is directly coupled to an electric motor 46 operable to drive rotation of the first shaft 38 about an axis X. Any suitable type of electric motor 46 is contemplated herein, including but not limited to an induction motor, permanent magnet (PM) motor, and switch reluctance motor for example. In an embodiment, the first rotor 22 is fixed to the first shaft 38 by a fastener, coupling, integral formation, interference fit, and/or any additional structures or methods known to a person having ordinary skill in the art (not shown), such that the first rotor 22 and the first shaft 38 rotate about axis X in unison.
The fluid machine 20 additionally includes a second shaft 48 operable to rotationally support the second rotor 24. The second rotor 24 includes an axially extending bore 50 within which the second shaft 48 is received. In an embodiment, the second shaft 48 is stationary or fixed relative to the casing 40 and the second rotor 24 is configured to rotate about the second shaft 48. However, embodiments where the second shaft 48 is also rotatable relative to the casing 40 are also contemplated herein.
With specific reference to
By including lobes 30, 32 with having opposite helical configurations, opposing axial flows are created between the first and second helical lobes 30, 32. Due to the symmetry of the axial flows, thrust forces resulting from the helical lobes 30, 32 are generally equal and opposite, such that the thrust forces substantially cancel one another. As a result, this configuration of the opposing helical lobes 30, 32 provides a design advantage since the need for thrust bearings in the fluid machine can be reduced or eliminated.
The second rotor 24 has a first portion 52 configured to mesh with the first helical lobes 30 and a second portion 54 configured to mesh with the second helical lobes 32. To achieve proper intermeshing engagement between the first rotor 22 and the second rotor 24, each portion 52, 54 of the second rotor 24 includes one or more lobes 56 having an opposite configuration to the corresponding helical lobes 30, 32 of the first rotor 22. In the illustrated, non-limiting embodiment, the first portion 52 of the second rotor 24 has at least one right-handed lobe 56a, and the second portion 54 of the second rotor 24 includes at least one left-handed lobe 56b.
In an embodiment, the first portion 52 of the second rotor 24 is configured to rotate independently from the second portion 54 of the second rotor 24. However, embodiments where the first and second portions 52, 54 are rotationally coupled are also contemplated herein. Each portion 52, 54 of the second rotor 24 may include any number of lobes 56. In an embodiment, the total number of lobes 56 formed in each portion 52, 54 of the second rotor 24 is generally larger than a corresponding portion, 34 and 36, respectively, of the first rotor 22. For example, if the first rotor 22 includes four first helical lobes 30, the first portion 54 of the second rotor 24 configured to intermesh with the first helical lobes 30 may include five helical lobes 56a. However, embodiments where the total number of lobes 56 in a portion 52, 54 of the second rotor 24 is equal to a corresponding group of helical lobes (i.e. the first helical lobes 30 or the second helical lobes 32) of the first rotor 22 are also within the scope of the disclosure.
Returning to
During operation of the fluid machine 20 of one embodiment, a gas or other fluid, such as a low GWP refrigerant for example, is drawn to a central location by a suction process generated by the fluid machine 20. Rotation of the first rotor 22 and the second rotor 24 compresses the refrigerant and forces the refrigerant toward first and second ends 42, 44 of the casing 40 between the sealed surfaces of the meshed rotors 22, 24 due to the structure and function of the opposing helical rotors 22, 24. The compressed refrigerant is routed by an internal gas passage within the casing 40 and discharged through the second end 44 of the casing 40. The discharged refrigerant passes through the electric motor 46 and out of a discharge passage 64.
With reference now to
The one or more spacers may be formed from any suitable material, including but not limited to a plastic or metal for example. In an embodiment, the spacer 70 is generally circular in shape and has a centrally located opening extending there through. An inner diameter of the opening is greater than the diameter of a corresponding shaft 38, 48 associated with the rotor 22, 24 such that the shaft 38, 48 may be received therein to mount the spacer concentrically with the shaft 38, 48. Further, an outer diameter of the spacer 70 is larger than the inner diameter of the bore, such as bore 50 for example, formed in the rotor 22, 24 to retain the spacer 70 at a position between the ends of adjacent rotor portions.
With reference to
The thickness of the at least one spacer 70 should be selected to avoid interference between lobes 56a and 32, and between lobes 56b and 30 during operation of the machine 20 in various worst case scenarios. In a first scenario, illustrated in
In this first scenario, the sum of the second lower rotor length F2 and the thickness T2 of the spacer 70b positioned between the first and second portions 52, 54 of the second rotor 24 must be greater than the sum of the first lower rotor length F2, the first upper rotor axial clearance C1, and the first lower rotor axial clearance C2. Expressed differently, the thickness T2 of the spacer 70b is greater than the summation of the first lower rotor length M2, the first upper rotor axial clearance C1 and the first lower rotor axial clearance C2 minus the second lower rotor length F2.
In a second scenario, illustrated in
Similarly, in this second scenario, the sum of the second upper rotor length F1 and the thickness T2 of the spacer 70b positioned between the first and second portions 52, 54 of the second rotor 24 must be greater than the sum of the first upper rotor length M1, the first upper rotor axial clearance C1, and the first lower rotor axial clearance C2. Expressed differently, the thickness T2 of the spacer 70b is greater than the summation of the first upper rotor length M1, the first upper rotor axial clearance C1 and the first lower rotor axial clearance C2 minus the second upper rotor length F1. If the thickness of a spacer varies between the first scenario and the second scenario, the greater thickness should be selected.
In an embodiment, the thickness of the first spacer 70a and the thickness of the second spacer 70b may be selected such that the first upper rotor axial clearance C1 is equal to the second upper rotor axial clearance D1 and the first lower rotor axial clearance C2 is equal to the second lower rotor axial clearance D2. In such embodiments, the thickness of the first spacer 70a is equal to a total axial length L of the rotor case 40 minus the summation of the first upper rotor length M1, the first lower rotor length M1, the first upper rotor axial clearance C1 and the first lower rotor axial clearance C2. Similarly, the thickness of the second spacer 70b is equal to the total axial length L of the rotor case 40 minus the summation of the second upper rotor length F1, the second lower rotor length F1, the second upper rotor axial clearance D1 and the second lower rotor axial clearance D2.
Inclusion of one or more spacers 70 as described herein provides a more secure operation of the fluid machine 20 with minimal additional cost. Not only are the one or more spacers 70 operable to avoid unintentional interference between lobes, but also to control the axial clearance of the machine 20. Further, use of such spacers is most cost effective than restricting the manufacturing tolerances of the machine 20 to avoid such interference.
While the disclosure has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the disclosure is not limited to such disclosed embodiments. Rather, the disclosure can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the disclosure. Additionally, while various embodiments of the disclosure have been described, it is to be understood that aspects of the disclosure may include only some of the described embodiments. Accordingly, the disclosure is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
This application claims the benefit of U.S. Provisional Application Ser. No. 62/580,744, filed Nov. 2, 2017, which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62580744 | Nov 2017 | US |
