Patent Application
20140140857
The field of the invention relates generally to power systems and, more particularly, to a rotor assembly that may be used in power systems.
At least some known systems, such as power systems, use at least one turbine engine that is coupled to a load, wherein the load is an electrical system, such as an electrical generator or inverter. More specifically, a rotating element, such as a drive shaft, of the turbine engine is coupled to a rotor shaft of the generator. The drive shaft rotates to enable the turbine engine to generate mechanical rotational energy. As the drive shaft rotates, the generator rotor shaft rotates and the generator is able to convert the mechanical energy to electrical energy.
Some power systems may use high speed generators to facilitate an increased power density. When using high speed generators, relatively high rotational speeds are implemented by the rotor shaft of the generator. The rotational speeds result in centrifugal forces being applied to the rotor shaft. The centrifugal forces cause mechanical stress on the rotor shaft, which may cause misalignment of rotor shaft and/or the generator with respect to the drive shaft and/or the turbine engine. Such misalignment may lead to a failure of at least one component of the power system and/or adversely affect the operation of the power system.
Accordingly, there is a need for a rigid rotor apparatus or system that may be used with high speed generators that is configured to facilitate a secure connection with a turbine engine and to maintain proper alignment during operation.
In one embodiment, a rotor assembly is provided. The rotor assembly generally comprises a sleeve apparatus that includes a first sleeve portion and a second sleeve portion positioned a predefined distance from the first sleeve portion. The sleeve apparatus also includes at least one channel defined between the first sleeve portion and the second sleeve portion. A rotor shaft is coupled to the sleeve apparatus such that at least a portion of the rotor shaft is positioned within the sleeve apparatus, wherein the rotor shaft includes an end portion that is configured to be removably coupled to a drive shaft. At least one magnetic attachment is removably coupled within the channel to facilitate maintaining the rotor shaft in alignment within the sleeve apparatus during operation of the rotor assembly.
In another embodiment, a power system is provided. The power system generally comprises a turbine engine that includes a drive shaft and a load that is coupled to the turbine engine. The load includes a rotor assembly that includes a sleeve apparatus having a first sleeve portion and a second sleeve portion positioned a predefined distance from the first sleeve portion. The sleeve apparatus also includes at least one channel defined between the first sleeve portion and the second sleeve portion. A rotor shaft is coupled to the sleeve apparatus such that at least a portion of the rotor shaft is positioned within the sleeve apparatus, wherein the rotor shaft includes an end portion that is configured to be removably coupled to the drive shaft. At least one magnetic attachment is removably coupled within the channel to facilitate maintaining the rotor shaft in alignment within the sleeve apparatus during operation of the rotor assembly.
In yet another embodiment, a method for using a rotor assembly is provided. A sleeve apparatus is provided, wherein the sleeve apparatus includes a first sleeve portion and a second sleeve portion positioned a predefined distance from the first sleeve portion. The sleeve apparatus further includes at least one channel defined between the first sleeve portion and the second sleeve portion. At least a portion of a rotor shaft is positioned within the sleeve apparatus, wherein the rotor shaft includes an end portion that is configured to be removably coupled to a drive shaft. At least one magnetic attachment is removably coupled within the channel to facilitate maintaining the rotor shaft in alignment within the sleeve apparatus during operation of the rotor assembly.
The exemplary apparatus, systems, and methods described herein provide a substantially rigid rotor assembly that may be used with a load, such as a high speed generator, wherein the rotor assembly is configured to facilitate a secure connection with a turbine engine, and the rotor assembly is configured to maintain proper alignment during operation. The rotor assembly generally comprises a sleeve apparatus that includes at least one channel. A rotor shaft is coupled to the sleeve apparatus such that at least a portion of the rotor shaft is positioned within the sleeve apparatus. The rotor shaft includes an end portion that is configured to be removably coupled to, for example, a drive shaft of a turbine engine. Moreover, at least one magnetic attachment is removably coupled within the channel to facilitate maintaining the rotor shaft in alignment within the sleeve apparatus during operation of the rotor assembly.
Moreover, in the exemplary embodiment, the turbine engine 102 includes an intake section 112, a compressor section 114 coupled downstream from the intake section 112, a combustor section 116 coupled downstream from the compressor section 114, a turbine section 118 coupled downstream from the combustor section 116, and an exhaust section 120. It should be noted that, as used herein, the term “couple” is not limited to a direct mechanical, thermal, communication, and/or an electrical connection between components, but may also include an indirect mechanical, thermal, communication and/or electrical connection between multiple components.
The turbine section 118, in the exemplary embodiment, is coupled to the compressor section 114 via a drive shaft 122. In the exemplary embodiment, the combustor section 116 includes a plurality of combustors 124. The combustor section 116 is coupled to the compressor section 114 such that each combustor 124 is positioned in flow communication with the compressor section 114. The turbine section 118 is coupled to the compressor section 114 and to at least one load 128 via the drive shaft 122. In the exemplary embodiment, the load 128 may be an electrical system, such as a high speed electrical generator. The load 128 may be enclosed with a housing apparatus (not shown), such as the housing apparatus described in co-pending U.S. patent application Ser. No. 13/682,357 entitled HOUSING APPARATUS AND METHOD OF USING SAME (attorney docket no. 31938-7) filed Nov. 20, 2012, which is incorporated herein by reference in its entirety. The load 128 may also be a part of a load apparatus (not shown), which may be the load apparatus that is described in co-pending U.S. patent application Ser. No. 13/682,313 entitled LOAD APPARATUS AND METHOD OF USING SAME (attorney docket no. 31938-6), filed Nov. 20, 2012, which is incorporated herein by reference in its entirety.
In the exemplary embodiment, the load 128 includes a rotor assembly 130 that includes a rotor shaft (not shown in
During operation, the intake section 112 channels air towards the compressor section 114 wherein the air is compressed to a higher pressure and temperature prior to being discharged towards the combustor section 116. The compressed air is mixed with fuel and other fluids and ignited to generate combustion gases that are channeled towards the turbine section 118. More specifically, fuel, such as natural gas and/or fuel oil, air, diluents, and/or Nitrogen gas (N2), is injected in respective combustors 124, and into the air flow. The blended mixtures are ignited to generate high temperature combustion gases that are channeled towards the turbine section 118. The turbine section 118 converts the thermal energy from the gas stream to mechanical rotational energy, as the combustion gases impart rotational energy to the turbine section 118 and to the rotor disk assembly. The mechanical rotational energy is converted to electrical energy via the load 128.
In the exemplary embodiment, the mechanical rotational energy that is generated by the turbine section 118 is enabled by the rotation of the drive shaft 122. As the drive shaft 122 rotates, the rotor assembly 128 rotates. More specifically, the rotor shaft of the rotor assembly 130 rotates. Due to the high rotational speeds implemented by the drive shaft and/or the rotor shaft, mechanical stress may be endured by the rotor shaft. The mechanical stress may cause misalignment of the rotor shaft, the rotor assembly 130, and/or the load 128 with respect to the drive shaft 122 and/or the turbine engine 102. However, as described in more detail below, the rotor assembly 130 is substantially rigid and facilitates a secure coupling between the rotor shaft and the drive shaft 122 of the turbine engine 102. The rotor assembly also maintains proper alignment during operation.
In the exemplary embodiment, the outer sleeve 201 of the first sleeve portion 202 includes an opening (not shown) extending therethrough and the inner sleeve 203 includes an opening (not shown) that is substantially concentrically aligned with the opening of the outer sleeve 201. Similarly, the outer sleeve 205 of the second sleeve portion 204 includes an opening 209 and the inner sleeve 207 includes an opening (not shown) that is substantially concentrically aligned with the opening of the outer sleeve 205. Moreover, in the exemplary embodiment, the first sleeve portion 202 is oriented with respect to the second sleeve portion 204 such that the openings of the outer sleeve 201 and the inner sleeve 203 of the first sleeve portion 202 are each substantially coaxially aligned with the openings of the outer sleeve 205 and the inner sleeve 207 of the second sleeve portion 204.
In the exemplary embodiment, the first sleeve portion 202 and the second sleeve portion 204 are coupled together with at least one support leg, such as a first support leg 214 and a second support leg 216. Each support leg 214 and 216, in the exemplary embodiment, has a substantially rectangular prism shape. Alternatively, each support leg 214 and 216 may have any suitable shape that enables the rotor assembly 130 and/or the power system 100 to function as described herein. In the exemplary embodiment, the first support leg 214 extends from the first sleeve portion 202 to the second sleeve portion 204. Similarly, the second support leg 216 extends from the first sleeve portion 202 and the second sleeve portion 204. More specifically, each of the support legs 214 and 216 extend from the outer sleeve 201 of the first sleeve portion 202 to the outer sleeve 205 of the second sleeve portion 204.
Moreover, in the exemplary embodiment, the first and second support legs 214 and 216, respectively, are oriented such that the second support leg 216 is substantially parallel with respect to the first support leg 214 to define a first opening or channel 218 and a second opening or channel 220 between the first sleeve portion 202 and the second sleeve portion 204. More specifically, the channels 218 and 220 are defined between the outer sleeve 201 of the first sleeve portion 202 and the outer sleeve 205 of the second sleeve portion 204. Alternatively, the support legs 214 and 216 may have any suitable orientation that enables the rotor assembly 130 and/or the power system 100 to function as described herein.
In the exemplary embodiment, the first sleeve portion 202, the second sleeve portion 204, the first support leg 214, and the second support leg 216 are formed integrally together such that the sleeve apparatus 200 is a single unitary component. Alternatively, one or more of the components may be formed separate and removably or permanently coupled together. Each of the first sleeve portion 202, the second sleeve portion 204, the first support leg 214, and the second support leg 216 may be formed via a variety of manufacturing processes known in the art, such as, but not limited to, molding processes, drawing processes or machining processes. One or more types of materials may be used to fabricate the sleeve apparatus 200 and the components therein with the materials selected based on suitability for one or more manufacturing techniques, dimensional stability, cost, moldability, workability, rigidity, and/or other characteristic of the material(s). For example, the sleeve apparatus 200 and the components therein may be at least partially formed from a crystalline particle, such as a Nanocrystal. In the exemplary embodiment, each of the first sleeve portion 202, the second sleeve portion 204, the first support leg 214, and the second support leg 216 are formed from the same material(s). Alternatively, different and varying materials may be used to form each of the components.
The rotor assembly 130 also includes a substantially cylindrical rotor shaft 230 that is coupled to the sleeve apparatus 200 such that at least a portion of the rotor shaft 230 is positioned within the sleeve apparatus 200. More specifically, in the exemplary embodiment, the rotor shaft 230 includes a first end portion 234, a middle portion 236, and a second portion 238. The rotor shaft 230 is positioned within the sleeve apparatus 200 such that at least a portion of the middle portion 236 is positioned within the sleeve apparatus 200, and the first end portion 234 and the second end portion 238 are not positioned within the sleeve apparatus 200. For example, when the rotor shaft 230 is positioned within the sleeve apparatus 200, the first end portion 234 of the rotor shaft 230 extends outwardly from the opening of the inner sleeve 203 of the first sleeve portion 202 and the second end portion 238 extends outwardly from the opening of the inner sleeve 207 of the second sleeve portion 204.
In the exemplary embodiment, the second end portion 238 of the rotor shaft 230 has a diameter that is substantially equal to the diameter of the middle portion 236. The first end portion 234 of the rotor shaft 230 is configured to be removably coupled to the drive shaft 122 (shown in
In the exemplary embodiment, the first end portion 234, the middle portion 236, and the second end portion 238 of the rotor shaft 230 are formed integrally together such that the rotor shaft 230 is a single unitary component. Alternatively, one or more of the components of the rotor shaft 230 may be formed separate and removably or permanently coupled together. Each of the first end portion 234, the middle portion 236, and the second end portion 238 may be formed via a variety of manufacturing processes known in the art, such as, but not limited to, molding processes, drawing processes, or machining processes. One or more types of materials may be used to fabricate the rotor shaft 230 with the materials selected based on suitability for one or more manufacturing techniques, dimensional stability, cost, moldability, workability, rigidity, and/or other characteristic of the material(s). For example, the rotor shaft 230 may be at least partially formed from lightweight and rigid materials, such as an alumina material, a ceramic material, and/or a metal matrix composite material. The metal matrix composite material may include a first metal material and at least one other material, such as a second metal material and/or a ceramic compound. Alternatively, the rotor shaft 230 may be formed of any suitable material that enables the rotor assembly 130 and/or the power system 100 to function as described herein.
The rotor assembly 130 also includes at least one magnetic attachment, such as a first magnetic attachment 300 and a second magnetic attachment 302 that are removably coupled to the sleeve apparatus 200. More specifically, the first magnetic attachment 300 is coupled within the first channel 218 of the sleeve apparatus 200 and the second magnetic attachment 302 is coupled within the second channel 220 of the sleeve apparatus 200. In the exemplary embodiment, each magnetic attachment 300 and 302 has a substantially arcuate outer surface 312 and an opposing arcuate inner surface 314. As such, the first magnetic attachment 300 and the second magnetic attachment 302 are positioned between the first sleeve portion 202 and the second sleeve portion 204 such that the sleeve apparatus 200 with the magnetic attachments 300 and 302 form a substantially cylindrical structure that substantially encloses at least a portion of the middle portion 236 of the rotor shaft 230. Accordingly, the magnetic attachments 300 and 302 facilitate maintaining the rotor shaft 230 in alignment within the sleeve apparatus 200 during operation of the rotor assembly 130 and/or of the power system 100.
In the exemplary embodiment, the rotor assembly 130 also includes a substantially cylindrical housing 330 that includes an opening 334 extending therethrough such that the housing 330 substantially circumscribes at least a portion of the sleeve apparatus 200 and at least a portion of the magnetic attachments 300 and 302 to facilitate securing the magnetic attachments 300 and 302 within the channels 218 and 220, respectively. In the exemplary embodiment, the housing 330 may be formed onto the sleeve apparatus 200 and the magnetic attachments 300 and 302 via any suitable method known in the art, such as via heating. For example, after the housing 330 has been placed to substantially circumscribe at least a portion of the sleeve apparatus 200 and at least a portion of the magnetic attachments 300 and 302, then the housing 330 may be cured in at a temperature of, for example, 300° F., for approximately one hour. In the exemplary embodiment, the housing 330 is at least partially formed from a fiber-reinforced polymer, such as carbon fiber. Alternatively, the housing 330 may be formed from any suitable material that enables the rotor assembly 130 and/or the power system 100 to function as described herein.
During operation, the turbine section 118 (shown in
In the exemplary embodiment, the rotor assembly 130 is substantially rigid and facilitates a secure connection between the rotor shaft 230 and the drive shaft 122 of the turbine engine 102, and the rotor assembly 130 maintains proper alignment during operation of the power system 100. More specifically, because the first end portion 234 of the rotor shaft 230 includes the first surface 250 that is substantially arcuate and the second surface 252 that is substantially planar, the first end portion 234 is positionable within an opening on an end portion of the drive shaft 122. Moreover, when positioned within the drive shaft 122, the shape of the first end portion 234 of the rotor shaft 230 enables a secure connection with the drive shaft 122.
In addition, when at least a portion of the rotor shaft 230 is positioned within the sleeve apparatus 200 and the magnetic attachments 300 and 302 are coupled to the sleeve apparatus 200, then the rotor shaft 230 is substantially enclosed within the substantially cylindrical structure formed by the sleeve apparatus 200 and the magnetic attachments 300 and 302. Such an enclosure prevents the rotor shaft 230 from deviating from proper alignment during operation of the rotor assembly 130 and/or the power system 100.
As compared to known rotor assemblies that are used with loads, such as high speed generators, the embodiments described herein provides a substantially rigid rotor assembly that facilitates a secure connection with a turbine engine, and the rotor assembly is configured to maintain proper alignment during operation. The rotor assembly generally comprises a sleeve apparatus that includes at least one channel. A rotor shaft is coupled to the sleeve apparatus such that at least a portion of the rotor shaft is positioned within the sleeve apparatus. The rotor shaft includes an end portion that is configured to be removably coupled to, for example, a drive shaft of a turbine engine. Moreover, at least one magnetic attachment is removably coupled within the channel to facilitate maintaining the rotor shaft in alignment within the sleeve apparatus during operation of the rotor assembly.
Exemplary embodiments of systems, apparatus, and methods are described above in detail. The systems, apparatus, and methods are not limited to the specific embodiments described herein, but rather, components of each system, apparatus, and/or method may be utilized independently and separately from other components described herein. For example, each system may also be used in combination with other systems and is not limited to practice with only systems as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other applications.
Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.
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 language of the claims.
