This invention principally concerns electric actuators that are primarily intended for use in subsea installations such as process control systems.
Such actuators are used to control various devices, and particularly, but not exclusively, to open and close valves which themselves control the flow of fluids such as fluid hydrocarbons.
EP-0984133 discloses an actuation module in which a motor drives a rotatable socket that rotates and thereby advances and retracts a drive screw. The motor is provided with a self-contained secondary power source.
WO 2002/039203 and US 2006/0048602 disclose an actuator in which a drive shaft is connected to a rotating sleeve connected to a fixed ball nut that displaces axially a rotating spindle coupled to an actuating stem by a spindle head.
U.S. Pat. No. 6,595,487 discloses an actuator in which either of two motors with respective storage batteries can drive by way of a reduction gearbox an axially fixed nut that drives a valve spindle.
WO 2007/027097 discloses an actuator wherein the spindle of a motor directly drives a nut connected to a valve spindle by an auxiliary frame that can be used to retract the valve spindle when the nut is decoupled from the valve spindle.
Two important requirements of an electric actuator intended for use in a subsea installation are to minimize the power required for operation and to allow the actuator to be put into a predetermined state (typically one that closes a respective valve) on the occurrence of to partial or complete failure of the electrical supply to a motor that drives the actuator. These two requirements may well be in conflict. More particularly, it is currently considered desirable to provide a return spring that is disposed to act to return the actuator to a datum state. A drive system that has to work against the force of the return spring consumes power unnecessarily and it is one object of the electric actuator to include the safety feature of a return (or ‘fail-safe’) spring and to allow normal working of the motor or motors for the actuator free from the action of the return spring.
In one aspect of the invention, a subsea electric actuator comprises an electric motor, a telescopic drive connection from the motor to a drive unit that can be moved to and fro and converts rotary motion of the connection to linear motion of an operating member, a return spring operable on the drive unit to urge the operating member towards a datum state and a latch that is operative when set to maintain the drive unit in a predetermined position so as to decouple the action of the return spring on the operating member, whereby the stem can be advanced and retracted relative to the drive unit free from the action of the return spring, and operative on release to allow the return spring to operate on the drive unit to return the operating member to the datum state.
Whether a return spring is employed or not, it is desirable to provide a construction that allows working of the actuator by a motor or either one of two motors or possibly any one of more than two motors in a manner that allows the movement of the actuator, for example, either by a spring or by ROV intervention, to a datum state without decoupling of the drive system.
In another aspect of the technical development, therefore, a subsea electric actuator comprises an electric motor, a telescopic drive connection between the motor and a drive unit that can move to and fro and includes a drive nut that couples rotary motion of the drive connection to a screw that is disposed for axial movement without rotation and is connected to an operating member.
As will be apparent from further explanation herein, practical embodiments of the electric actuator include a latch that is operative to decouple the action of a return spring on the actuator and is operative on the absence of electrical supply to the latch to release the action of the return spring. Various embodiments of such latches are described herein. However, at least some of the latches have a utility independent of the specific purpose of latching a return spring.
The invention further provides various latches for maintaining a unit (such as a drive unit as aforesaid) in a predetermined position so as to prevent movement of that unit away from that position in a given direction, but to allow such movement on release of the latch.
There follows a description by way of example of a specific embodiment of an electric actuator, as well as embodiments of latches that may be used in such an actuator or otherwise.
The actuator is intended for operation by either one of dual redundant electrical devices, which each comprise a storage battery, an electric motor and associated electrical components. In
This valve stem 5 is intended to be moved to and fro axially to operate the valve (not shown) or other device. It is shaped at its right-hand end to engage (for example) a valve gate. Its left-hand end 6 may be engaged, employing a suitable interface, by an ROV (remotely operating vehicle) whereby the ROV can operate the valve by movement of the stem 5.
A first drive shaft 8 protrudes from the actuator enclosure 3 into the motor enclosure 2 so as to be driven by the respective motor. The drive shaft 8 is supported by bearings in an end wall 7 of the enclosure 3 and an end wall 9 of a gear train casing. Beyond the wall 9, the shaft 8 drives a gear train 10 (that may comprise a pinion and a sun gear) for driving through a speed reduction and a roller nut 11 that is rotatable (and supported by bearings) within a casing 12 that can move axially within the actuator enclosure 3. The roller nut 11 has an internal screw threading engaging a complementary roller screw threading 13 formed on or otherwise connected to the stem 5. The gear train 10, the nut 11 and the drive casing 12 constitute a movable drive unit by which the rotary movement of the drive shaft is converted to linear movement of the stem 5. More complex gear trains (e.g., epicyclic) may be employed provided that the gear train, the nut and the casing can move as a unit.
In like manner, the motor within enclosure 2a is coupled to drive the roller nut by way of a second, respective drive shaft 8a that is coupled to the drive unit in the same manner as the shaft 8. Thus, either motor (or both) can drive the stem 5.
Each of the drive shafts 8 and 8a is ‘telescopic’, i.e., it is axially extensible and collapsible to accommodate, without loss of drive connection, movement of the drive unit and the stem 5 relative to the motor to and fro in the enclosure 3. The shaft 8 may, for example and as shown in other figures, comprise a splined rod within an outer sleeve. In
This embodiment includes a return or ‘fail-safe’ spring 14 in order to return the actuator stem to a datum position in the event of power failure. In this example, the spring 14 is disposed in the actuator enclosure 3 and bears against the casing 12 for the gear train and the roller nut. The spring 14 in this example is constituted by a stack of conical disc springs, but other forms of spring may be employed.
In order to maintain the drive unit in a predetermined position against the force of the return spring 14, and thereby to decouple the action of the return spring from the actuator to stem, the actuator includes an ESD (emergency shut down) latch mechanism 15. This is shown purely diagrammatically in
The stem 5 has end stops that limit the axial movement of the valve stem in each axial direction. These stops are shown in later figures.
Operation of the Actuator
The basic operation of the actuator shown in
If, however, the latch mechanism is released, the spring 14 acts to force the return of the drive unit and the valve stem. The roller nut 11 may be prevented from rotating by de-energized electromechanical brakes 25, 25a (
It will be noted that, owing to the provision of the telescopic drive shafts, the operation of the spring 14 does not require any decoupling of the drive connection between the motors 2, 2a and the stem 5.
Each of the motors may receive power by way of a respective ‘wet-mate’ connector 16, 16a.
The Supply and Instrumentation System
With reference to
The ‘B’ module 2a is organized in a similar manner, corresponding parts being denoted by the suffix ‘a’.
Introduction to the Latches
Each of the latches described in the following is intended to be capable of use as the ESD latch 15 in the context of the actuator shown in
The Star Disc Latch
The purpose of the latch in that context is to maintain the return spring 14 of
In this embodiment, the latch is disposed within the enclosure 3 of the actuator. An end plate 31 of the drive unit previously described defines with the enclosure 3 a chamber 32 for the return spring 14 (not shown in this figure).
The telescopic drive shaft 8, driven by a motor (as previously described) extends axially of the enclosure and into the drive unit that includes the roller nut 11 and the roller screw previously described. The roller nut 11 is disposed within a sleeve that extends axially from the endplate 31 of the drive unit.
The drive unit includes an inner sleeve 34. The stem 5 extends through this sleeve and through the left-hand endplate 7 of the enclosure 3. The end plate 7 has an axially extending socket 36 into which the stem 5 extends. The stem further extends through an end wall 37 of the socket 36. The stem is splined between two shoulders 38 and 39 that constitute end stops. The spline 40 engages the interior of the socket 36 so that the stem 5 (together with the integral roller screw) can move axially, but does not rotate. The outer end stop 38 can abut the end 37 of the socket 36 to limit the movement of the stem 5 and the railer screw in the retracting direction, whereas the inner end stop 39 can engage the end of the sleeve 34.
A compression spring 41 is disposed within a hollow hammer 42 of which the end remote from the end plate 35 has an aperture that fits over and is guided by the sleeve 34. The hammer 42 has at its end nearer the end plate 7 a flange 43 that can abut an electromagnet 44 comprising a grooved ring of magnetic material, the ring including a coil (not shown) that normally is continuously energized so that the hammer 42 is held in position near the end plate 7 against the force of the spring 41. As will become apparent from further description herein, cessation or sufficient reduction of the energization of the electromagnet will release the hammer 42 and will cause release of the latch.
The drive unit includes in its outer cylindrical part circumferentially spaced shoes 45 that are capable of radially inward movement. Each shoe has on its outside a set of serrations that can engage grooves 46 in the inside of the enclosure 3 as shown by the contact surface 47.
The drive unit is advanced against the force of the return spring by means of the motor that drives the shaft 8 to rotate the roller nut to produce axial movement of the drive unit when the outer end stop 38 abuts the end of the socket 36. When the shape-lock shoes 45 reach the grooves 46, they can engage the grooves and thereby be prevented from rearward movement.
Within the drive unit is an inner member in the form of a ring 48, which extends axially outside the stem 5 and is mounted on the sleeve 34. This ring member 48 supports at its periphery a lever coupling that engages the shoes 45. In this example, the coupling comprises two axially spaced sets of circumferentially spaced levers 49 that extend from bearing slots in the outside of the ring to the inside of the shoes. These levers have rounded ends that are received in part-circular grooves 50 on the outside of the ring 48 and the insides of the shoes 45.
Multiple reload springs (of which only one spring 51 is shown) extend between an inwardly directed rim 52 of the ring 48 and a wall of the drive unit. These springs hold the ring 48 in a position wherein the connecting levers 49 hold the shoes 45 in engagement with the grooves 46.
When the electromagnet 44 is de-energized, the hammer's spring 41 propels the hammer 42 towards the ring 48. When the hammer impacts on the ring 48, as shown in
Re-energizing the electromagnet 44 will retain the hammer 42 in its energized ‘ready’ state. The advancement of the gear train and the associated components will eventually cause the shoes 45 to re-engage the grooves 46 to maintain the assembly in a latched state.
Roller Lock Latch
In the construction shown in
The actuator is put in the state shown in
Extending leftwards (in the sense shown in the drawing) from the gear train casing is a sleeve 61. On this sleeve is mounted an annular electromagnet 62. An armature 63 for the electromagnet is connected by a tension spring 64 to a wall of the gear train housing, so that if the energization of the electromagnet 62 is sufficiently reduced, the armature 63 will move rapidly to the right in the axial direction of the stem 5.
The armature 63 has a pivot for a radial lever 65 that is pivotally connected to an axially extending lever 66 that is pivoted about an axis coincident with a roller 67 mounted in the casing 12. A roller 68 is carried on the axial fever 66. The rollers 67 and 68 are in rolling contact. The lever 66 is shown straight in
The roller 68 can, when the lever 65 is substantially disposed in the axial direction, enter an annular recess 70 on the inside of the actuator enclosure 3. In this state of the mechanism, the force of the spring 14 is transmitted to the enclosure 3, provided that the line of action of force from the roller 67 to the roller 68 has an outward component.
In a practical embodiment, there are several mechanisms as described, disposed in parallel, each with respective rollers 67 and 68, spaced around the enclosure 3. This is illustrated in the perspective view shown in
PSC Latch
The inner rod 8′ of the telescopic drive shaft 8 extends into the gear train casing 12. It drives the gear train 10 and thereby the roller nut 11 that engages the roller screw 13 on the stem 5 as previously described. The fail-safe spring 14 bears against the gear train casing 12.
The end plate 7 of the actuator enclosure 3 carries an annular frame 101 in which is movable, in the axial direction, an annular plate 102. Reset pistons 103 (only one being shown in
Each mechanism comprises a ‘radial’ lever 105 that is pivoted to the plate 102 and, in the position shown in
The end of the pivot arm 106 defines a shoulder 108 in which is located the distal end of a respective ‘snap’ rod 109 extending to a pivot 110 on the gear train casing.
The plate 102 is held against the force of the reset springs by means of an electromagnet 111 disposed on the end plate 7.
As is shown in
The mechanism reaches the condition shown in
The latch can be released by cessation of the power supply to the electromagnet 111. Thereupon the plate 102 is rapidly drawn away by the reset springs 104. This action rotates each radial lever 105 and thereby the pivot arms 106 to displace the distal ends of the snap rods 109 from the shoulders 108 as shown in
The fail-safe spring 14 is now released and forces the gear train casing and the stem 5 rearward, collapsing the latch mechanisms to the state shown in
Pure Roller Latch
On the end plate 7 of the actuator enclosure 3 remote from the fail-safe spring 14 is an annular electromagnet 141. While the electromagnet is sufficiently energized, it holds an annular hammer 142 against the force of a compression spring 143 disposed between the end plate 7 and a rim of the hammer 142.
The latch in this embodiment preferably has a multiplicity of sets of latching rollers (shown in
Two of the sets of rollers are shown in
With reference to
The bracket includes a latch guide 156 that can extend between the two halves of the roller 150 to engage the end of the arm 151 so that, under the influence of the spring 146, the rotation of the bracket away from the axis causes the rollers 149 and 150 to be in a slightly over-center position, whereby the force of the spring 14 is transmitted through the support 147 and the rollers 149 and 150 to be sustained by the seat 152 and, therefore, by the enclosure 3.
On de-energization of the electromagnet 141, the hammer 142 is released and is driven by the spring 143 to strike the bracket 145. On impact, the bracket rotates in a sense towards the axis of the stem 5. The roller 149 rolls around the roller 150 though a dead-center position and the latch is released (
As shown in
While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the invention. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the invention. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the invention.
Number | Date | Country | Kind |
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1104394.0 | Mar 2011 | GB | national |
This is a division of copending U.S. Ser. No. 13/418,801 filed Mar. 13, 2012, which claims priority from GB Patent Application No. 1104394.0 filed Mar. 16, 2011. The entire contents of both applications are hereby incorporated by reference.
Number | Date | Country | |
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Parent | 13418801 | Mar 2012 | US |
Child | 14613108 | US |