Patent Application
20120107106
The subject matter described herein relates generally to supersonic compressor systems and, more particularly, to a supersonic compressor systems that include a supersonic compressor rotor and a compressor assembly.
At least some known supersonic compressor systems include a drive assembly, a drive shaft, and at least one supersonic compressor rotor for compressing a fluid. The drive assembly is coupled to the supersonic compressor rotor with the drive shaft to rotate the drive shaft and the supersonic compressor rotor.
At least some known supersonic compressor assemblies include an axial-flow supersonic compressor rotor. Known supersonic compressor rotors include a plurality of strakes coupled to a rotor disk. Each strake is oriented circumferentially about the rotor disk and define an axial flow channel between adjacent strakes. At least some known supersonic compressor rotors include a supersonic compression ramp that is coupled to the rotor disk. Known supersonic compression ramps are positioned within the axial flow path and are configured to form a compression wave within the flow path.
During operation of known supersonic compressor systems, the drive assembly rotates the supersonic compressor rotor at a high rotational speed. A fluid is channeled to the supersonic compressor rotor such that the fluid is characterized by a velocity that is supersonic with respect to the supersonic compressor rotor at the flow channel. At least some known supersonic compressor rotors discharge fluid from the flow channel in an axial direction. As fluid is channeled in an axial direction, supersonic compressor system components downstream of the supersonic compressor rotor are required to be designed to receive axial flow. As such, an efficiency in compressing a fluid may be limited to the efficiency of the axial-flow supersonic compressor rotor. Known supersonic compressor systems are described in, for example, U.S. Pat. Nos. 7,334,990 and 7,293,955 filed Mar. 28, 2005 and Mar. 23, 2005 respectively, and United States Patent Application 2009/0196731 filed Jan. 16, 2009.
In one embodiment, a supersonic compressor system is provided. The supersonic compressor system includes a casing that defines a cavity that extends between a fluid inlet and a fluid outlet, and a first drive shaft that is positioned within the cavity. A centerline axis extends along a centerline of the first drive shaft. A supersonic compressor rotor is coupled to the first drive shaft and is positioned in flow communication between the fluid inlet and the fluid outlet. The supersonic compressor rotor includes at least one supersonic compression ramp that is configured to form at least one compression wave for compressing a fluid. A centrifugal compressor assembly is positioned in flow communication between the supersonic compressor rotor and the fluid outlet. The centrifugal compressor assembly is configured to compress fluid received from the supersonic compressor rotor.
In another embodiment, a supersonic compressor system is provided. The supersonic compressor system includes a casing that defines a cavity that extends between a fluid inlet and a fluid outlet, and a first drive shaft that is positioned within the cavity. A centerline axis extends along a centerline of the first drive shaft. A supersonic compressor rotor is coupled to the first drive shaft and is positioned in flow communication between the fluid inlet and the fluid outlet. The supersonic compressor rotor includes at least one supersonic compression ramp that is configured to form at least one compression wave for compressing a fluid. An axial compressor assembly is positioned in flow communication between the supersonic compressor rotor and the fluid outlet. The axial compressor assembly is configured to compress fluid received from the supersonic compressor rotor.
In a further embodiment, a supersonic compressor system is provided. The supersonic compressor system includes a casing that defines a cavity that extends between a fluid inlet and a fluid outlet, and a first drive shaft that is positioned within the cavity. A centerline axis extends along a centerline of the first drive shaft. A supersonic compressor rotor is coupled to the first drive shaft and is positioned in flow communication between the fluid inlet and the fluid outlet. The supersonic compressor rotor includes at least one supersonic compression ramp that is configured to form at least one compression wave for compressing a fluid. A mixed-flow compressor assembly is positioned in flow communication between the supersonic compressor rotor and the fluid outlet. The mixed-flow compressor assembly is configured to compress fluid received from the supersonic compressor rotor.
In yet another embodiment, a method of assembling a supersonic compressor system is provided. The method includes providing a casing that defines a cavity that extends between a fluid inlet and a fluid outlet. A first drive shaft is coupled to a driving assembly. The first drive shaft is at least partially positioned within the cavity. A supersonic compressor rotor is coupled to the first drive shaft. The supersonic compressor rotor includes at least one supersonic compression ramp that is configured to form at least one compression wave for compressing a fluid. A compressor assembly is coupled in flow communication between the supersonic compressor rotor and the fluid outlet. The compressor assembly is configured to compress fluid received from the supersonic compressor rotor.
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
Unless otherwise indicated, the drawings provided herein are meant to illustrate key inventive features of the invention. These key inventive features are believed to be applicable in a wide variety of systems comprising one or more embodiments of the invention. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the invention.
In the following specification and the claims, which follow, reference will be made to a number of terms, which shall be defined to have the following meanings
The singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.
“Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.
Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.
As used herein, the term “supersonic compressor rotor” refers to a compressor rotor comprising a supersonic compression ramp disposed within a fluid flow channel of the supersonic compressor rotor. Supersonic compressor rotors are said to be “supersonic” because they are designed to rotate about an axis of rotation at high speeds such that a moving fluid, for example a moving gas, encountering the rotating supersonic compressor rotor at a supersonic compression ramp disposed within a flow channel of the rotor, is said to have a relative fluid velocity which is supersonic. The relative fluid velocity can be defined in terms of the vector sum of the rotor velocity at the supersonic compression ramp and the fluid velocity just prior to encountering the supersonic compression ramp. This relative fluid velocity is at times referred to as the “local supersonic inlet velocity”, which in certain embodiments is a combination of an inlet gas velocity and a tangential speed of a supersonic compression ramp disposed within a flow channel of the supersonic compressor rotor. The supersonic compressor rotors are engineered for service at very high tangential speeds, for example tangential speeds in a range of 300 meters/second to 800 meters/second.
The exemplary systems and methods described herein overcome disadvantages of known supersonic compressor assemblies by providing a supersonic compressor system that includes a supersonic compressor rotor coupled to a compressor assembly to facilitate increasing efficiency in compressing a fluid. More specifically, the embodiments described herein include a supersonic compression rotor that is positioned in flow communication between a fluid inlet and a centrifugal compressor assembly to compress fluid and channel the compressed fluid to the centrifugal compressor assembly. In addition, by providing a supersonic compressor rotor upstream of the centrifugal compressor assembly, the supersonic compressor system is able to compress a higher volume of fluid than known centrifugal compressor assemblies.
In the exemplary embodiment, fluid inlet 28 is configured to channel fluid from a fluid source 36 to intake section 12. The fluid may be any fluid such as, for example a gas, a gas mixture, a solid-gas mixture, and/or a liquid-gas mixture. Intake section 12 is positioned in flow communication between compressor section 14 and fluid inlet 28 for channeling fluid from fluid inlet 28 to compressor section 14. Discharge section 16 is positioned in flow communication between compressor section 14 and fluid outlet 30.
In the exemplary embodiment, intake section 12 includes one or more inlet guide vane assemblies 38. Inlet guide vane assembly 38 is configured to condition a fluid to include one or more predetermined parameters, such as a swirl, a velocity, a mass flow rate, a pressure, a temperature, and/or any suitable flow parameter to enable compressor section 14 to function as described herein. Inlet guide vane assembly 38 is coupled between fluid inlet 28 and compressor section 14 for channeling fluid from fluid inlet 28 to compressor section 14.
In the exemplary embodiment, compressor section 14 is coupled between intake section 12 and discharge section 16 for channeling at least a portion of fluid from intake section 12 to discharge section 16. Compressor section 14 includes at least one supersonic compressor rotor 40, a transition assembly 42, and a compressor assembly 44. Supersonic compressor rotor 40 is positioned in flow communication between inlet guide vane assembly 38 and compressor assembly 44. Compressor assembly 44 includes a centrifugal compressor assembly 46. In the exemplary embodiment, compressor housing 26 includes a diaphragm assembly 48 positioned adjacent supersonic compressor rotor 40, transition assembly 42, and centrifugal compressor assembly 46. Diaphragm assembly 48 at least partially defines a flow path, represented by arrow 50, through supersonic compressor system 10.
In the exemplary embodiment, supersonic compressor rotor 40 is configured to increase a pressure of fluid, reduce a volume of fluid, and/or increase a temperature of fluid being channeled from intake section 12 to discharge section 16. Supersonic compressor rotor 40 channels fluid from inlet guide vane assembly 38 to transition assembly 42. In the exemplary embodiment, supersonic compressor rotor 40 includes a radial flow path 52 that channels fluid along a radial direction 54 that is substantially perpendicular to centerline axis 24. Transition assembly 42 is configured to channel fluid from supersonic compressor rotor 40 to centrifugal compressor assembly 46. Transition assembly 42 includes an inner surface 56 that defines a transition flow channel 58 that extends between supersonic compressor rotor 40 and centrifugal compressor assembly 46. Transition flow channel 58 is sized, shaped, and oriented to transition an orientation of fluid from radial direction 54 to an axial direction 60 that is substantially parallel to centerline axis 24. In one embodiment, transition assembly 42 includes one or more rows 59 of circumferentially-spaced stationary blades 61 that are configured to condition fluid being channeled to centrifugal compressor assembly 46.
In the exemplary embodiment, centrifugal compressor assembly 46 is positioned in flow communication between transition assembly 42 and discharge section 16. Centrifugal compressor assembly 46 includes a plurality of centrifugal vanes 62 that are coupled to a compressor disk 64. Adjacent centrifugal vanes 62 are spaced circumferentially about compressor disk 64 to define a centrifugal flow channel 66 that extends between each adjacent centrifugal vane 62. Centrifugal flow channel 66 extends between a flow channel inlet 68 and a flow channel outlet 69. Flow channel inlet 68 is positioned adjacent supersonic compressor rotor 40 and is configured to receive fluid from supersonic compressor rotor 40 along axial direction 60. Flow channel outlet 69 is positioned adjacent discharge section 16 and is configured to discharge fluid in radial direction 54 to discharge section 16. Centrifugal flow channel 66 is sized, shaped, and oriented to channel fluid from axial direction 60 to radial direction 54, and to impart a centrifugal force to fluid to increase a pressure and a velocity of fluid discharged through flow channel outlet 69.
In an alternative embodiment, compressor assembly 44 includes a mixed-flow compressor assembly 70. Mixed-flow compressor assembly 70 includes at least one inner surface 71 that is oriented obliquely with respect to axial direction 60 and/or radial direction 54. In one embodiment, mixed flow compressor assembly 70 is configured to receive fluid from supersonic compressor rotor 40 at an angle that is oblique to axial direction 60. Mixed-flow compressor assembly 70 is also configured to discharge fluid in a direction that is oblique to radial direction 54.
In the exemplary embodiment, drive assembly 18 includes a first drive shaft 72. Each supersonic compressor rotor 40, transition assembly 42, and centrifugal compressor assembly 46 are coupled to first drive shaft 72. Drive assembly 18 is configured to rotate first drive shaft 72 such that each supersonic compressor rotor 40, transition assembly 42, and centrifugal compressor assembly 46 rotate at a same rotational velocity. In an alternative embodiment, drive assembly 18 includes a second drive shaft 74 coupled to drive motor 22. In this alternative embodiment, first drive shaft 72 is coupled to supersonic compressor rotor 40. Second drive shaft 74 is coupled to compressor assembly 44. Drive assembly 18 is configured to rotate supersonic compressor rotor 40 in a first rotational direction, represented by arrow 76, and to rotate compressor assembly 44 in a second rotational direction, represented by arrow 78, that is opposite first rotational direction 76. Moreover, drive assembly 18 may be configured to rotate supersonic compressor rotor 40 at a first rotational velocity, and to rotate compressor assembly 44 at a second rotational velocity that is different than the first rotational velocity. In one embodiment, first drive shaft 72 is positioned within second drive shaft 74 and is oriented concentrically with respect to second drive shaft 74.
In the exemplary embodiment, discharge section 16 includes a vane diffuser 80 and a discharge scroll 82. Vane diffuser 80 is positioned in flow communication between compressor assembly 44 and discharge scroll 82, and is configured to impart a swirl to fluid being discharged from compressor assembly 44. Discharge scroll 82 is configured to condition fluid to include one or more predetermined parameters, such as a velocity, a mass flow rate, a temperature, and/or any suitable flow parameter. Discharge scroll 82 is also configured to channel fluid from compressor assembly 44 to fluid outlet 30. Fluid outlet 30 includes a discharge flange 84 and is configured to channel fluid from discharge scroll 82 to an output system 86 such as, for example, a turbine engine system, a fluid treatment system, and/or a fluid storage system.
During operation, inlet guide vane assembly 38 channels a fluid 88 from fluid inlet 28 to supersonic compressor rotor 40. Inlet guide vane assembly 38 increases a velocity of fluid 88, and imparts a swirl to fluid 88 being channeled to supersonic compressor rotor 40. Supersonic compressor rotor 40 receives fluid 88 from inlet guide vane assembly 38, reduces a volume of fluid 88, and increases a pressure in fluid 88 prior to discharging fluid 88 into transition assembly 42. Transition assembly 42 turns fluid 88 from radial direction 54 to axial direction 60 and channels fluid 88 into centrifugal compressor assembly 46. Centrifugal compressor assembly 46 receives fluid 88 along axial direction 60 and imparts a centrifugal force to fluid 88 that causes an increase in a pressure of fluid 88, and discharges fluid 88 along radial direction 54 to vane diffuser 80. In one embodiment, transition assembly 42 turns fluid 88 from a direction that is oblique to radial direction 54 to discharge fluid in a direction that is oblique to axial direction 60.
In the exemplary embodiment, each vane 90 is coupled to endwall 102 and extends outwardly from endwall 102 in an axial direction 60 that is generally parallel to centerline axis 24. Each vane 90 includes an inlet edge 106 and an outlet edge 108. Inlet edge 106 is positioned adjacent radially outer surface 100. Outlet edge 108 is positioned adjacent radially inner surface 98. In the exemplary embodiment, adjacent vanes 90 form a pair 112 of vanes 90. Each pair 112 is oriented to define an inlet opening 114, an outlet opening 116, and a flow channel 118 between adjacent vanes 90. Flow channel 118 extends between inlet opening 114 and outlet opening 116 and defines a flow path, represented by arrow 120, (shown in
Referring to
Referring to
During operation of supersonic compressor rotor 40, inlet guide vane assembly 38 (shown in
Referring to
In the exemplary embodiment, flow channel 118 defines a cross-sectional area 152 that varies along flow path 120. Cross-sectional area 152 of flow channel 118 is defined perpendicularly to flow path 120 and is equal to width 150 of flow channel 118 multiplied by axial height 126 (shown in
In the exemplary embodiment, supersonic compression ramp 140 is coupled to pressure side 148 of vane 90 and defines a throat region 160 of flow channel 118. Throat region 160 defines minimum cross-sectional area 158 of flow channel 118. In an alternative embodiment, supersonic compression ramp 140 may be coupled to suction side 146 of vane 90, endwall 102, and/or shroud assembly 128. In a further alternative embodiment, supersonic compressor rotor 40 includes a plurality of supersonic compression ramps 140 that are each coupled to suction side 146, pressure side 148, endwall 102, and/or shroud assembly 128. In such an embodiment, each supersonic compression ramp 140 collectively defines throat region 160.
In the exemplary embodiment, supersonic compression ramp 140 includes a compression surface 162 and a diverging surface 164. Compression surface 162 includes a first edge, i.e. a leading edge 166 and a second edge, i.e. a trailing edge 168. Leading edge 166 is positioned closer to inlet opening 114 than trailing edge 168. Compression surface 162 extends between leading edge 166 and trailing edge 168 and is oriented at an oblique angle 170 from vane 90 towards adjacent suction side 146 and into flow path 120. Compression surface 162 converges towards adjacent suction side 146 such that a compression region 172 is defined between leading edge 166 and trailing edge 168. Compression region 172 includes a converging cross-sectional area 174 of flow channel 118 that is reduced along flow path 120 from leading edge 166 to trailing edge 168. Trailing edge 168 of compression surface 162 defines throat region 160.
Diverging surface 164 is coupled to compression surface 162 and extends downstream from compression surface 162 towards outlet opening 116. Diverging surface 164 includes a first end 176 and a second end 178 that is positioned closer to outlet opening 116 than first end 176. First end 176 of diverging surface 164 is coupled to trailing edge 168 of compression surface 162. Diverging surface 164 extends between first end 176 and second end 178 and is oriented at an oblique angle 180 from pressure side 148 towards adjacent suction side 146. Diverging surface 164 defines a diverging region 182 that includes a diverging cross-sectional area 184 that increases from trailing edge 168 of compression surface 162 to outlet opening 116. Diverging region 182 extends from throat region 160 to outlet opening 116.
In the exemplary embodiment, supersonic compression ramp 140 is sized, shaped, and oriented to cause a system 186 of compression waves 142 to be formed within flow channel 118. During operation, as fluid 88 contacts leading edge 166 of supersonic compression ramp 140, a first oblique shock wave 188 of system 186 is formed. Compression region 172 of supersonic compression ramp 140 is configured to cause first oblique shock wave 188 to be oriented at an oblique angle with respect to flow path 120 from leading edge 166 towards adjacent vane 90, and into flow channel 118. As first oblique shock wave 188 contacts adjacent vane 90, a second oblique shock wave 190 is reflected from adjacent vane 90 at an oblique angle with respect to flow path 120, and towards throat region 160 of supersonic compression ramp 140. Supersonic compression ramp 140 is configured to cause each first oblique shock wave 188 and second oblique shock wave 190 to form within compression region 172. As fluid passes through throat region 160 towards outlet opening 116, a normal shock wave 192 is formed within diverging region 182. Normal shock wave 192 is oriented perpendicular to flow path 120 and extends across flow path 120.
As fluid 88 passes through compression region 172, a velocity of fluid 88 is reduced as fluid 88 passes through each first oblique shock wave 188 and second oblique shock wave 190. In addition, a pressure of fluid 88 is increased, and a volume of fluid 88 is decreased. As fluid 88 passes through throat region 160, a velocity of fluid 88 is increased downstream of throat region 160 towards normal shock wave 192. As fluid passes through normal shock wave 192, a velocity of fluid 88 is decreased to a subsonic velocity with respect to rotor disk 92.
In an alternative embodiment, supersonic compression ramp 140 is configured to condition fluid 88 to have an outlet velocity at outlet opening 116 that is supersonic with respect to rotor disk 92. Supersonic compression ramp 140 is further configured to prevent a normal shock wave from being formed downstream of throat region 160 and within flow channel 118.
In this alternative embodiment, radially outer surface 100 is coupled between upstream surface 194 and downstream surface 196, and extends a distance 202 defined from upstream surface 194 to downstream surface 196 in axial direction 60. Each vane 90 is coupled to radially outer surface 100 and extends outwardly from radially outer surface 100. Inlet edge 106 of each vane 90 is positioned adjacent upstream surface 194 of rotor disk 92. Outlet edge 108 of each vane 90 is positioned adjacent downstream surface 196. Each inlet opening 114 is defined by radially outer surface 100 and is adjacent upstream surface 194. Each outlet opening 116 is defined by radially outer surface 100 and is adjacent downstream surface 196. Inlet opening 114 is positioned a first radial distance 204 from centerline axis 24. Outlet opening 116 is positioned a second radial distance 206 from centerline axis 24 that is greater than first radial distance 204.
Referring to
In this alternative embodiment, during operation fluid 88 enters inlet opening 114 and is channeled through radial flow path 214 along radial direction 54. As fluid enters transition flow path 218, flow channel 118 channels fluid from radial direction 54 to axial direction 60 and channels fluid from radial flow path 214 to axial flow path 216. Fluid 88 is then discharged from axial flow path 216 through outlet opening 116 in axial direction 60.
In an alternative embodiment, supersonic compressor rotor 40 includes a first radial width 198 of upstream surface 194 that is equal to second radial width 200 of downstream surface 196. Each vane 90 is coupled to radially outer surface 100 and extends circumferentially about rotor disk 92 in a helical shape. Vane 90 of each vane 90 extends outwardly from radially outer surface 100 in radial direction 54. Each vane 90 is spaced axially from an adjacent vane 90 such that flow channel 118 is oriented generally in axial direction 60 between inlet opening 114 and outlet opening 116. Flow channel 118 defines an axial flow path 244 along axial direction 60 from inlet opening 114 to outlet opening 116.
During operation, in an alternative embodiment, inlet guide vane assembly 38 channels fluid 88 in radial direction 54 to transition assembly 42. Transition assembly 42 channels fluid 88 from radial direction 54 to axial direction 60. Supersonic compressor rotor 40 compresses fluid 88 in axial direction 60 and discharges fluid 88 axially toward axial compressor assembly 226. Axial compressor assembly 226 further compresses fluid 88 and discharges fluid 88 to outlet guide vane assembly 224 in axial direction 60.
The above-described supersonic compressor rotor provides a cost effective and reliable method for compressing a fluid through a supersonic compressor system. More specifically, the supersonic compressor system described herein includes a supersonic compressor rotor that is positioned in flow communication between a fluid inlet and a centrifugal compressor assembly to compress fluid and channel the compressed fluid to the centrifugal compressor assembly. Moreover, by providing a supersonic compressor rotor upstream of the centrifugal compressor assembly, the supersonic compressor system is able to compress a higher volume of fluid than known supersonic compressor assemblies. As a result, the cost of operating a supersonic compressor system to compress a fluid may be reduced.
Exemplary embodiments of systems and methods for assembling a supersonic compressor rotor are described above in detail. The system 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. For example, the systems and methods may also be used in combination with other rotary engine systems and methods, and are not limited to practice with only the supersonic compressor system as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other rotary system 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. Moreover, references to “one embodiment” in the above description are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. 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 languages of the claims.
