Active energy recovery device with a modular hydrodynamic compensation dynamic and static pressure rotor

Abstract

The present invention belongs to the technical field of energy recovery devices, and provides an active energy recovery device with a modular hydraulic compensation dynamic and static pressure rotor. Distribution disc assemblies are arranged at both the upper and lower ends of the rotor assembly. The distribution disc assembly includes a metal outer ring and a ceramic disc embedded in the inner side of the metal outer ring; the rotor assembly includes a shaft assembly, a valve plate assembly, a hydraulic thrust disc and a rotor cylinder that are modularly connected. The valve plate assembly includes a metal ring and a ceramic valve plate embedded in the inner side of the metal ring. The hydraulic thrust disc realizes automatic axial clearance compensation through high / low-pressure hydraulic fluid in the radial fluid holes and hydraulic flow channel holes. The present invention adopts a modular structure, which is convenient for maintenance, can work under low pressure, has high applicability, and the hydraulic thrust disc can adjust the height of the upper valve plate assembly to realize automatic compensation of the clearance between the valve plate assembly and the first distribution disc assembly, ensuring operation at an efficient value with a pressure conversion efficiency greater than 98%. By combining ceramics and stainless steel, the cost is lower.

Description

Technical Field

[0001] The present invention belongs to the technical field of energy recovery devices, and particularly relates to an active energy recovery device with a modular hydraulic compensation dynamic and static pressure rotor, which can efficiently recover the pressure energy in high-pressure fluid and transfer it to low-pressure fluid, and is widely used in industrial fields such as seawater desalination, chemical processes, carbon dioxide refrigeration, energy recovery, and other industrial fields that require high-pressure fluid treatment. Background Art

[0002] In many industrial processes, the discharge of high-pressure fluid is often accompanied by a large amount of energy waste. For example, in a reverse osmosis seawater desalination system, a high-pressure pump pressurizes seawater and desalinates it through a reverse osmosis membrane, while the concentrated brine is discharged at high pressure as a by-product. In this process, more than 50% of the input energy will be lost with the discharge of the concentrated brine. If this part of the energy can be effectively recovered, it can not only significantly reduce the energy consumption of the system, but also reduce the operating cost, which helps to improve the economic efficiency and sustainability of industrial processes.

[0003] Currently, the energy recovery devices existing on the market mainly include the following types:

[0004] (1) Turbine type energy recovery device:

[0005] The turbine type device converts the pressure energy of high-pressure fluid into mechanical energy, and then drives the high-pressure pump through a coupling. However, the energy recovery efficiency of this device is usually low (about 60% - 80%), and the structure is complex and the maintenance cost is high.

[0006] (2) Isobaric pressure exchanger:

[0007] The pressure exchanger is one of the most widely used energy recovery devices at present. It realizes energy recovery by directly exchanging pressure between high-pressure fluid and low-pressure fluid. Although its energy recovery efficiency is relatively high (up to more than 90%), the existing pressure exchangers generally have the following problems:

[0008] Fluid mixing problem: Cross-contamination may occur between high-pressure fluid and low-pressure fluid, especially in working conditions that require strict fluid separation, this problem is particularly prominent.

[0009] Unstable operation: In working conditions with large flow fluctuations or pressure changes, the existing devices are difficult to maintain a stable operating state.

[0010] Limited application range: For fluids with high viscosity or containing solid particles, the adaptability of existing devices is poor.

[0011] Traditional isobaric exchangers often integrate the flow distribution structure with the inlet and outlet ports to ensure strength, which often results in high manufacturing costs. After wear, the entire inlet and outlet ports need to be replaced, resulting in high costs.

[0012] (3) Plunger type energy recovery device:

[0013] The plunger type device realizes the transfer of pressure energy through mechanical reciprocating motion, and has high energy recovery efficiency and good adaptability. However, this type of device generally has the disadvantages of complex structure, large volume, and difficult maintenance.

[0014] In summary, the existing energy recovery technologies still have many deficiencies in terms of efficiency, stability, applicability, and maintainability, which limit their wide application in the industrial field. Therefore, developing an energy recovery device with high efficiency, stability, compact structure, and strong adaptability has become a research hotspot in the current technical field. Summary of the Invention

[0015] The purpose of the present invention is to overcome the existing defects, and provide an active energy recovery device with a modular hydraulic compensation dynamic and static pressure rotor. By optimizing the structural design and fluid control method, high-efficiency and stable energy recovery are achieved, and it has broad industrial application prospects.

[0016] In order to solve the above technical problems, the present invention provides the following technical solutions:

[0017] An active energy recovery device with a modular hydraulic compensation dynamic and static pressure rotor includes a housing. Upper end covers and lower end covers are respectively installed at the upper and lower ends of the housing. A low-pressure fluid inlet and a high-pressure fluid outlet are opened on the side surface of the upper end cover. A high-pressure fluid inlet and a low-pressure fluid outlet are opened on the side surface of the lower end cover. A rotor assembly is installed in the inner cavity of the housing through a dynamic and static pressure bearing. A first flow distribution plate assembly and a second flow distribution plate assembly are respectively arranged on the upper and lower sides of the rotor assembly. Both the first flow distribution plate assembly and the second flow distribution plate assembly include a metal outer ring and a ceramic disc embedded in the inner side of the metal outer ring;

[0018] The rotor assembly includes a modularly connected shaft assembly, a valve plate assembly, a hydraulic thrust disc, and a rotor cylinder. The shaft assembly is provided with a radially communicating fluid hole and a hydraulic flow channel hole. High / low-pressure fluid is filled in the radially communicating fluid hole and the hydraulic flow channel hole. A driving shaft passing through the top of the housing is arranged at the upper end of the shaft assembly. A valve plate assembly is installed at each of the upper and lower ends of the rotor cylinder. The upper valve plate assembly is a floating disc structure that can move up and down. The valve plate assembly includes a metal ring and a ceramic valve plate embedded in the inner side of the metal ring. The hydraulic thrust disc realizes automatic axial clearance compensation between the valve plate assembly and the first flow distribution plate assembly through the hydraulic force of the high / low-pressure fluid in the radially communicating fluid hole and the hydraulic flow channel hole;

[0019] A static pressure pool is provided in the middle of the outer periphery of the rotor cylinder. Tapered groove stepped shafts are provided on both the upper and lower sides of the static pressure pool. An annular thin-wall damping structure is integrally arranged on the inner wall of the flow channel of the rotor cylinder. Dislocated flow channel grooves and damping holes are provided on the outer periphery of the hybrid journal bearing.

[0020] In one embodiment, a hydraulic clearance adjustment assembly is connected to the middle of the lower end of the housing. The hydraulic clearance adjustment assembly includes a pressure reducing valve, a pressure gauge, and a liquid filling connecting pipe connected in sequence. The other end of the liquid filling connecting pipe is communicated with the lower end of the shaft assembly. The liquid inlet of the pressure reducing valve is communicated with an external pressure supply pipeline or is communicated with the upper side of the high-pressure fluid outlet through a high-pressure water outlet pressure guiding pipe.

[0021] In one embodiment, a liquid inlet and a liquid outlet are oppositely provided at the lower part of the pressure reducing valve. A first valve core and a second valve core that cooperate with each other are installed in the flow channel between the liquid inlet and the liquid outlet through a valve core seat. A first spring is installed at the lower end of the first valve core. At the upper end of the first valve core, a valve core adjustment guiding part, a spring lower base, a main spring, an upper spring base, a spring adjustment guiding part, and a valve adjustment part are sequentially and cooperatively installed from bottom to top.

[0022] In another embodiment, a hydraulic clearance adjustment assembly is connected to the middle of the lower end of the housing. The hydraulic clearance adjustment assembly includes a step control pressure reducing valve, a pressure sensor, and a liquid filling connecting pipe connected in sequence. The other end of the liquid filling connecting pipe is communicated with the lower end of the shaft assembly. The other end of the step control pressure reducing valve is communicated with the upper side of the high-pressure fluid outlet through a high-pressure water outlet pressure guiding pipe;

[0023] A position sensor for detecting the position of the valve plate is installed on the upper side of the upper end cover and the lower side of the lower end cover respectively. The step control pressure reducing valve, the pressure sensor, and the position sensor are respectively connected to an intelligent control system.

[0024] In one embodiment, a ceramic disk of the first flow distribution plate assembly is provided with a low-pressure inlet and a high-pressure outlet. One ends of the low-pressure inlet and the high-pressure outlet are respectively communicated with a first variable cross-section damping flow channel. A hydraulic slope is provided at the other end of the low-pressure inlet. A first friction variable cross-section is provided at the edge of the low-pressure inlet.

[0025] A ceramic disk of the second flow distribution plate assembly is provided with a low-pressure outlet and a high-pressure inlet. The low-pressure outlet and the high-pressure inlet are respectively communicated with a second variable cross-section damping flow channel. A second friction variable cross-section is provided at the edge of the low-pressure outlet.

[0026] In one embodiment, the hydraulic flow channel holes are arranged along the axial direction of the shaft assembly. A check valve is installed at the lower end of the hydraulic flow channel holes. A check valve sealing ring is installed at the upper end of the check valve.

[0027] In one embodiment, the check valve includes a valve body, an upper valve cover and a lower valve cover are respectively installed at the upper and lower ends of the valve body, a spherical valve core is installed inside the valve body, a valve core guide is installed at the upper end of the spherical valve core, a second spring is sleeved outside the spherical valve core, a valve seat is installed between the lower end of the spherical valve core and the lower valve cover, and a valve seat retaining ring is clamped between the valve seat and the inner wall of the valve body.

[0028] In one embodiment, the valve plate assembly further includes a sealing assembly. The upper side of the sealing assembly is connected to a metal ring through a mounting plate, and a retaining ring and an O-ring are installed outside the sealing assembly;

[0029] An outer ring radial O-ring and an outer ring radial retaining ring are installed on the outer ring of the hydraulic thrust disk, and an inner ring radial retaining ring and an inner ring radial O-ring are installed on the inner ring;

[0030] An axial sealing retaining ring and an axial sealing O-ring are installed outside the shaft assembly.

[0031] In one embodiment, the upper end of the shaft assembly is cooperatively installed with the housing through a first low-pressure shaft seal and an auxiliary bearing, and the lower end of the shaft assembly is cooperatively installed with the housing through a second low-pressure shaft seal.

[0032] In one embodiment, the internal flow path of the valve plate assembly and the internal flow path of the rotor cylinder adopt a variable cross-section structure, and the cross-section of the internal flow path of the valve plate assembly gradually decreases outward on one side of the rotor cylinder.

[0033] Combined with the above technical solutions, the beneficial effects of the present invention compared with the prior art are as follows:

[0034] The rotor assembly in the present invention adopts a modular structure, which can make the cost lower, the maintenance simpler, and there are more categories. It can be applied to different working conditions through random combination (it can be used for the recovery of hydraulic residual pressure or the recovery of gas pre-pressure). The drive shaft at the upper end of the shaft assembly can be connected to an external drive device, and by adopting an active drive method, it can have stronger anti-pollution ability and improve stability. By adopting an innovative design of combining ceramics and stainless steel for both the flow distribution disk assembly and the valve plate assembly, the traditional integral design is changed to a split design, with lower cost and convenient maintenance. Through the cooperation of the rotor cylinder and the hydrostatic and hydrodynamic bearings, the product can work at a very low pressure, and the working pressure range can be 5 - 120 barg, with high applicability. The rotor cylinder can be completely made of stainless steel, and products with lower mixing degrees can be designed according to different usage conditions.

[0035] The hydraulic thrust disk in the present invention can adjust the height of the upper valve plate assembly by using the hydraulic force provided by the high / low-pressure fluid in the shaft assembly, realizing automatic compensation of the axial clearance between the valve plate assembly and the first flow distribution disk assembly, thereby ensuring a constant clearance value and ensuring that the device always operates at an efficiency value of 98%.

[0036] In summary, through the improvement of the overall structure and materials, the present invention realizes the optimization of the hydrodynamic and mechanical efficiency of the overall structure, can reduce turbulence and secondary vortices. By adding an annular thin-wall damping structure to the inner wall of the flow channel of the rotor cylinder, the residence time of the fluid in the rotor cylinder can be extended, the conversion efficiency can be improved, the mixing degree can be reduced, the noise can be reduced, the service life can be increased, the cost can be reduced, and the maintenance is convenient. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The drawings are used to provide a further understanding of the present invention, and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention, but do not constitute a limitation to the present invention. In the drawings:

[0038] Figure 1 is a schematic structural diagram of an active energy recovery device with a modular hydrodynamic compensation dynamic and static pressure rotor provided by an embodiment of the present invention;

[0039] Figure 2 is a sectional view of an active energy recovery device with a modular hydrodynamic compensation dynamic and static pressure rotor provided by an embodiment of the present invention;

[0040] Figure 3 is a schematic structural diagram of a hydrodynamic clearance adjustment assembly provided by Embodiment 1 of the present invention;

[0041] Figure 4 is a schematic structural diagram of a hydrodynamic clearance adjustment assembly provided by Embodiment 2 of the present invention;

[0042] Figure 5 is a schematic structural diagram of a hydrodynamic clearance adjustment assembly provided by Embodiment 3 of the present invention;

[0043] Figure 6 is a schematic structural diagram of a first flow distribution disc assembly provided by an embodiment of the present invention;

[0044] Figure 7 is a schematic structural diagram of a first ceramic disc provided by an embodiment of the present invention;

[0045] Figure 8 is a schematic structural diagram of a second flow distribution disc assembly provided by an embodiment of the present invention;

[0046] Figure 9 is a schematic structural diagram of a second ceramic disc provided by an embodiment of the present invention;

[0047] Figure 10 is a schematic structural diagram of a rotor assembly provided by an embodiment of the present invention;

[0048] Figure 11 is a schematic structural diagram of a shaft assembly provided by an embodiment of the present invention;

[0049] Figure 12 It is a schematic structural diagram of the check valve provided by an embodiment of the present invention;

[0050] Figure 13 It is a schematic structural diagram of the valve plate assembly provided by an embodiment of the present invention;

[0051] Figure 14 It is a schematic structural diagram of the hydraulic thrust disc provided by an embodiment of the present invention;

[0052] Figure 15 It is a schematic structural diagram of the rotor cylinder provided by an embodiment of the present invention;

[0053] Figure 16 It is a schematic structural diagram of the hydrostatic and hydrodynamic bearing provided by an embodiment of the present invention;

[0054] Figure 17 It is a schematic structural diagram of the pressure reducing valve provided by an embodiment of the present invention;

[0055] In the figure: 1. Low-pressure fluid inlet; 2. High-pressure fluid outlet; 3. Low-pressure fluid outlet; 4. High-pressure fluid inlet; 5. Shaft seal end cover; 6. First low-pressure shaft seal; 7. First flow distribution plate assembly; 8. Rotor assembly; 9. Outer shell; 10. Hydrostatic and hydrodynamic bearing; 11. Second flow distribution plate assembly; 12. Second low-pressure shaft seal; 13. Auxiliary bearing; 14. Pressure reducing valve; 15. Pressure gauge; 16. Liquid filling connection pipe; 17. Plug; 18. High-pressure water outlet pressure guiding pipe; 19. Step control pressure reducing valve; 20. Pressure sensor; 21. Position sensor; 7.1. First metal outer ring; 7.2. First ceramic disc; 7.2.1. Low-pressure inlet; 7.2.2. Hydraulic slope; 7.2.3. First friction variable cross-section; 7.2.4. First variable cross-section damping flow channel; 7.2.5. High-pressure outlet; 8.1. Shaft assembly; 8.2. Valve plate assembly; 8.3. Hydraulic thrust disc; 8.4. Rotor cylinder; 8.1.1. Driving shaft; 8.1.2. Radial fluid hole; 8.1.3. Hydraulic flow channel hole; 8.1.4. Axial seal retaining ring; 8.1.5. Axial seal O-ring; 8.1.6. Check valve sealing ring; 8.1.7. Check valve; 8.1.7.1. Upper valve cover; 8.1.7.2. Valve body; 8.1.7.3. Second spring; 8.1.7.4. Valve core guide; 8.1.7.5. Spherical valve core; 8.1.7.6. Valve seat retaining ring; 8.1.7.7. Valve seat; 8.1.7.8. Lower valve cover; 8.2.1. Metal ring; 8.2.2. Ceramic valve plate; 8.2.3. Mounting plate; 8.2.4. Sealing assembly; 8.2.5. Retaining ring; 8.2.6. O-ring; 8.3.1. Hydraulic thrust disc body; 8.3.2. Outer ring radial O-ring; 8.3.3. Outer ring radial retaining ring; 8.3.4. Inner ring radial retaining ring; 8.3.5. Inner ring radial O-ring; 8.3.6. Supporting valve plate surface; 8.4.1. Hydrostatic pool; 8.4.2. Tapered shaft with inclined groove; 8.4.3. Annular thin-wall damping structure; 10.1. Misaligned flow channel groove; 10.2. Damping hole; 11.1. Second metal outer ring; 11.2. Second ceramic disc; 11.2.1. Low-pressure outlet; 11.2.2. Second friction variable cross-section; 11.2.3. High-pressure inlet; 11.2.4. Second variable cross-section damping flow channel; 14.1. Liquid inlet; 14.2. Liquid outlet; 14.3. First spring; 14.4. First valve core; 14.5. Second valve core; 14.6. Valve core seat; 14.7. Valve core adjustment guide; 14.8. Spring lower base; 14.9. Main spring; 14.10. Upper spring base; 14.11. Spring adjustment guide; 14.12. Valve adjustment part. Specific embodiments

[0056] The following describes the preferred embodiments of the present invention with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are only for the purpose of illustration and explanation of the present invention, and are not intended to limit the present invention.

[0057] Example 1, as Figure 1 and Figure 2 shown, is an embodiment of the active energy recovery device with a modular hydrodynamic compensation hybrid bearing rotor provided by the present invention, including a housing 9. Upper end covers and lower end covers are respectively installed at the upper and lower ends of the housing 9. A low-pressure fluid inlet 1 and a high-pressure fluid outlet 2 are provided on the side surface of the upper end cover, and a high-pressure fluid inlet 4 and a low-pressure fluid outlet 3 are provided on the side surface of the lower end cover. A rotor assembly 8 is installed in the inner cavity of the housing 9 through a hybrid bearing 10. A first flow distribution disc assembly 7 (low-pressure inlet and high-pressure outlet) and a second flow distribution disc assembly 11 (low-pressure outlet and high-pressure inlet) are respectively arranged on the upper and lower sides of the rotor assembly 8.

[0058] The energy recovery device will perform at least 1 energy exchange during one rotation, and can be designed to perform 1 - 3 times according to needs (by selecting the number of flow distribution ports of the first flow distribution disc assembly 7 and the second flow distribution disc assembly 11, the number of times can be regulated). The pressure of the high-pressure fluid inlet 4 will be transmitted to the low-pressure fluid inlet 1, the fluid at the low-pressure fluid inlet 1 will be transformed into the fluid at the high-pressure fluid outlet 2, and the fluid at the high-pressure fluid inlet 4 that has been exchanged will be discharged as the low-pressure fluid at the low-pressure fluid outlet 3.

[0059] As Figure 10 shown, the rotor assembly 8 in the embodiment of the present invention includes a shaft assembly 8.1, a valve plate assembly 8.2, a hydrodynamic thrust disc 8.3, and a rotor cylinder 8.4 that are modularly connected. The shaft assembly 8.1 passes through the middle of the valve plate assembly 8.2, the hydrodynamic thrust disc 8.3, and the rotor cylinder 8.4. One valve plate assembly is respectively installed at the upper and lower ends of the rotor cylinder 8.4. The upper valve plate assembly 8.2 is a floating disc structure that can move up and down. The hydrodynamic thrust disc 8.3 realizes automatic axial clearance compensation through the hydrodynamics of high / low-pressure fluids in the radial fluid holes and the hydrodynamic flow channels. An axial seal retaining ring 8.1.4 and an axial seal O-ring 8.1.5 are installed on the outer side of the shaft assembly 8.1.

[0060] In the embodiment of the present invention, the clearance h can be accurately and automatically adjusted through the hydrodynamic thrust disc 8.3, so that the energy recovery device can work in the high-efficiency range of about 98% for a long time. The appearance of this structure has completely changed the current mainstream rotor manufacturing method. The traditional rotor manufacturing has extremely high precision requirements and completely relies on the final closed ring to control the tolerance. The combined structure adopted by the present invention completely eliminates the need to consider the tolerance in the length direction, greatly reducing the manufacturing cost.

[0061] It should be noted that the clearance h directly affects the leakage of the energy recovery device. The larger the clearance h, the greater the leakage, which will cause a decrease in energy recovery efficiency, an increase in mixture ratio, a decrease in the efficiency of the entire system, an increase in pressure, and an increase in energy consumption. If the clearance h is too small, there will be insufficient lubrication, increased heat generation, increased wear, increased torque, and a decrease in energy recovery efficiency. Therefore, a reasonable clearance h can not only ensure efficient lubrication but also ensure efficient operation. This reasonable clearance h is determined by the balanced force formed by the upward thrust of the hydraulic thrust disk and the separating force between the first flow distribution disk and the valve plate assembly, that is, after the thrust and the separating force reach equilibrium, the clearance between the first flow distribution disk and the valve plate assembly at this time is the reasonable clearance h. The separating force between the first flow distribution disk and the valve plate assembly naturally exists when the fluid flows between the first flow distribution disk and the valve plate assembly.

[0062] As Figure 11 shown, at the upper end of the shaft assembly 8.1 in the embodiment of the present invention, there is a drive shaft 8.1.1 that penetrates through the top of the housing 9 and can be directly connected to a motor, a hydraulic motor, a servo motor, etc. The shaft assembly 8.1 is provided with a radially communicating fluid hole 8.1.2 and a hydraulic flow channel hole 8.1.3. The radially communicating fluid hole 8.1.2 and the hydraulic flow channel hole 8.1.3 are filled with high / low-pressure fluid. The hydraulic flow channel hole 8.1.3 is arranged along the axial direction of the shaft assembly 8.1. A check valve 8.1.7 is installed at the lower end of the hydraulic flow channel hole 8.1.3, and a check valve sealing ring 8.1.6 is installed at the upper end of the check valve 8.1.7.

[0063] As Figure 3 shown, in the embodiment of the present invention, a hydraulic clearance adjustment assembly is connected to the middle of the lower end of the housing 9. The hydraulic clearance adjustment assembly includes a pressure reducing valve 14, a pressure gauge 15, and a liquid filling connecting pipe 16 that are connected in sequence. The liquid filling connecting pipe 16 is communicated with the lower end of the shaft assembly 8.1, and the liquid inlet of the pressure reducing valve 14 is communicated with an external pressure supply pipeline.

[0064] As Figure 17 shown, at the lower part of the pressure reducing valve 14 in the embodiment of the present invention, a liquid inlet 14.1 and a liquid outlet 14.2 are oppositely arranged. A first valve core 14.4 and a second valve core 14.5 that cooperate with each other are installed in the flow channel between the liquid inlet 14.1 and the liquid outlet 14.2 through a valve core seat 14.6. A first spring 14.3 is installed at the lower end of the first valve core 14.4. At the upper end of the first valve core 14.4, a valve core adjustment guide 14.7, a spring lower base 14.8, a main spring 14.9, an upper spring base 14.10, a spring adjustment guide 14.11, and a valve adjustment part 14.12 are sequentially installed in a cooperating manner from bottom to top.

[0065] Specifically, the hydraulic clearance adjustment assembly fills the lower side of the hydraulic thrust disk 8.3 with liquid. The hydraulic thrust disk 8.3 pushes the upper valve plate assembly 8.2 upward to adjust the clearance h. A high-precision pressure reducing valve 14 is adopted to ensure the constant pressure of the hydraulic thrust disk 8.3 and obtain an accurate clearance h.

[0066] The hydraulic clearance adjustment assembly in this embodiment adopts an external pressure supply form. Due to the existence of external pressure supply and the pressure reducing valve, a clearance can be pre-formed between the valve plate assembly pushed by the hydraulic thrust disk and the first row of distribution disks. Fine adjustment is carried out according to whether the conversion efficiency meets the design requirements, and finally an efficient clearance h is achieved. During subsequent operation, after wear occurs, the hydraulic pressure on the lower side of the hydraulic thrust disk 8.3 will decrease. The hydraulic clearance adjustment assembly can be opened for pressure compensation. Due to the function of the check valve, a sealed damper is formed in the internal sealed cavity, which can compensate for a certain amount of wear clearance. Normally, one adjustment can be used for at least 5 years.

[0067] During normal installation, the clearance h will be reserved at 1mm, 0.9mm, 0.8mm, 0.7mm, 0.6mm, 0.5mm or 0.4mm, etc. After installation is completed, the rotor assembly 8 can rotate easily. Install the assembled energy recovery device on the test platform and connect the pipelines. First, start the original water pump to ensure that the pressure is not lower than 2 barg, then start the energy recovery device, and then open the pressure reducing valve 14 so that the pressure at the liquid outlet 14.2 is not higher than 2 barg. Observe the changes in the conversion efficiency and the current of the drive motor. The current should not exceed 5 A. Then start the high-pressure pump and adjust the pressure at the liquid outlet 14.2 of the pressure reducing valve 14 according to the efficiency data to make the efficiency stable between 96-98%. At this time, the clearance h between the valve plate assembly 8.2 and the first distribution disk assembly 7 is the optimal value. The normal clearance value will not be greater than 0.1mm, and it is normally between 0.01-0.05mm.

[0068] As Figure 2 shown, after normal adjustment is completed, the pressure reducing valve 14, the pressure gauge 15, and the liquid filling connection pipe 16 can be removed, and the openings can be blocked with plugs 17. Due to the existence of the check valve 8.1.7, the axial seal retaining ring 8.1.4 and the axial seal O-ring 8.1.5 on the shaft, including the outer ring radial O-ring 8.3.2, the outer ring radial retaining ring 8.3.3, the inner ring radial retaining ring 8.3.4, and the inner ring radial O-ring 8.3.5 of the hydraulic thrust disk, the internal liquid will not leak. When the wear between the valve plate assembly 8.2 and the first distribution disk assembly 7 is within 0.05mm, there is no need to inject liquid again, and it can normally last for 5-8 years.

[0069] As Figure 6 and Figure 8As shown in the figure, the first flow distribution disk assembly 7 in the embodiment of the present invention includes a first metal outer ring 7.1 and a first ceramic disk 7.2 embedded in the inner side of the first metal outer ring 7.1. The second flow distribution disk assembly 11 includes a second metal outer ring 11.1 and a second ceramic disk 11.2 embedded in the inner side of the second metal outer ring 11.1.

[0070] Specifically, in the embodiment of the present invention, the toughness of the metal is combined with the brittleness of the ceramic, reducing the use of ceramics. Alumina or silicon carbide ceramics can be used to ensure material uniformity and purity, reduce micro defects, utilize surface treatment processes to reduce surface roughness, and combine with the application of nano-coating technology to reduce surface friction. In traditional isobaric exchangers, in order to ensure strength, the flow distribution structure and the water inlet and outlet are often made together, resulting in a high manufacturing cost. After wear, the entire water inlet and outlet need to be replaced, which is costly. In the embodiment of the present invention, the metal and ceramic are combined by means of metal-ceramic hot inlay technology, making the originally high-cost components low-cost. At the same time, after wear, the replacement is simpler and the cost is lower.

[0071] As Figure 7 and Figure 9 shown, the first ceramic disk 7.2 is provided with a low-pressure inlet 7.2.1 and a high-pressure outlet 7.2.5. One end of the low-pressure inlet 7.2.1 and the high-pressure outlet 7.2.5 are respectively communicated with a first variable cross-section damping flow channel 7.2.4. The other end of the low-pressure inlet 7.2.1 is provided with a hydraulic ramp 7.2.2, and the edge of the low-pressure inlet 7.2.1 is provided with a first friction variable cross-section 7.2.3. The second ceramic disk 11.2 is provided with a low-pressure outlet 11.2.1 and a high-pressure inlet 11.2.3. The low-pressure outlet 11.2.1 and the high-pressure inlet 11.2.3 are respectively communicated with a second variable cross-section damping flow channel 11.2.4, and the edge of the low-pressure outlet 11.2.1 is provided with a second friction variable cross-section 11.2.2.

[0072] It should be noted that Figure 7 and Figure 9 the arrow directions shown in the figure are the rotation directions when the rotor assembly 8 works. The first flow distribution disk assembly 7 and the second flow distribution disk assembly 11 do not rotate. The hydraulic ramp 7.2.2 can provide part of the torque for the rotor assembly 8. The first friction variable cross-section 7.2.3 and the second friction variable cross-section 11.2.2 are used to reduce friction. The first variable cross-section damping flow channel 7.2.4 and the second variable cross-section damping flow channel 11.2.4 are used to reduce fluid flow noise and turbulence. By adopting a variable cross-section channel design, the hydrodynamic performance is optimized and the fluid separation effect is improved.

[0073] As Figure 2 and Figure 10As shown, the upper end of the shaft assembly 8.1 in the embodiment of the present invention is cooperatively installed with the housing 9 through the first low-pressure shaft seal 6 and the auxiliary bearing 13, and the lower end of the shaft assembly 8.1 is cooperatively installed with the housing 9 through the second low-pressure shaft seal 12.

[0074] As Figure 12 shown, the check valve 8.1.7 in the embodiment of the present invention includes a valve body 8.1.7.2. The outer side of the valve body 8.1.7.2 is threadedly connected to the inner hole of the shaft assembly 8.1 through a G1 / 4 external thread. The upper and lower ends of the valve body 8.1.7.2 are respectively provided with an upper valve cover 8.1.7.1 (fluid outflow end) and a lower valve cover 8.1.7.8 (fluid inflow end). A spherical valve core 8.1.7.5 is installed inside the valve body 8.1.7.2. The spherical valve core 8.1.7.5 has a highly reliable sealing performance. A valve core guide 8.1.7.4 is installed at the upper end of the spherical valve core 8.1.7.5. A second spring 8.1.7.3 is sleeved outside the spherical valve core 8.1.7.5. A valve seat 8.1.7.7 is installed between the lower end of the spherical valve core 8.1.7.5 and the lower valve cover 8.1.7.8. A valve seat retaining ring 8.1.7.6 is clamped between the valve seat 8.1.7.7 and the inner wall of the valve body 8.1.7.2.

[0075] As Figure 13 shown, the valve plate assembly 8.2 in the embodiment of the present invention includes a metal ring 8.2.1, a ceramic valve plate 8.2.2 embedded in the inner side of the metal ring 8.2.1, and a sealing assembly 8.2.4. The sealing assembly 8.2.4 is connected to the metal ring 8.2.1 through a mounting plate 8.2.3. A retaining ring 8.2.5 and an O-ring 8.2.6 are installed outside the sealing assembly 8.2.4.

[0076] Specifically, in the embodiment of the present invention, by combining the toughness of metal with the brittleness of ceramic, the use of ceramic is reduced. Alumina or silicon carbide ceramic can be used to ensure material uniformity and purity, reduce micro defects, utilize surface treatment technology to reduce surface roughness, and combine with the application of nano coating technology to reduce surface friction. In order to ensure strength, traditional isobaric exchangers often make the entire rotor out of ceramic, which often results in high manufacturing costs. After wear, the entire ceramic rotor needs to be replaced, resulting in high costs. The present invention combines metal and ceramic through a metal-ceramic hot inlay process, making the originally high-cost components low-cost. The valve plate assembly 8.2 at the upper end of the rotor assembly 8 adopts a floating disk design. When wear occurs, the hydraulic thrust disk 8.3 can be used to compensate for the worn gap h, which can greatly improve the service life. At the same time, due to the use of a split structure, if irreversible wear occurs, only the valve plate assembly 8.2 needs to be replaced, which is simpler and lower in cost. The sealing assembly 8.2.4 is used to seal each flow channel of the rotor assembly 8.

[0077] As Figure 10 andFigure 13 As shown, the internal flow channels of the valve plate assembly 8.2 in the embodiments of the present invention and the internal flow channels of the rotor cylinder 8.4 adopt a variable cross-section structure, and the outer cross-section of the internal flow channels of the valve plate assembly 8.2 gradually decreases on one side of the rotor cylinder 8.4.

[0078] By optimizing the chamfers at the inlet / outlet of the valve plate assembly 8.2, local losses are reduced, and by optimizing the geometric shape of the channels, flow resistance is reduced.

[0079] As Figure 14 shown, an outer ring radial O-ring 8.3.2 and an outer ring radial retaining ring 8.3.3 are installed on the outer ring of the hydraulic thrust disk body 8.3.1 in the embodiments of the present invention, and an inner ring radial retaining ring 8.3.4 and an inner ring radial O-ring 8.3.5 are installed on the inner ring. The supporting valve plate surface 8.3.6 is the contact surface with the valve plate assembly 8.2.

[0080] As Figure 15 and Figure 16 shown, a static pressure pool 8.4.1 is provided in the middle of the outer periphery of the rotor cylinder 8.4 in the embodiments of the present invention. Oblique groove stepped shafts 8.4.2 are provided on both the upper and lower sides of the static pressure pool 8.4.1, and an annular thin-wall damping structure 8.4.3 is integrally provided on the inner wall of the flow channel of the rotor cylinder 8.4. Misaligned flow channel grooves 10.1 and damping holes 10.2 are provided on the outer periphery of the hydrostatic bearing 10.

[0081] At the beginning of startup, since static pressure cannot be established, the gap between the shaft and the bearing is too small and can be regarded as two parallel cylindrical surfaces, and no pressure (dynamic pressure support or lubrication) will be generated in the gap. In the present invention, by providing an oblique groove stepped shaft 8.4.2 on the rotor cylinder 8.4, when the fluid flows through the oblique groove stepped shaft 8.4.2, it is like passing through a series of stepped bearings, and because the flow direction is not directly facing the direction of the stepped shaft, a lateral pumping effect is also generated. Both situations cause the pressure in the lubricating liquid to increase (the formation of dynamic pressure characteristics). For the dynamic pressure to form good lubrication support characteristics before the static pressure is fully established, so this product can work at a very low pressure. By adding an annular thin-wall damping structure 8.4.3 to the inner wall of the flow channel of the rotor cylinder 8.4, the residence time of the fluid in the rotor cylinder 8.4 can be extended, the conversion efficiency can be improved, the mixing degree can be reduced, and the noise can be reduced. The perfect cooperation between the rotor cylinder 8.4 and the hydrostatic bearing 10 enables the energy recovery device to be used well at pressures ranging from 5 - 120 barg.

[0082] Embodiment 2: On the basis of Embodiment 1, the active energy recovery device with a modular hydraulic compensation hydrostatic rotor provided in the embodiments of the present invention improves the connection method of the hydraulic clearance adjustment assembly.

[0083] As Figure 4As shown, the liquid inlet of the pressure reducing valve 14 is connected to the upper side of the high-pressure fluid outlet 2 through the high-pressure water outlet pressure guiding pipe 18, adopting an internal pressure supply form. Due to the existence of the hydraulic clearance adjustment component and the pressure reducing valve 14 with internal pressure supply, the self-adaptive clearance h can be achieved through the balance between the upward thrust of the hydraulic thrust plate and the separation force between the first flow distribution plate and the valve plate assembly.

[0084] Embodiment 3, as Figure 5 shown, on the basis of Embodiment 1, the active energy recovery device with a modular hydraulic compensation dynamic and static pressure rotor provided by the embodiment of the present invention improves the structure and connection mode of the hydraulic clearance adjustment component.

[0085] The hydraulic clearance adjustment component in the embodiment of the present invention includes a step control pressure reducing valve 19, a pressure sensor 20, and a liquid filling connecting pipe 16 connected in sequence. The other end of the liquid filling connecting pipe 16 is connected to the lower end of the shaft assembly, and the other end of the step control pressure reducing valve 19 is connected to the upper side of the high-pressure fluid outlet 2 through the high-pressure water outlet pressure guiding pipe 18; a position sensor 21 for detecting the position of the valve plate assembly is installed on the upper side of the upper end cover and the lower side of the lower end cover respectively. The step control pressure reducing valve 19, the pressure sensor 20, and the position sensor 21 are respectively connected to the intelligent control system.

[0086] The intelligent control system in this embodiment can adopt the existing adaptive control algorithm to achieve in the control process:

[0087] Parameter self-optimization based on machine learning;

[0088] Predictive control strategy to cope with working condition changes in advance;

[0089] Multi-objective optimization control to balance efficiency and reliability.

[0090] Real-time optimization technology can also be added:

[0091] Online efficiency calculation and optimization;

[0092] Dynamic working point adjustment;

[0093] Energy consumption minimization control strategy.

[0094] The hydraulic clearance adjustment component in the embodiment of the present invention adopts an internal pressure supply form. By detecting the position of the valve plate assembly through the position sensor 21, the clearance h can be calculated according to the position information. This valve plate clearance measurement method forms a PID control with the step control pressure reducing valve to accurately control the clearance h between the valve plate assembly and the first flow distribution plate.

[0095] When this embodiment is adopted, the seal on the hydraulic thrust disk can be removed, and the clearance between the hydraulic thrust disk and its mating surface can be controlled within 0.01 - 0.02 mm to form a PID control. At this time, the hydraulic thrust disk is the hydrostatic support disk, which has a good regulating effect on the real-time operation status.

[0096] In the description of the present invention, unless otherwise specified, "a plurality of" means two or more; the orientation or positional relationship indicated by the terms "upper", "lower", "left", "right", "inner", "outer", "front end", "rear end", "head", "tail", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus cannot be construed as a limitation on the present invention. In addition, the terms "first", "second", "third", etc. are only used for descriptive purposes and cannot be construed as indicating or implying relative importance.

[0097] Finally, it should be noted that the above are only the preferred embodiments of the present invention and are not used to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions recorded in the foregoing embodiments or perform equivalent replacements for some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. An active energy recovery device with a modular hydrodynamic compensated hybrid journal bearing rotor, comprising a housing, an upper end cover and a lower end cover are respectively installed at the upper and lower ends of the housing, a low-pressure fluid inlet and a high-pressure fluid outlet are provided on the side surface of the upper end cover, and a high-pressure fluid inlet and a low-pressure fluid outlet are provided on the side surface of the lower end cover, characterized in that, The inner cavity of the housing is equipped with a rotor assembly through a hybrid bearing. A first flow distribution plate assembly and a second flow distribution plate assembly are respectively arranged on the upper and lower sides of the rotor assembly. Both the first flow distribution plate assembly and the second flow distribution plate assembly include a metal outer ring and a ceramic disc embedded in the inner side of the metal outer ring. The rotor assembly includes a modularly connected shaft assembly, a valve plate assembly, a hydraulic thrust disc, and a rotor cylinder. The shaft assembly is provided with a radially communicating fluid hole and a hydraulic flow channel hole. High / low pressure fluid is filled in the radially communicating fluid hole and the hydraulic flow channel hole. A driving shaft passing through the top of the housing is arranged at the upper end of the shaft assembly. One valve plate assembly is installed at each of the upper and lower ends of the rotor cylinder. The upper valve plate assembly is a floating disc structure that can move up and down. The valve plate assembly includes a metal ring and a ceramic valve plate embedded in the inner side of the metal ring. The hydraulic thrust disc realizes automatic axial clearance compensation between the valve plate assembly and the first flow distribution plate assembly through the hydraulic force of the high / low pressure fluid in the radially communicating fluid hole and the hydraulic flow channel hole. A static pressure pool is opened in the middle of the outer periphery of the rotor cylinder. Oblique grooves are opened on both the upper and lower sides of the static pressure pool. An annular thin-wall damping structure is integrally arranged on the inner wall of the flow channel of the rotor cylinder. Misaligned flow channel grooves and damping holes are opened on the outer periphery of the hybrid bearing.

2. The active energy recovery device with a modular hydrodynamic compensation dynamic and static pressure rotor according to claim 1, characterized in that, A hydraulic clearance adjustment assembly is connected to the middle of the lower end of the housing. The hydraulic clearance adjustment assembly includes a pressure reducing valve, a pressure gauge, and a liquid filling connecting pipe connected in sequence. The other end of the liquid filling connecting pipe is communicated with the lower end of the shaft assembly. The liquid inlet of the pressure reducing valve is communicated with an external pressure supply pipeline or is communicated with the upper side of the high-pressure fluid outlet through a high-pressure water outlet pressure guiding pipe.

3. The active energy recovery device with a modular hydrodynamic compensated hybrid journal bearing according to claim 2, wherein The lower part of the pressure reducing valve is provided with a liquid inlet and a liquid outlet opposite to each other. A first valve core and a second valve core that cooperate with each other are installed in the flow channel between the liquid inlet and the liquid outlet through a valve core seat. A first spring is installed at the lower end of the first valve core. At the upper end of the first valve core, a valve core adjustment guide, a spring lower base, a main spring, an upper spring base, a spring adjustment guide, and a valve adjustment part are sequentially installed in a cooperating manner from bottom to top.

4. The active energy recovery device with a modular hydrodynamic compensated hybrid journal bearing rotor according to claim 1, wherein A hydraulic clearance adjustment assembly is connected to the middle of the lower end of the housing. The hydraulic clearance adjustment assembly includes a step control pressure reducing valve, a pressure sensor, and a liquid filling connecting pipe connected in sequence. The other end of the liquid filling connecting pipe is communicated with the lower end of the shaft assembly. The other end of the step control pressure reducing valve is communicated with the upper side of the high-pressure fluid outlet through a high-pressure water outlet pressure guiding pipe. A position sensor for detecting the position of the valve plate is installed on the upper side of the upper end cover and the lower side of the lower end cover respectively. The step control pressure reducing valve, the pressure sensor, and the position sensor are respectively connected to an intelligent control system.

5. The active energy recovery device with a modular hydrodynamic compensated hybrid journal bearing rotor according to claim 1, characterized in that, The ceramic disc of the first flow distribution plate assembly is provided with a low-pressure inlet and a high-pressure outlet. One end of the low-pressure inlet and the high-pressure outlet are respectively communicated with a first variable cross-section damping flow channel. A hydraulic slope is opened at the other end of the low-pressure inlet. A first friction variable cross-section is opened at the edge of the low-pressure inlet. The ceramic disc of the second flow distribution plate assembly is provided with a low-pressure outlet and a high-pressure inlet. The low-pressure outlet and the high-pressure inlet are respectively communicated with a second variable cross-section damping flow channel. A second friction variable cross-section is opened at the edge of the low-pressure outlet.

6. The active energy recovery device with a modular hydrodynamic compensation static and dynamic pressure rotor according to claim 1, wherein The hydraulic flow channel hole is arranged along the axial direction of the shaft assembly. A check valve is installed at the lower end of the hydraulic flow channel hole, and a check valve sealing ring is installed at the upper end of the check valve.

7. The active energy recovery device with a modular hydrodynamic compensated hybrid journal bearing rotor according to claim 6, characterized in that, The check valve includes a valve body. An upper valve cover and a lower valve cover are respectively installed at the upper and lower ends of the valve body. A spherical valve core is installed inside the valve body. A valve core guide is installed at the upper end of the spherical valve core. A second spring is sleeved outside the spherical valve core. A valve seat is installed between the lower end of the spherical valve core and the lower valve cover. A valve seat retaining ring is clamped between the valve seat and the inner wall of the valve body.

8. The active energy recovery device with a modular hydrodynamic compensated hybrid journal bearing rotor according to claim 1, characterized in that The valve plate assembly further includes a sealing assembly. The upper side of the sealing assembly is connected to a metal ring through a mounting plate. A retaining ring and an O-ring are installed outside the sealing assembly. An outer ring radial O-ring and an outer ring radial retaining ring are installed on the outer ring of the hydraulic thrust disk, and an inner ring radial retaining ring and an inner ring radial O-ring are installed on the inner ring. An axial sealing retaining ring and an axial sealing O-ring are installed outside the shaft assembly.

9. The active energy recovery device with a modular hydrodynamic compensation dynamic and static pressure rotor according to claim 1, characterized in that, The upper end of the shaft assembly is cooperatively installed with the housing through a first low-pressure shaft seal and an auxiliary bearing, and the lower end of the shaft assembly is cooperatively installed with the housing through a second low-pressure shaft seal.

10. The active energy recovery device with a modular hydrodynamic compensation dynamic and static pressure rotor according to claim 1, characterized in that, The internal flow channel of the valve plate assembly and the internal flow channel of the rotor cylinder adopt a variable cross-section structure, and the cross-section of the internal flow channel of the valve plate assembly gradually decreases outward on the side of the rotor cylinder.

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