Explosion-proof high-efficiency pipeline differential pressure power generation device

Abstract

The application discloses a kind of anti-explosion high-efficiency pipeline pressure difference power generation device.The flow passage cavity (3) of the pipeline pressure difference power generation device is provided with fixed isolator (4) between motor cavity (2), fixed isolator adopts non-metallic magnetic material, fixed isolator is completely separated from flow passage cavity and motor cavity, the shaft end of impeller (31) is equipped with inner magnetic rotor (32) with permanent magnet, the shaft end of generator (21) is equipped with outer magnetic rotor (22) with permanent magnet, inner magnetic rotor and outer magnetic rotor non-contact magnetic coupling synchronous rotation.The pipeline pressure difference power generation device of the application completely converts dynamic seal into static seal using fixed isolator, constructs high-reliability explosion-proof cavity, completely eliminates the possibility of flammable and explosive medium along the shaft to the motor cavity.

Description

Technical Field

[0001] This invention relates to a pipeline control device, and more particularly to an explosion-proof, high-efficiency pipeline differential pressure power generation device. Background Technology

[0002] Currently, there are numerous pressure regulating valves in natural gas transmission and distribution networks, chemical gas transmission networks, and industrial gas pipeline networks. These valves generate a significant amount of differential pressure energy (pressure energy) during the pressure regulation process. Utilizing differential pressure generators to recover this energy and convert it into electrical energy is a key technology for achieving green and low-carbon development of pipeline systems.

[0003] Specifically, existing technologies often use mechanical seals (dynamic seals) to isolate the dangerous gas in the flow channel from the generator, and use magnetic transmission (non-contact magnetic coupling) to physically isolate the flow channel from the motor. At the same time, in order to meet the mandatory explosion-proof standards such as GB / T3836.2 and reduce the cost of mass production, the device shell is usually made of cast iron and mass-produced.

[0004] However, due to the extremely high flammability and explosiveness of the transported media (such as natural gas, hydrogen, and industrial combustible gases), there is a significant technical contradiction between explosion-proof performance, mass production cost, and power generation efficiency in such power generation devices. On the one hand, under high-frequency rotation, high-pressure, or high-pressure differential environments, dynamic sealing components are prone to wear and aging, leading to the leakage of high-pressure dangerous gases along the generator shaft and causing significant explosion hazards. On the other hand, due to the large volume of the cast iron shell and its magnetic and electrical conductivity, during magnetic coupling transmission, stray magnetic fields will pass through and cut through the thick cast iron explosion-proof shell, generating severe eddy current losses and iron losses inside the cast iron shell. This not only causes severe local heating of the equipment and creates safety hazards, but also severely impacts the generator output power, resulting in extremely low overall efficiency. Under low-flow conditions, it may even fail to start working due to excessive losses, failing to meet industrial promotion standards.

[0005] In summary, the main problem at present is:

[0006] 1) Wear of dynamic seals can lead to explosion safety hazards due to leakage of media. Specifically, conventional mechanical seals (dynamic seals) are prone to wear and aging under high-frequency rotation, high pressure or high pressure differential environments, which can cause high-pressure dangerous gases to leak out along the generator shaft, failing to meet the standard explosion-proof requirements and posing a major explosion hazard.

[0007] In addition, there are other technical issues, as follows:

[0008] 2) When the cast iron explosion-proof enclosure is used for magnetic transmission, the magnetic field leakage will cause serious eddy current loss and iron loss. Specifically, due to the magnetic and electrical conductivity of the cast iron enclosure, the stray magnetic field will pass through and cut through the cast iron explosion-proof enclosure, resulting in serious eddy current loss and iron loss. This will cause the equipment to heat up severely in some areas and violently impact the generator output power, resulting in extremely low overall efficiency of the machine. Summary of the Invention

[0009] The purpose of this invention is to provide an explosion-proof and high-efficiency pipeline differential pressure power generation device, which eliminates the possibility of flammable and explosive media leaking out along the rotating shaft into the motor cavity.

[0010] To achieve the above-mentioned technical objectives, the present invention adopts the following technical solution:

[0011] An explosion-proof, high-efficiency pipeline differential pressure power generation device includes an explosion-proof housing, a generator, and an impeller. The explosion-proof housing contains a motor cavity and a flow channel cavity. The generator is disposed within the motor cavity, and the impeller is disposed within the flow channel cavity. A fixed isolation cover, made of non-metallic magnetically permeable material, is provided between the flow channel cavity and the motor cavity, completely separating the flow channel cavity and the motor cavity. An inner magnetic rotor with a permanent magnet is mounted at the end of the impeller's shaft, and an outer magnetic rotor with a permanent magnet is mounted at the end of the generator's shaft. The inner and outer magnetic rotors rotate synchronously through non-contact magnetic coupling.

[0012] Furthermore, the connection and joint surface between the fixed isolation cover and the explosion-proof shell constitutes an explosion-proof joint surface that conforms to the GB / T3836.2 standard.

[0013] Furthermore, the outer circumferential surface of the outer magnetic rotor is tightly wrapped with an outer magnetic sleeve, the outer magnetic sleeve being made of magnetically conductive steel, specifically No. 45 steel.

[0014] Furthermore, the thickness of the outer magnetic sleeve is set in the range of 1.5mm to 5mm, and the thickness of the outer magnetic sleeve is set to 2mm.

[0015] Furthermore, the explosion-proof housing is made of cast iron.

[0016] The main advantages of the explosion-proof, high-efficiency pipeline differential pressure power generation device of the present invention compared with the prior art are as follows:

[0017] In the pipeline differential pressure power generation device of the present invention, a fixed isolation cover is provided between the flow channel cavity and the motor cavity. The fixed isolation cover completely transforms the dynamic seal into a static seal, constructing a highly reliable explosion-proof cavity and completely eliminating the possibility of flammable and explosive media leaking out to the motor cavity along the rotating shaft. Attached Figure Description

[0018] Figure 1 This is a first structural schematic diagram of the explosion-proof, high-efficiency pipeline differential pressure power generation device of the present invention, in which the generator and impeller are removed;

[0019] Figure 2 This is a schematic diagram of the second structure of the explosion-proof high-efficiency pipeline differential pressure power generation device of the present invention, in which a generator and an impeller are arranged;

[0020] Figure 3 This is a first schematic diagram of the magnetic field of the magnetic transmission component. This diagram is used to... Figure 4 Make a comparison;

[0021] Figure 4 This is a second schematic diagram of the magnetic field of the magnetic transmission component, which is used to... Figure 3 Make a comparison. Detailed Implementation

[0022] The following provides further details on specific embodiments of the present invention:

[0023] This embodiment provides an explosion-proof, high-efficiency pipeline differential pressure power generation device, the main innovative concept of which is:

[0024] 1) A fixed isolation cover 4 is used to completely convert the dynamic seal into a static seal, thereby eliminating the risk of dynamic seal leakage;

[0025] 2) At the same time, a magnetically conductive steel outer magnetic sleeve 52 of a specific thickness is tightly wrapped around the outer periphery of the outer magnetic rotor 22. Its high magnetic permeability is used to construct a low magnetic resistance closed magnetic circuit, which strongly constrains the magnetic lines of force, suppresses and eliminates the eddy current loss and iron loss generated inside the cast iron explosion-proof shell 1 from the source, and significantly reduces the magnetic damping of the system.

[0026] Specifically

[0027] See Figure 1 and Figure 2 The pipeline differential pressure power generation device of this embodiment includes an explosion-proof housing 1.

[0028] Those skilled in the art will understand that the explosion-proof housing 1 has two chambers, namely the motor chamber 2 and the flow channel chamber 3, wherein the flow channel chamber 3 is used to introduce flammable and explosive gases or high-pressure industrial gases.

[0029] The pipeline differential pressure power generation device also includes a generator 21 and an impeller 31. The generator 21 is installed in the motor cavity 2, and the impeller 31 is installed in the flow channel cavity 3.

[0030] One of the key innovations of the pipeline differential pressure power generation device in this embodiment is:

[0031] A fixed isolation cover 4, made of non-metallic, magnetically permeable material, is fixedly installed between the flow channel cavity 3 and the motor cavity 2. The fixed isolation cover 4 completely separates the flow channel cavity 3 and the motor cavity 2 inside the explosion-proof housing 1. The flow channel cavity 3 serves as the hazardous area, while the motor cavity 2 serves as the safe area, thus achieving physical isolation between the hazardous and safe areas. The connection surface between the fixed isolation cover 4 and the explosion-proof housing 1 constitutes an explosion-proof joint surface conforming to GB / T 3836.2 standard (e.g., Figure 1 (The location indicated by the middle arrow A).

[0032] The impeller 31 has an inner magnetic rotor 32 with a permanent magnet at the end of its shaft, and the inner magnetic rotor 32 is located inside the fixed isolation cover 4; the generator 21 has an outer magnetic rotor 22 with a permanent magnet at the end of its shaft, and the outer magnetic rotor 22 is located outside the fixed isolation cover 4.

[0033] The inner magnetic rotor 32 and the outer magnetic rotor 22 rotate synchronously through non-contact magnetic coupling via the magnetic field penetrating the fixed isolation cover 4.

[0034] See Figure 3 and Figure 4 The outer magnetic rotor 22 is tightly wrapped with an outer magnetic sleeve 52, which is made of magnetically conductive steel (specifically, No. 45 steel, with a thickness of 1.5mm-5mm, and an optimal thickness of 2mm). The explosion-proof housing 1 is made of cast iron. During non-contact magnetic transmission, the No. 45 steel outer magnetic sleeve 52 forms a closed magnetic circuit with low magnetic resistance inside itself, thereby efficiently confining the magnetic field lines and preventing the magnetic field from escaping to the external cast iron explosion-proof housing 1 to the greatest extent.

[0035] The specific principle by which the pipeline differential pressure power generation device of this embodiment solves the technical problem and achieves innovative technical effects is as follows:

[0036] 1) Static sealing and explosion protection are achieved by using a fixed isolation enclosure 4.

[0037] Specifically, a fixed isolation cover 4 made of non-metallic, magnetically permeable material is fixedly installed between the flow channel cavity 3 and the motor cavity 2, permanently dividing the interior of the device into a hazardous area and a safe area, achieving physical isolation. The connection surface between the fixed isolation cover 4 and the explosion-proof shell 1 is precision machined to form a standard explosion-proof joint surface, and is secured with bolts to ensure airtightness and explosion-proof limit safety.

[0038] The impeller 31 has an inner magnetic rotor 32 with a permanent magnet connected to its shaft end, and the generator 21 has an outer magnetic rotor 22 with a permanent magnet connected to its shaft end. The inner and outer magnetic rotors 22 rotate synchronously through non-contact magnetic coupling via the magnetic field penetrating the fixed isolation cover 4, thereby completely eliminating the dynamic sealing structure.

[0039] This solves the technical problem of explosion safety hazards caused by media leakage due to dynamic seal wear, thereby achieving the technical effect of standard structural explosion-proof safety and completely eliminating the possibility of flammable and explosive media leaking out along the shaft to the motor cavity 2.

[0040] 2) A low-resistivity closed magnetic circuit is constructed using a No. 45 steel outer magnetic sleeve 52 to confine the magnetic field.

[0041] In this embodiment, a 45 steel outer magnetic sleeve 52 of a specific thickness (optimal thickness 2mm) is tightly wrapped around the outer periphery of the outer magnetic rotor 22. Since 45 steel has extremely high magnetic permeability, a low magnetic resistance magnetic field loop is constructed around the core area of ​​the magnetic transmission. When the inner magnetic rotor 32 rotates with the impeller 31 and drives the outer magnetic rotor 22 to rotate synchronously, the magnetic field lines are firmly constrained within the 45 steel outer magnetic sleeve 52, thereby preventing stray magnetic fields from leaking in and cutting the thick cast iron explosion-proof shell 1.

[0042] This solves the technical problems of high iron loss and eddy current damping caused by the leakage of the magnetic field into the cast iron shell, thereby achieving the technical effects of significantly increasing efficiency, reducing losses, and boosting power (experiments show that under the same test conditions, the charging current reaches 3.42 times that of the conventional stainless steel solution), while eliminating the safety hazard of severe local overheating in the equipment.

[0043] 3) Eliminate magnetic damping to lower the system startup threshold

[0044] Because the 45# steel outer magnetic sleeve 52 effectively constrains the magnetic field dissipation, it completely eliminates the eddy current damping caused by magnetic field cutting inside the cast iron explosion-proof shell 1. In the traditional stainless steel solution, due to excessive internal magnetic resistance and eddy current damping, the power generation is completely offset by internal losses under low flow conditions, and the device cannot start. However, the solution in this embodiment relies on the extreme optimization of the magnetic circuit by the 45# steel outer magnetic sleeve 52, which significantly reduces the magnetic damping of the system.

[0045] This solves the technical problem of being unable to start working due to excessive losses under low flow conditions, thus achieving the technical effect of extremely low start-up threshold and broadened adaptability to various working conditions.

[0046] 4) Balancing explosion-proof safety, economy, and power generation efficiency.

[0047] Because the 45# steel outer magnetic sleeve 52 perfectly controls magnetic leakage, the outer shell can be safely made of cast iron material, which is cheaper and easier to mass-produce. This not only meets the strength requirements of the mandatory explosion-proof structure, but also eliminates the need to use expensive non-magnetic outer shell material to avoid eddy current loss. At the same time, the isolation cover is made of non-metallic permeable magnetic material (such as PEEK), which itself has no eddy current loss.

[0048] This solves the technical dilemma of balancing explosion-proof performance with mass production costs and power generation efficiency, achieving excellent economic efficiency and a technical effect suitable for mass production. Under the premise of using cost-effective cast iron explosion-proof housing 1 and meeting the national mandatory explosion-proof standards, it also achieves high-efficiency power generation output.

[0049] To further demonstrate the technical effectiveness of the pipeline differential pressure power generation device of this embodiment, test data from a real test case is provided below. In this case, comprehensive performance tests were conducted on power generation devices with and without the outer magnetic sleeve 52 and with different outer shell materials. The specific test data are shown in Table 1 below:

[0050] Table 1 Performance Comparison Test Table for Power Generation Units

[0051]

[0052] Technical effect analysis and demonstration:

[0053] Based on the actual test data in Table 1, the No. 45 steel outer magnetic sleeve 52 has demonstrated groundbreaking technical effects in improving power generation efficiency and reducing the start-up threshold of the device:

[0054] 1. Power generation capacity and efficiency have more than doubled (up to 3.42 times):

[0055] At 60m 3 At the same airflow rate of / h, when using a standard stainless steel outer magnetic sleeve 52, the stainless steel material cannot effectively confine the stray magnetic field. A large number of magnetic lines of force pass through the isolation cover, cutting into the thick cast iron explosion-proof shell, resulting in severe iron loss and eddy currents, causing the battery charging current to be only 280mA. However, after replacing it with a 45# steel outer magnetic sleeve 52, the extremely high permeability of 45# steel creates a closed, low-resistivity magnetic circuit within itself, perfectly trapping the stray magnetic field that originally overflowed into the cast iron shell. Under the same operating conditions, the battery charging current soared to 960mA, reaching 3.42 times that of the stainless steel solution. This powerfully demonstrates that a significant increase in efficiency and reduction in losses was achieved without changing the low-cost cast iron material of the shell.

[0056] 2. Significantly reduced the startup threshold of the device and broadened its adaptability to various operating conditions:

[0057] Traditional stainless steel solutions suffer from excessive internal magnetic reluctance and eddy current damping, at 44m 3 At a low airflow rate of / h, the power generation is completely offset by internal losses, and the charging current drops directly to 0mA (i.e., due to the inability to overcome starting damping, the device is in a dead zone and cannot operate). In contrast, the solution in this embodiment, relying on the extreme optimization of the 52 pairs of magnetic circuits in the 45 steel outer magnetic sleeve, successfully reduces the minimum starting flow threshold of the device to a mere 28.8m³. 3 / h. Therefore, at 44m 3 Under low operating conditions with a flow rate of / h, this device can not only start easily, but also maintain a high charging current of 340mA (this charging performance under low operating conditions even surpasses that of traditional solutions at 60mA). 3 Performance under high flow rates ( / h).

[0058] In summary, by specifically configuring a 45 steel outer magnetic sleeve 52 of a certain thickness around the non-contact magnetic drive, not only is the industry problem of "eddy current loss easily generated by cast iron shell" under mass production solved, but the pipeline differential pressure power generation device is also endowed with excellent power generation capability under low flow and weak operating conditions.

[0059] The above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Therefore, any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An explosion-proof, high-efficiency pipeline differential pressure power generation device, the pipeline differential pressure power generation device comprising an explosion-proof housing (1), a generator (21) and an impeller (31), wherein the explosion-proof housing (1) has a motor cavity (2) and a flow channel cavity (3), the generator (21) is disposed in the motor cavity (2), and the impeller (31) is disposed in the flow channel cavity (3); Its features are: A fixed isolation cover (4) is provided between the flow channel cavity (3) and the motor cavity (2). The fixed isolation cover (4) is made of non-metallic magnetically permeable material. The fixed isolation cover (4) completely separates the flow channel cavity (3) from the motor cavity (2). The impeller (31) is equipped with an internal magnetic rotor (32) with a permanent magnet at the end of its shaft. The generator (21) is equipped with an external magnetic rotor (22) with a permanent magnet at the end of its shaft. The inner magnetic rotor (32) and the outer magnetic rotor (22) rotate synchronously through non-contact magnetic coupling.

2. The explosion-proof, high-efficiency pipeline differential pressure power generation device according to claim 1, characterized in that: The connection and joint surface between the fixed isolation cover (4) and the explosion-proof shell (1) constitutes an explosion-proof joint surface that conforms to the GB / T 3836.2 standard.

3. The explosion-proof, high-efficiency pipeline differential pressure power generation device according to claim 1, characterized in that: The outer magnetic rotor (22) is tightly wrapped with an outer magnetic sleeve (52), which is made of magnetic steel, and the magnetic steel is No. 45 steel.

4. The explosion-proof, high-efficiency pipeline differential pressure power generation device according to claim 3, characterized in that: The thickness of the outer magnetic sleeve (52) is set in the range of 1.5mm to 5mm, and the thickness of the outer magnetic sleeve (52) is set to 2mm.

5. The explosion-proof, high-efficiency pipeline differential pressure power generation device according to claim 1, characterized in that: The explosion-proof housing (1) is made of cast iron.

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