Both-End Turbo Compressor with Integrated Motor Chamber Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Turbo compressors face challenges in achieving high pressure ratios, efficiency, and stability due to issues such as axial turbulence, complex structures, and inefficient heat dissipation, particularly in multi-stage designs, which affect the performance and size of both end-type compressors.
Innovation Solution
A turbo compressor design that includes a motor chamber with axial and radial bearings, utilizing a gas foil bearing system, where refrigerant is supplied directly into the motor chamber to uniformly cool and stabilize the rotary shaft, and a refrigerant control valve to direct refrigerant flow based on load conditions, enhancing efficiency and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a both end-type turbo compressor is used to prevent axial turbulence and decrease thrust bearing size, then bearing size and motor efficiency are improved, but the structure becomes complicated and pressure loss increases due to long fluid passages
Solution Approach 1:
The compressor is divided into two independent compression sections (first compression section with first impeller, second compression section with second impeller) operating on opposite sides of the rotary shaft. Each section has its own independent fluid passage, allowing the sections to function autonomously while sharing the same motor and bearing system, thus reducing overall structural complexity.
Solution Approach 2:
The motor chamber is merged with the bearing chamber, creating an integrated structure where the motor and bearings share the same housing space. This merging eliminates the need for separate motor housing and bearing housing, simplifying the overall structure while maintaining the benefits of both-end-type configuration.
2Productivity
If high-speed rotation is used to increase compression capacity, then productivity is improved, but heat generation from motor and friction increases
Solution Approach 1:
The refrigerant fluid serves dual functions: it acts as the working fluid for compression and simultaneously serves as the cooling medium for the motor and bearings. The system uses its own operational fluid to dissipate heat generated during high-speed operation, eliminating the need for separate cooling systems.
Solution Approach 2:
The refrigerant fluid, which must be cooled before compression, is directed through the motor chamber and bearing chamber to absorb heat. The heat generation that was previously a harmful byproduct of high-speed operation is converted into a beneficial cooling effect, pre-cooling the refrigerant while removing excess heat from critical components.
3Stress or pressure
If multi-stage compression is used to achieve high pressure ratio, then compression efficiency is improved, but the overall size increases due to multiple impellers and complex fluid passages
Solution Approach 1:
Instead of arranging multiple impellers in a single axial sequence, the patent arranges impellers in a two-dimensional configuration on opposite sides of the rotary shaft. This spatial arrangement allows multi-stage compression to be achieved without proportionally increasing the axial length of the compressor, effectively utilizing the radial and circumferential dimensions.
Solution Approach 2:
The compression process is segmented into independent first and second compression sections, each with its own impeller and fluid passage. This segmentation allows each section to be optimized independently and enables parallel operation, reducing the overall size compared to a sequential multi-stage design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves improved heat dissipation, increased rotational stability, and enhanced compressor performance by uniformly cooling bearings and optimizing refrigerant flow, leading to efficient operation even at high speeds.
Implementation Method 1
refrigerant is supplied directly into the motor chamber to uniformly cool and stabilize the rotary shaft
Implementation Method 2
refrigerant flow to uniformly cool and stabilize the rotary shaft
Implementation Method 3
utilizing a gas foil bearing system
Data Source
AI summary
A turbo compressor and a refrigeration cycle device having a turbo compressor are provided. The turbo compressor includes a housing having a motor chamber; a drive motor having a stator and a rotor in the motor chamber of the housing; a first compression portion and a second compression portion, respectively, provided on opposite ends of a rotary shaft; a connecting passage that connects an exit of the first compression portion and an entrance of the second compression portion; an inlet passage that penetrates a first side of the housing to communicate with an inside of the motor chamber and guide a refrigeration fluid to the motor chamber; and an outlet passage that penetrates a second side of the housing to communicate with the inside of the motor chamber and guide the refrigeration fluid in the motor chamber out of the housing. Thus, a gas foil bearing provided in the motor chamber may be quickly actuated by supplying the refrigeration fluid to the motor chamber, and at a same time, heat generated from the motor chamber may be quickly dissipated even in a high-speed operation, thereby improving efficiency of the turbo compressor and a refrigeration cycle device having a turbo compressor.