Fuel Cell Compressor Water Bearing Layout to Suppress Foaming
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Solution Overview
Problem
The use of water as a lubricant in hydrodynamic bearings for high-speed compressor elements in fuel cell systems leads to bearing failures due to foaming, which reduces the load-carrying capacity and can cause damage.
Innovation Solution
Ensuring the entire cross-section area of the lubricant outlet is completely covered with lubricant, maintaining a closed circulation system, and pressurizing the lubricant to suppress foam formation, along with degassing and strategic lubricant routing to prevent air entrainment and enhance operational reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If water is used as a lubricant in hydrodynamic bearings for high-speed compressor elements, then oil contamination of the fuel cell is prevented, but bearing failures occur due to foaming which reduces load-carrying capacity
Solution Approach 1:
The invention extracts and removes air bubbles from the water lubricant using a centrifugal separator. The separator is integrated into the bearing housing and uses centrifugal force generated by rotation to separate air bubbles from the water lubricant, preventing foaming and maintaining bearing reliability while continuing to use water as the lubricant
Solution Approach 2:
The invention implements a feedback mechanism where the centrifugal separator continuously monitors and removes air bubbles from the lubricant circulation system. The separator is positioned to receive lubricant from the bearing and return it after separation, creating a closed-loop system that actively maintains lubricant quality and prevents bearing failure
2Productivity
If high-speed operation is maintained in the compressor element, then productivity is improved, but foaming occurs in the lubricant which reduces load-carrying capacity and causes bearing damage
Solution Approach 1:
The invention applies preliminary action by pre-separating air bubbles from the lubricant before the lubricant enters the bearing. The centrifugal separator is positioned in the lubricant circulation path to remove air bubbles in advance, preventing foaming from occurring in the bearing and maintaining load-carrying capacity during high-speed operation
Solution Approach 2:
The invention uses hydraulic principles by implementing a centrifugal separator that utilizes centrifugal force (a hydraulic effect) to separate air bubbles from the water lubricant. The separator creates a centrifugal field that forces air bubbles outward while the water lubricant remains in the center, enabling continuous separation without mechanical moving parts in the lubricant path
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
This approach effectively prevents bearing damage by minimizing foam formation and ensuring a continuous, reliable lubricant supply, enhancing the operational reliability of the compressor system.
Implementation Method 1
at least one hydrodynamic or hydrostatic bearing is used to mount the shaft in a rotatable manner... the lubricant can be routed to the plain bearing via the lubricant inlet and the lubricant can be discharged from the plain bearing via the lubricant outlet
Implementation Method 2
pressurizing the lubricant to suppress foam formation
Data Source
AI summary
The invention relates to a compressor (20) for generating a compressed air flow for a fuel cell (10), having a compressor element (21), in particular a compressor wheel, wherein the compressor element (21) is coupled in a to a drive shaft (23) for co-rotation, the drive shaft (23) being driven by a motor (22), in particular an electric motor, wherein at least one hydrodynamic or hydrostatic bearing (24, 25) is used to mount the shaft (23) in a rotatable manner, wherein the plain bearing (24, 25) is connected to a lubricant supply means (30), which is used to supply a lubricant for hydrodynamic or hydrostatic pressure generation to the plain bearing (24, 25), wherein the lubricant is water or a fluid mixture, predominantly comprising water, wherein the plain bearing (24, 25) has a lubricant inlet and a lubricant outlet, wherein the lubricant can be routed to the plain bearing (24, 25) via the lubricant inlet and the lubricant can be discharged from the plain bearing (24, 25) via the lubricant outlet, and wherein a discharge area of the circulation system (30) is disposed in the area of the lubricant outlet. An operationally safe design can be implemented for such a compressor if provision is made for the cross-section area of the outlet of the liquid outlet of the plain bearing (24, 25) to be completely covered by the lubricant held in the discharge area.