Conductive Roller Assembly for ESP Motor Arc Prevention

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Solution Overview

Problem

Electric submersible pump (ESP) motor systems face electrical arcing issues between the rotor and stator, leading to component damage and increased wear due to the development of electrical potentials, which existing solutions like conductive brushes exacerbate by generating particles through friction.

Innovation Solution

A conductive roller assembly is used, mounted on the stator and capable of rotating freely, to maintain an electrical pathway between the rotor and stator without rubbing, thus preventing arcing and particle generation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conductive brush is used to maintain an electrical pathway between the rotor and stator, then electrical arcing is prevented, but friction generates particles that damage motor components

Engineering Contradiction:

Improveprevention of electrical arcingVSAvoidparticle generation from friction

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the sliding brush mechanism with a roller mechanism that converts sliding friction into rolling contact. The roller assembly includes a conductive roller that rolls along the shaft surface while maintaining electrical contact, thereby preventing particle generation through friction while preserving the electrical pathway function

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the contact mechanism from sliding to rolling by introducing a roller assembly. This parameter change in the mode of contact fundamentally alters the friction characteristics, eliminating the particle generation problem while maintaining the electrical conductive pathway between rotor and stator

Inventive Principle:

Principle #35Parameter changes

2Reliability

If a spring-loaded brush is used to maintain constant contact with the rotating shaft, then electrical continuity is maintained, but continuous rubbing causes surface pitting and particle detachment

Engineering Contradiction:

Improveelectrical continuityVSAvoidsurface integrity of shaft

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent substitutes the sliding brush contact system with a roller contact system. The roller assembly maintains constant electrical contact with the rotating shaft through rolling motion, which prevents surface pitting and particle detachment while ensuring continuous electrical pathways for arc prevention

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If PWM motor controllers are used to improve motor control, then motor efficiency increases, but electrical potential differences between rotor and stator increase causing more frequent arcing

Engineering Contradiction:

Improvemotor control efficiencyVSAvoidelectrical stability between rotor and stator

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent introduces a conductive roller assembly as an intermediary element between the rotor and stator. This roller assembly provides a controlled electrical pathway that safely dissipates the increased electrical potential differences generated by PWM controllers, preventing uncontrolled arcing while allowing efficient PWM motor control operation

Inventive Principle:

Principle #24Intermediary (Mediator)

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 conductive roller assembly effectively reduces electrical potentials between the rotor and stator, minimizing component damage and particle contamination in ESP motor systems, thereby extending their lifespan.

Implementation Method 1

The roller is electrically coupled to the support structure, so that when the roller is positioned against the shaft, an electrically conductive pathway is formed between the stator and the rotor

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

When the shaft rotates, the roller rolls against the outer surface of the shaft and maintains contact with the shaft without rubbing against the shaft

Methodology Applied

Scientific EffectRolling friction: Friction

Data Source

PatentUS9627945B2Systems and methods for preventing electrical arcing between components of an ESP motor

Publication Date: 2017.04.18 BAKER HUGHES CO

AI summary

Systems and methods for preventing electrical arcing in motors by placing an electrically conductive roller assembly between the stator and rotor of the motor. A rotor is mounted on a shaft, and this assembly is positioned within the bore of a stator. The roller assembly has a stationary portion that is secured to the stator. The roller assembly also has a movable portion on which a roller is mounted. The movable portion of the roller assembly is spring-loaded to urge the roller toward the shaft and thereby maintain contact between the roller and the shaft. When the shaft rotates within the bore, the roller rotates and rolls on the surface of the shaft, maintaining contact without rubbing against the shaft. An electrically conductive pathway is formed from the stator, through the roller assembly to the shaft and rotor thereby preventing an electrical potential from developing between the rotor and stator.