Conical Pump Motors for Axial Thrust Balancing
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Solution Overview
Problem
Centrifugal pumps experience unbalanced axial thrusts due to unequal forward and aft axial loads, leading to axial shaft displacement and potential damage, especially at varying operational speeds, with conventional thrust bearings failing to efficiently adapt and support these forces.
Innovation Solution
The implementation of conical rotors and stators in electric motors to adjust torque output, counteracting axial shaft movement by electromagnetic forces, and controlling current flow based on positional and operating conditions to balance axial loads and minimize frictional losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional thrust bearings are used to support axial loads in centrifugal pumps, then the pump can operate with standard motor designs, but the thrust bearings fail to efficiently adapt to varying axial thrusts at different operational speeds, leading to axial shaft displacement and potential damage
Solution Approach 1:
The patent applies asymmetry by using conical rotors and stators instead of conventional cylindrical designs. The conical geometry creates asymmetric magnetic field distribution that generates axial electromagnetic forces to counteract axial thrusts. This asymmetric design allows the motor to adapt to varying axial loads at different speeds, preventing shaft displacement while maintaining reliability across varying operational conditions.
Solution Approach 2:
The patent replaces the mechanical thrust bearing system with an electromagnetic force generation system. Instead of relying on mechanical thrust bearings that cannot efficiently adapt to varying loads, the conical motor design generates axial electromagnetic forces that actively counteract axial thrusts. This substitution of mechanical support with electromagnetic counteraction provides adaptability to varying operational speeds while maintaining axial shaft position stability.
2Reliability
If conical rotors and stators are implemented to counteract axial shaft movement, then axial thrusts are balanced and shaft vibrations are reduced, but the motor design becomes more complex
Solution Approach 1:
The patent merges the motor function with the thrust counteraction function into a single integrated conical motor design. The conical rotors and stators simultaneously generate rotational torque and axial electromagnetic forces, eliminating the need for separate thrust bearing systems. This merging of functions achieves operational stability and axial thrust balance while avoiding the complexity of additional separate components, as the same conical structure performs both rotational and axial force generation.
3Loss of energy
If current flow is controlled based on positional and operating conditions to balance axial loads, then frictional losses are minimized and maintenance intervals are extended, but the control system becomes more complex
Solution Approach 1:
The patent implements feedback control by monitoring shaft position and operating conditions, then adjusting current flow to the conical rotors and stators accordingly. This feedback mechanism dynamically balances axial loads by generating appropriate electromagnetic counterforces, minimizing frictional losses in the process. The feedback-based control optimizes energy efficiency and extends maintenance intervals, with the control complexity justified by the significant reduction in frictional energy losses and improved operational efficiency.
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 balances axial thrusts, reduces shaft vibrations, enhances pump efficiency, and extends maintenance intervals by minimizing component wear and improving operational stability.
Implementation Method 1
The motor includes a conical stator and a conical rotor... the conical rotor and conical stator generate axial electromagnetic forces that counteract axial thrusts
Implementation Method 2
The controller adjusts current flow to the rotor based on shaft position and operating conditions
Data Source
AI summary
Conical motors for use with pumps are disclosed. Examples disclosed herein include an electric motor including a conical rotor, a first end of the conical rotor having a first diameter and a second end of the conical rotor having a second diameter, the second diameter different from the first diameter, and a conical stator aligned to the conical rotor.