Axial Flux Submersible Motor Structure for Torque and Heat Loss
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Solution Overview
Problem
Conventional electric submersible pumps used in oil well operations are inefficient due to the use of radial flux motors, which result in reduced torque production and increased heat generation, as well as material wastage and non-active sections that do not contribute to magnetic flux.
Innovation Solution
The implementation of an axial flux motor with a disk-shaped rotor and stator configuration, where magnetic flux travels axially between the rotor and stator, reducing heat generation and material usage while increasing torque efficiency, powered by a controller that monitors and adjusts motor operation based on sensor feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If radial flux motors are used in conventional electric submersible pumps, then the motor structure is traditional and easier to manufacture, but the efficiency is reduced and heat generation is increased
Solution Approach 1:
The patent transitions from radial flux motor design to axial flux motor design, changing the dimension of magnetic flux flow from radial to axial direction. This dimensional change enables the motor to achieve higher efficiency and reduced heat generation while maintaining manufacturability through the disk-shaped rotor and stator configuration.
2Ease of manufacture
If radial flux motors are used in conventional electric submersible pumps, then the motor construction is traditional, but torque production is reduced
Solution Approach 1:
By changing the magnetic flux direction from radial to axial and using disk-shaped rotor and stator components, the patent achieves improved torque production. The axial flux configuration allows for more effective magnetic field interaction across the disk surfaces, generating higher torque compared to traditional radial flux designs.
3Ease of manufacture
If radial flux motors are used in conventional electric submersible pumps, then the motor design is standard, but material wastage is increased
Solution Approach 1:
The axial flux motor design with disk-shaped rotor and stator eliminates the need for extensive axial end sections required in radial flux motors. This dimensional reconfiguration reduces material usage by concentrating the magnetic flux path within the disk planes, thereby reducing material wastage while maintaining a manufacturable design.
4Ease of manufacture
If radial flux motors are used in conventional electric submersible pumps, then the motor follows traditional construction, but non-active sections are increased that do not contribute to magnetic flux
Solution Approach 1:
By reorienting the magnetic flux flow axially through disk-shaped components, the patent eliminates non-active sections that exist in radial flux motors. The axial flux configuration ensures that all material between the rotor and stator disks contributes directly to the magnetic flux path, maximizing productivity and magnetic flux contribution throughout the motor structure.
5Ease of manufacture
If radial flux motors are used in conventional electric submersible pumps, then the motor design is conventional, but heat generation is increased
Solution Approach 1:
The axial flux motor design with disk-shaped rotor and stator reduces heat generation by creating a more efficient magnetic flux path that minimizes resistive losses. The axial configuration allows for better heat dissipation across the disk surfaces and reduces the concentration of current in specific regions, thereby lowering overall heat generation while maintaining conventional manufacturability.
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 axial flux motor design enhances efficiency and torque production while minimizing material usage and heat generation, leading to improved performance and reliability in oil well operations.
Implementation Method 1
The stator has a plurality of stator windings, wherein the rotor has a plurality of permanent magnets... the magnetic flux travels axially between the rotor and stator
Implementation Method 2
axial flux motor with a disk-shaped rotor and stator configuration, where magnetic flux travels axially between the rotor and stator, reducing heat generation and material usage while increasing torque efficiency
Data Source
AI summary
A pump system for pumping production fluids from a wellbore or pumping well treatment fluids into a wellbore comprising: an axial flux electric motor; a seal section coupled to the axial flux motor; a pump intake coupled to the seal section; a pump coupled to the pump intake, and a fluid discharge coupled to the pump. The torque capacity axial flux motor may be modified without removing the axial flux motor from the pump.