Electromagnetic Carbon Seal Loading for Wear and Leakage Control

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Solution Overview

Problem

Carbon seals in rotating mechanical systems, such as gas turbine engines, face challenges with varying loads due to wear and changing operating conditions, leading to premature wear, leakage, and inconsistent frictional heat generation, which affects their sealing efficiency and lifespan.

Innovation Solution

An electromagnetic carbon seal system that uses a controller circuitry to dynamically adjust the magnetic fields generated by electromagnets, allowing for variable sealing force loading, optimized across different operating conditions, by controlling the current and polarity supplied to the electromagnets, in conjunction with mechanical springs or permanent magnets, to maintain consistent sealing force and frictional heat.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional carbon seals are used in rotating mechanical systems, then the structure is simple and ease of manufacture is good, but the sealing performance becomes inconsistent and reliability deteriorates under varying loads and operating conditions

Engineering Contradiction:

Improvesealing performance consistencyVSAvoidsystem structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies dynamics by making the sealing force adjustable through electromagnetic actuators that can dynamically change the contact pressure between the carbon seal and runner based on operating conditions, transforming a static seal into a dynamic one that adapts to varying loads and speeds

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent replaces traditional mechanical spring-loaded sealing mechanisms with an electromagnetic actuation system that uses magnetic fields to control the sealing force, eliminating the need for complex mechanical springs and providing more precise control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If the sealing force is increased to prevent leakage, then the sealing performance improves, but the frictional heat generation increases and wear accelerates

Engineering Contradiction:

Improvesealing effectivenessVSAvoidfrictional heat

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The electromagnetic actuation system dynamically adjusts the sealing force in real-time, applying higher force only when leakage is detected or anticipated, and reducing force during normal operation to minimize frictional heat and wear

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the sealing force parameter dynamically based on operating conditions such as speed, load, and temperature, optimizing the balance between preventing leakage and minimizing frictional heat generation

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If the carbon seal operates under varying loads and speeds, then the adaptability to different operating conditions is good, but the sealing force becomes inconsistent and reliability deteriorates

Engineering Contradiction:

Improveoperating condition rangeVSAvoidsealing force consistency

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The system incorporates feedback mechanisms that monitor operating conditions and seal performance, using this information to continuously adjust the electromagnetic actuation force and maintain consistent sealing under varying loads and speeds

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The electromagnetic actuation system serves multiple functions: it provides sealing force, adjusts for varying operating conditions, compensates for wear, and minimizes frictional heat, making the seal adaptable to a wide range of operating conditions while maintaining consistency

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 system ensures consistent sealing performance and extended seal life by optimizing the sealing force and frictional heat generation, reducing downtime and improving the reliability of rotating mechanical systems across varying conditions.

Implementation Method 1

a plurality of electromagnets, each having a respective variable magnetic field generated based on a variable current supplied to the respective electromagnets

Methodology Applied

Scientific EffectElectromagnetic field generation: Electromagnetic Induction

Implementation Method 2

a controller circuitry configured to dynamically and selectively control the respective variable magnetic field of the electromagnets to adjust a sealing force loading of an interface of the carbon seal and the sealing surface of the runner

Methodology Applied

Scientific EffectMagnetic force application: Electromagnet

Data Source

PatentUS11473506B2Electromagnetic carbon seal system

Publication Date: 2022.10.18 ROLLS ROYCE NORTH AMERICAN TECHNOLOGIES INC

AI summary

A seal system may include a static housing, a carbon seal positioned in the static housing, a runner having a sealing surface aligned with the carbon seal, a number of electromagnets positioned in the static housing, and a controller circuitry. The controller circuitry may control a variable flow of electric current to control an electromagnetic field respectively generated by each of the electromagnets. The controller circuitry may variably apply the electromagnetic field to move at least one of the carbon seal or the runner and correspondingly adjust an applied force loading of an interface of the carbon seal and the sealing surface of the runner.