Methods and apparatuses for real-time rotor balancing for a generator and connected equipment
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Solution Overview
Problem
Existing rotor balancing systems in generators require downtime for adjustments and are unable to reduce vibrations in real-time, leading to potential damage from unbalanced forces.
Innovation Solution
A dynamic rotor shaft balancing system that uses a moveable weight coupled to the rotor shaft, which can be adjusted in real-time using a closed-loop control algorithm to monitor and reduce vibrations while the generator is operating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixed balancing weights are physically secured to the rotor shaft, then the rotor balancing is stable, but the generator must be stopped for any adjustments and cannot be made in real-time
Solution Approach 1:
The patent applies the dynamics principle by replacing fixed balancing weights with moveable weights that can be dynamically adjusted during generator operation. The control system actuates the weights to different positions on the rotor shaft based on real-time vibration feedback, enabling continuous adaptation without stopping the generator. This transforms a static balancing system into a dynamic one that can respond to changing operational conditions.
Solution Approach 2:
The patent implements feedback by using vibration sensors to continuously monitor rotor shaft vibrations and feeding this information back to the control system. The control system processes the vibration data and adjusts the positions of the moveable weights accordingly, creating a closed-loop control system that automatically maintains optimal balancing during generator operation.
2Device complexity
If fixed balancing weights are used on the rotor shaft, then the structure is simple, but adjustments require downtime and additional testing
Solution Approach 1:
The system transforms static balancing weights into dynamic, moveable weights that can be repositioned during operation. This allows the balancing system to adapt to different operational conditions without requiring the generator to be shut down, eliminating downtime for adjustments while maintaining reasonable structural complexity through automated control.
Solution Approach 2:
The balancing system performs self-adjustment through automated control based on real-time vibration monitoring. The control system independently determines the optimal positions of the moveable weights and actuates them accordingly, eliminating the need for external intervention, manual adjustments, or additional testing during generator operation.
3Productivity
If the generator operates continuously without real-time balancing adjustments, then productivity is maintained, but vibrations can cause damage to rotor components over time
Solution Approach 1:
The system uses continuous vibration monitoring with feedback control to detect and respond to imbalance conditions in real-time. Vibration sensors monitor the rotor shaft during continuous operation, and when vibrations exceed acceptable thresholds, the control system automatically repositions the moveable weights to correct the imbalance, preventing vibration-induced damage while maintaining continuous operation.
Solution Approach 2:
The dynamic adjustability of the balancing weights allows the system to adapt to changing operational conditions and developing imbalances during continuous operation. By enabling real-time repositioning of weights, the system can continuously optimize balancing performance and prevent the accumulation of vibration damage that would occur with fixed weights.
Data Source
AI summary
A generator rotor shaft balancing system is disclosed. The generator rotor shaft balancing system includes a generator that includes a rotor and a rotor shaft. A weight is coupled to the rotor shaft. The weight is dynamically moveable, while the rotor is operating, to facilitate reducing vibrations in the rotor shaft.