Hydrogen-Cooled Magnetic Bearing Expander Generator Layout
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydrogen expander generators face safety risks due to hydrogen leakage and require operating gases or lubricants, which are undesirable for high-speed rotation.
Innovation Solution
An expander generator design that uses hydrogen as a cooling fluid for magnetic bearings and electric generators, eliminating the need for sealing gases or lubricants by integrating hydrogen pathways within the casing to cool magnetic bearings and generators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydrogen is used as cooling fluid for magnetic bearings and electric generator, then safety is improved by eliminating sealing gases and lubricants, but device complexity increases due to integrated cooling pathways
Solution Approach 1:
Hydrogen serves multiple functions simultaneously: it cools the magnetic bearings, cools the electric generator, and acts as the working fluid for expansion. This multi-functionality eliminates the need for separate sealing gases and lubricants, improving safety while managing complexity through functional integration.
Solution Approach 2:
The cooling pathways for magnetic bearings and electric generator are merged with the hydrogen expansion system. The hydrogen fluid that would otherwise be wasted is redirected through cooling channels, combining the expansion function with the cooling function in a single integrated system.
2Reliability
If hydrogen flow pathways are integrated within the casing to cool magnetic bearings and electric generator, then safety and efficiency are enhanced, but manufacturing complexity increases
Solution Approach 1:
The casing is segmented into multiple functional zones with dedicated cooling channels for magnetic bearings and electric generator. This segmentation allows for modular manufacturing of cooling components that can be assembled into the final integrated system, reducing overall manufacturing complexity.
Solution Approach 2:
The cooling pathways are nested within the existing casing structure, with cooling channels integrated into the walls and support structures. This nesting approach utilizes existing structural elements for dual purposes (structural support and heat dissipation), reducing the need for additional manufacturing steps.
3Device complexity
If hydrogen is used instead of inert gas for sealing, then device simplicity is improved by eliminating operating gases, but hydrogen leakage risk increases due to explosion hazard
Solution Approach 1:
The potential hazard of hydrogen leakage is converted into a benefit by using the hydrogen that would otherwise be wasted in cooling applications. The system is designed to contain and utilize hydrogen throughout, transforming a potential safety risk into a functional advantage where the same hydrogen provides both work expansion and thermal management.
Solution Approach 2:
The patent eliminates the need for inert sealing atmospheres by using magnetic bearings that operate without physical contact. This removes the requirement for inert gas barriers, allowing direct hydrogen operation without the safety compromises associated with hydrogen-inert gas interfaces.
4Temperature
If magnetic bearings are cooled by hydrogen from machine inlet, then cooling efficiency is improved, but temperature distribution uniformity may worsen
Solution Approach 1:
The cooling system is designed with local quality variations, providing different cooling intensities to different components based on their thermal requirements. Magnetic bearings receive targeted cooling from hydrogen flow paths positioned close to bearing locations, while other areas receive proportional cooling, optimizing thermal management for each specific component.
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
Enables safe high-speed operation without the introduction of operating gases or liquids, enhancing safety and efficiency by utilizing hydrogen for both magnetic bearing and electric generator cooling.
Implementation Method 1
a flow of hydrogen taken from the machine inlet flows through suitable paths inside the casing to cool at least the magnetic bearing(s)
Implementation Method 2
a flow of hydrogen taken from the machine inlet flows through suitable paths inside the casing to cool at least the magnetic bearing(s)
Implementation Method 3
Advantageously, also the electric generator is cooled by a flow of hydrogen taken from the machine inlet
Implementation Method 4
Advantageously, also the electric generator is cooled by a flow of hydrogen taken from the machine inlet
Implementation Method 5
an expander generator with magnetic bearings
Data Source
AI summary
An expander generator machine for hydrogen application has a machine inlet and a machine outlet and comprises an impeller which expands hydrogen and which is directly connected to an electric generator and at least one magnetic bearing cooled by a flow of hydrogen taken from the machine inlet. The expander generator machine is located inside a casing and preferably the hydrogen flows through suitable paths inside the casing to cool the at least one magnetic bearing. Advantageously, the electric generator is also cooled by a flow of hydrogen taken from the machine inlet.