Monolithic Rotor and Compressor Wheel for Microturbines
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Solution Overview
Problem
Existing microturbine and air compressor designs face reliability issues due to the use of fragile flexible couplings between magnetic rotors and compressor/wheel components, leading to design complexities and reduced reliability, especially in power generation applications.
Innovation Solution
A monolithic rotor and compressor wheel assembly with a reduced radius neck region facilitates enhanced stability and performance by eliminating the need for flexible couplings, utilizing a rigid connection and optimized geometric dimensions to prevent resonances and distribute loads effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flexible coupling is used to connect the magnetic rotor and compressor wheel, then torque can be transmitted between them, but the design becomes more complex and reliability decreases due to fragile components
Solution Approach 1:
The patent merges the magnetic rotor and compressor wheel into a single monolithic component formed from a single piece of material. This eliminates the flexible coupling entirely, combining two previously separate components (rotor and compressor wheel) into one integrated structure, thereby removing the fragile coupling element while maintaining torque transmission capability through the unified structure
Solution Approach 2:
The patent extracts and removes the flexible coupling from the system by creating a direct monolithic connection between the rotor and compressor wheel. The coupling component is completely eliminated from the design, leaving only the integrated rotor-compressor assembly where the coupling previously existed
2Ease of operation
If a flexible coupling is used between magnetic rotor and compressor wheel, then torque transmission is enabled, but device complexity increases
Solution Approach 1:
The patent merges the magnetic rotor and compressor wheel into a single monolithic component formed from a single piece of material. This eliminates the flexible coupling entirely, combining two previously separate components (rotor and compressor wheel) into one integrated structure, thereby removing the fragile coupling element while maintaining torque transmission capability through the unified structure
Solution Approach 2:
The patent extracts and removes the flexible coupling from the system by creating a direct monolithic connection between the rotor and compressor wheel. The coupling component is completely eliminated from the design, leaving only the integrated rotor-compressor assembly where the coupling previously existed
3Stability of the object's composition
If a monolithic structure with reduced radius neck region is used, then rotational stability is improved by tuning frequency response, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies local quality by creating a reduced radius neck region at a specific location on the monolithic component. This localized geometric feature is precisely positioned and dimensioned to serve as a vibration tuning element that modifies the frequency response characteristics of the entire rotor assembly, allowing rotational stability enhancement through targeted local geometry modification
Solution Approach 2:
The patent changes the geometric parameter of the neck region radius to create a reduced radius section. This parameter modification alters the mass distribution and stiffness characteristics of the monolithic structure, thereby tuning the natural frequencies to improve rotational stability and avoid resonances during operation
Data Source
AI summary
A rotational component includes a monolithic compressor component for rotation about a rotor axis defining proximal and distal directions, the monolithic compressor component including a compressor shaft defining a rotor core and a compressor wheel disposed distally from the rotor core.