Permanent Magnet Motor Coupling for Tandem Alignment
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Solution Overview
Problem
Current downhole permanent magnet motors cannot operate in tandem configurations due to difficulties in synchronizing the angular alignment of their magnetic fields, leading to limited power output and the need for larger, single motor sections to meet application requirements.
Innovation Solution
A coupling system that synchronizes the angular alignment of multiple permanent magnet motors by connecting their rotors through a male and female tapered member configuration, with a retention fastener to lock the members together, allowing torque transfer and synchronization of magnetic fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple permanent magnet motors are connected in tandem to increase power output, then torque and horsepower are improved, but the angular alignment of magnetic fields becomes difficult to synchronize
Solution Approach 1:
The motor assembly is segmented into multiple independent permanent magnet motor sections that can be connected in tandem. Each section has its own rotor and stator, allowing individual alignment while contributing to cumulative power output. The coupling system enables each segment to be synchronized independently through mechanical alignment features.
Solution Approach 2:
A coupling system acts as an intermediary between multiple motor sections, providing mechanical alignment features including alignment keys, tapered bore interfaces, and retention fasteners. This intermediary component facilitates the transfer of rotational force while maintaining precise angular alignment of magnetic fields between connected motors.
2Power
If a single long motor section is used to achieve required power output, then power rating is improved, but the device length and complexity increase
Solution Approach 1:
Instead of using one long motor section, the system divides the motor into multiple standard-length sections that can be connected in tandem. Each section maintains optimal magnetic field alignment and fits within standard downhole tool joint dimensions, avoiding the need for excessively long single sections while achieving cumulative power requirements.
Solution Approach 2:
Multiple motor sections are nested together through coupling systems that allow compact connection. The tapered bore and retention fastener design enables sections to be tightly coupled, minimizing the overall length of the assembled motor while maintaining the ability to achieve high power ratings through multiple sections.
3Adaptability or versatility
If multiple permanent magnet motors are connected in tandem, then customizable power ratings are achieved, but the coupling and alignment system becomes more complex
Solution Approach 1:
The coupling system is designed with universal applicability across different motor sections, using standardized tapered bore interfaces and retention fasteners that work regardless of the number of sections. This universal design allows flexible configuration for customizable power ratings without requiring different coupling mechanisms for each application.
Solution Approach 2:
Alignment keys and mechanical features are pre-configured in the coupling system to automatically establish correct angular alignment when sections are connected. This preliminary alignment mechanism eliminates the need for complex field adjustments or sophisticated synchronization systems, simplifying the overall coupling design while enabling versatile power configurations.
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 the creation of higher torque and horsepower outputs by aligning and locking the rotors of multiple permanent magnet motors, allowing for customizable power ratings by connecting multiple motors in series.
Implementation Method 1
a retention fastener, a device used for mechanical retention, may be tightened to increase the friction between the male and the female members to effectively lock the members together
Implementation Method 2
the rotor utilizes permanent magnets that create the magnetic field necessary for the motor to operate. This rotor with permanent magnets operates synchronously with the stator electric winding coils
Data Source
AI summary
Systems and methods for connecting rotors between multiple permanent magnet motors. By coupling the rotors of multiple modules, torque may be transferred while maintaining the angular alignment between the stator and rotor magnetic fields of each individual permanent magnet motor.