Integrated Rotor Bearing Layout for High-Speed Gas Turbine Stability
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Solution Overview
Problem
Traditional radial and thrust bearings in gas turbine generator sets face challenges at high speeds due to mechanical wear and limitations in mounting positions, leading to instability and potential damage, especially when rotor speeds exceed 40,000 rpm.
Innovation Solution
A rotor system with integrated non-contact gas-magnetic hybrid thrust and radial bearings, including foil-type and slot-type configurations, allowing for adjustable mounting positions and improved stability by distributing the center of gravity between radial bearings, thereby enhancing structural stability during high-speed rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If ordinary contact bearings are used in the rotor system, then the structure is simple and easy to manufacture, but the rotor cannot operate at high speeds exceeding 40,000 rpm due to mechanical wear
Solution Approach 1:
The patent replaces ordinary contact bearings with gas-magnetic hybrid bearings that combine magnetic suspension and gas lubrication effects. The magnetic bearing component uses electromagnetic fields to suspend the rotor, eliminating mechanical contact and wear, while the gas lubrication component provides stable support at high speeds. This substitution enables the rotor to operate reliably at speeds exceeding 40,000 rpm without the mechanical wear limitations of conventional bearings.
Solution Approach 2:
The gas-magnetic hybrid bearing integrates two different bearing technologies (magnetic bearing and gas lubrication bearing) into a single composite system. The magnetic bearing portion handles high-speed rotation without contact, while the gas lubrication portion provides additional stability and load support. This composite approach combines the advantages of both bearing types to achieve reliable high-speed operation.
2Stability of the object's composition
If the thrust bearing is placed between the air compressor and the turbine, then the mounting position is flexible, but the center of gravity becomes biased toward the turbine side, resulting in poor rotor system stability
Solution Approach 1:
The gas-magnetic hybrid thrust bearing uses magnetic fields and gas pressure to support axial loads without the mechanical constraints of traditional contact bearings. This allows the thrust bearing to be positioned optimally for balance rather than being constrained by mechanical mounting requirements. The bearing can be placed at the optimal location to balance the rotor system's center of gravity, improving stability while maintaining mounting flexibility through the non-contact support mechanism.
3Strength
If the thrust bearing is arranged on one side of the coupling facing the generator, then the mounting position is simplified, but the axial force acts entirely on the coupling, making it likely to be damaged
Solution Approach 1:
The gas-magnetic hybrid thrust bearing replaces the mechanical coupling's load-bearing function with a non-contact magnetic and gas support system. The thrust bearing independently handles axial forces through magnetic suspension and gas pressure, preventing these forces from being transmitted to the coupling. This protects the coupling from damage while maintaining a relatively simple overall arrangement, as the thrust bearing can be positioned to optimize force distribution without complicating the coupling design.
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 solution provides enhanced stability and meets high-speed requirements by adjusting the thrust bearing's mounting position, reducing mechanical wear and preventing damage to the coupling, ensuring the rotor system's structural integrity and efficiency.
Implementation Method 1
each first foil bearing is provided with a second magnetic component capable of interacting with the plurality of first magnetic components and generating magnetic forces with the plurality of first magnetic components
Implementation Method 2
each first foil bearing is arranged between the corresponding first magnetic bearing and the first thrust disc and has a first gap with the first thrust disc
Data Source
Figure 1~3
Figure 4~6
Figure 7~9
AI summary
Provided is a rotor system, comprising a rotating shaft (100), a shaft body of the rotating shaft (100) being of an integrated structure and the rotating shaft (100) being horizontally arranged; and a motor (200), an air compressor (300), a turbine (400), a thrust bearing (500) and at least two radial bearings (600) which are arranged on the rotating shaft (100). The thrust bearing (500) and the at least two radial bearings (600) are all non-contact bearings. The thrust bearing (500) is arranged at a preset position on one side of the turbine (400) close to the air compressor (300). The preset position is such a position that the center of gravity of the rotor system can be located between two radial bearings (600) that are farthest apart among the at least two radial bearings (600). The shaft body of the rotating shaft is of the integral structure, which eliminates the need for couplings used in the existing gas turbine generator sets, and solves the problem of limitations on a mounting position of a gas-magnetic hybrid thrust bearing caused by the couplings. Further, adjusting setting positions of the bearings is advantageous for maintaining the structure stability of the rotor system during high-speed rotation. Further disclosed are a control method of the rotor system, a gas turbine generator set having the rotor system, and a control method of the gas turbine generator set.