Rotor Keyway Assembly for Reduced Shaft Eccentricity Vibration
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Solution Overview
Problem
Existing electric submersible pumping systems experience vibration issues due to unbalanced rotor positioning on the shaft, primarily caused by assembly clearances and torque forces, which are exacerbated by increasing operating speeds.
Innovation Solution
A vibration reduction system using a key and keyway mechanism, including bi-metallic keys and alternating keyways, along with spring-like biases, to balance the rotor and reduce eccentric positioning, thereby minimizing vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a key and keyway mechanism is used to connect the rotor to the shaft, then the rotor can be securely mounted and torque can be transmitted, but assembly clearances and manufacturing tolerances cause eccentric positioning and vibration
Solution Approach 1:
The patent changes the physical state of the key from rigid to elastic by selecting materials with appropriate elastic moduli. The elastic key deforms under assembly loads to absorb clearance variations, maintaining secure torque transmission while reducing eccentric positioning and vibration. This parameter change (rigidity to elasticity) resolves the contradiction between strong mechanical connection and vibration reduction.
2Power
If multiple rotors are used with multiple keys and keyways, then more torque can be transmitted, but the randomized keyway angular orientation becomes unpredictable and unreliable in reducing vibration
Solution Approach 1:
The patent introduces asymmetric features on the rotors (such as asymmetric mass distribution or asymmetric keyway positioning relative to rotor geometry) that, when combined with the elastic key mechanism, create predictable vibration reduction. This asymmetry allows the elastic keys to compensate for clearance variations in a controlled manner, making the vibration reduction reliable even with multiple rotors and keys.
3Object-generated harmful factors
If the clearance between rotor and shaft is minimized to reduce eccentricity, then vibration is reduced, but assembly difficulty increases and manufacturing tolerances become harder to achieve
Solution Approach 1:
The patent changes the mechanical property of the key from rigid to elastic, allowing it to deform and accommodate larger assembly clearances. This elastic deformation compensates for manufacturing tolerances and assembly variations, maintaining low eccentricity and vibration while significantly easing assembly requirements and manufacturing tolerances.
4Productivity
If operating speed is increased to improve productivity, then pumping efficiency increases, but vibration is exacerbated due to unbalanced rotor positioning
Solution Approach 1:
The patent changes the key material properties to provide optimal elasticity that compensates for dynamic loads at high speeds. The elastic key maintains consistent rotor positioning under varying operational conditions, allowing high-speed operation and improved pumping efficiency without exacerbating vibration from unbalanced rotor positioning.
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 system effectively reduces rotor eccentricity and vibration by providing a stable, balanced assembly, even under varying temperature conditions, enhancing operational stability and reducing unwanted vibrations.
Implementation Method 1
The vibration reduction system incorporates the use of a key and keyway in a manner which helps balance the rotor, thus reducing vibration during operation. In some applications, the vibration reduction system is able to reduce eccentric positioning of the rotor on the shaft due to, for example, assembly clearances.
Data Source
AI summary
A technique facilitates the reduction of vibration in a variety of devices which have rotating components. According to an embodiment, a system may combine a shaft, a rotor mounted along the shaft for rotation with the shaft, and a vibration reduction system. The vibration reduction system incorporates the use of a key and keyway in a manner which helps balance the rotor, thus reducing vibration during operation. In some applications, the vibration reduction system is able to reduce eccentric positioning of the rotor on the shaft due to, for example, assembly clearances.