Speed-Driven Torque Calculation for Rotating Equipment
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Solution Overview
Problem
Existing methods for measuring torque in rotating equipment, such as turbo machinery, are either too costly, fragile, or impractical for real-time, in-field applications, as they rely on mechanical deformation measurements that are not robust enough to withstand operational challenges.
Innovation Solution
A method that calculates torque by taking real-time rotating speed measurements and using the natural decay curves of the system, combined with the equations of motion, to estimate the driving torque and losses, allowing for real-time monitoring and control of rotating equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain gauges or torque transducers are used to measure torque, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces mechanical torque measurement systems (strain gauges, torque transducers) with a computational method based on Newton's equations of motion. The system uses readily available speed measurements and pre-determined inertia and loss curves to calculate torque dynamically, eliminating the need for complex mechanical deformation measurement apparatus.
Solution Approach 2:
The patent creates a virtual model of the rotating equipment's dynamic characteristics by pre-determining inertia and loss curves through controlled testing. This virtual model is then used during operation to calculate torque from speed data, replacing the need for physical torque sensing instruments.
2Measurement precision
If torque transducers are used to measure torque, then measurement precision is improved, but the device becomes fragile and less reliable in field conditions
Solution Approach 1:
The patent replaces fragile mechanical torque transducers with a robust computational approach using Newton's equations. The method relies on pre-determined system characteristics and real-time speed measurements, which are far more reliable in harsh field conditions than delicate mechanical sensing devices.
Solution Approach 2:
The system uses the rotating equipment's own operational data (speed measurements) and pre-stored dynamic characteristics to calculate torque, eliminating the need for external fragile measurement devices. The equipment essentially measures itself through its operational behavior.
3Measurement precision
If traditional torque measurement methods are used, then torque can be measured, but the equipment adds mass and weight to the system
Solution Approach 1:
The patent replaces physical torque measurement devices with a computational method that uses existing speed sensing capabilities. By calculating torque from speed data and pre-determined system characteristics, the method eliminates the need for additional heavy mechanical measurement apparatus.
4Measurement precision
If strain gauges are installed on the shaft, then torque measurement is enabled, but the installation becomes costly and complex
Solution Approach 1:
The patent replaces the complex installation process of strain gauges with a computational method using existing speed sensors and pre-determined system characteristics. This approach eliminates the need for specialized installation procedures, reducing both cost and complexity.
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 accurate and efficient measurement of torque in both steady and unsteady state conditions, improving the reliability and energy efficiency of rotating machines without adding mass or weight, and facilitating predictive maintenance.
Implementation Method 1
where TIN (in Newton*m) is the driving torque, TLOSS, the power sink, (in Newton*m) is the negative torque due to losses, TN (in Newton*m) is the torque net of losses, I (kg*m2) is the moment of inertia of the system, W (Rad/s) is the angular speed of the system, and dW/dt (Rad/s2) represents the angular acceleration of the system.
Implementation Method 2
TIN-TLOSS=TN=I*dW/dt
Implementation Method 3
Measuring the speed of a shaft is straightforward with the use of standard speed measurement devices (tachometers) that measure rotational speed in Hertz (rad/s) or revolutions per minute (rpm).
Data Source
AI summary
Method for measuring torque in rotating-equipment, turbo-machinery, pumps, turbines, and compressors. The measured torque can be used as an input to control torque, power, or energy efficiency. The method can also measure force (or torque) in traversing-machinery or vehicles such as automobiles, ships, aircraft, bicycles and motorcycles. The method takes real-time rotating (or linear) speed measurements, applies the discrete form of equations of motion, captures the natural decay curve(s) of the machine to estimate the torque (or force) associated with the losses of the power sink, and then solves for the driving torque of the power source. The method relates to monitoring and control systems used to safely and efficiently operate rotating-equipment and traversing-machinery. The method can be used to determine a health index of a machine to make predictive and corrective maintenance, reliability, performance, safety, and efficiency-related decisions. It is accurate, robust, lightweight, space-saving, and low cost.