Tandem Permanent Magnet Motor Alignment Using External Reference Marks
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Solution Overview
Problem
The deployment of tandem permanent magnet motors in electric submersible pumping systems is hindered by the need for precise phase alignment between rotor and stator components, which is challenging in field installations, especially in deviated wellbores and surface applications with limited space.
Innovation Solution
A method and system utilizing an external visual reference system with reference marks and locking rings to align and secure the upper and lower permanent magnet motors, ensuring precise angular alignment of stator and rotor assemblies before installation, facilitated by threaded engagements and torque tools for locking the components into fixed positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If tandem permanent magnet motors are connected in series configuration at the wellsite, then the motor system can operate in deviated wellbores and limited space applications, but precise phase alignment between rotor and stator becomes extremely difficult to achieve
Solution Approach 1:
The patent applies preliminary action by pre-configuring alignment features (reference marks, alignment pins, keyed connections) on motor components before field assembly. These pre-built alignment mechanisms ensure that when motors are connected in tandem at the wellsite, the rotor and stator phases are automatically aligned without requiring complex field measurements or adjustments, thus resolving the contradiction between adaptability and manufacturing precision.
Solution Approach 2:
The patent uses intermediary alignment components such as coupling devices with built-in alignment features, reference mark systems, and mechanical keys that mediate between the two motor units during assembly. These intermediaries provide visual and mechanical guidance to ensure precise phase alignment during field connection, enabling tandem motor assembly in challenging well conditions while maintaining the required rotational synchronization.
2Device complexity
If conventional induction motors are used in ESP systems, then the motor design is simpler and more robust, but the motor length increases which causes deployment problems in deviated wellbores and limited space applications
Solution Approach 1:
The patent applies segmentation by dividing the motor system into multiple shorter permanent magnet motor units connected in tandem series configuration. Each motor unit has its own rotor and stator assembly, and when connected together, they function as a single integrated motor system. This segmentation reduces the length of individual motor shafts, making deployment in deviated wellbores and limited space applications feasible while maintaining the simplicity and robustness of the overall motor design through modular construction.
3Length of moving object
If permanent magnet motors are used instead of induction motors, then the motor length is reduced for better deployment, but precise phase alignment between rotor and stator becomes critical and difficult to maintain
Solution Approach 1:
The patent replaces complex mechanical alignment systems with visual reference mark systems and simplified mechanical keys. Instead of requiring precision mechanical fitments or complex alignment procedures, the invention uses visually detectable reference marks that guide the alignment process and simplified keyed connections that maintain phase relationship. This substitution maintains reliability of phase alignment while reducing the complexity and time required for field assembly of tandem motor 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 robust and precise alignment of tandem permanent magnet motors in the field, ensuring proper registration and operation of the motor assemblies, thereby facilitating efficient fluid extraction from wells by ensuring correct magnetic field interactions and motor synchronization.
Implementation Method 1
threading an upper locking ring into an upper housing of the upper permanent magnet motor, threading an upper stator adapter into the upper housing, unthreading the upper stator adapter until an upper reference mark on the upper stator adapter is aligned with an upper housing reference mark
Data Source
AI summary
A method of assembling a tandem permanent magnet motor includes the steps of using an external visual reference system to align the stator assembly of the upper permanent magnet motor with the stator assembly of the lower permanent magnet motor. The external visual reference system includes a series of external reference marks that provide a mechanism for quickly aligning the upper and lower permanent magnet motors in the field prior to installation in a well as part of an electric submersible pumping system.