Acknowledgement
This invention was made under contract with or supported by the ELECTRIC POWER RESEARCH INSTITUTE, INC. of Palo Alto, California.
Background of the Invention
It is a well-known phenomenon that many metals, alloys and chemical compounds substantially lose all of their electrical resistance and become superconductive at temperatures near absolute zero. This phenomenon is advantageously employed in electrical alternators or generators by cooling the rotor of the generator to a sufficiently low temperature. By operating a generator in its superconducting state, losses in the windings of the rotor are substantially eliminated and the generator efficiency is correspondingly increased. Additionally, the generator rotors and stators can be built to a much smaller dimension. This results in a reduction in weight of the generator. Moreover, when the rotor is smaller, there is a resultant reduction in operating problems such as vibrations, high material stresses and the like frequently encountered in high-speed rotors.
In general, superconducting rotors consist of a number of cylindrical concentric elements. On the outside there is a damper shield and a damper shield support which are supported by an outer rotor. Inside the outer rotor is an inner rotor including superconducting field windings or coils immersed in a helium refrigerated annulus. This helium refrigerated annulus typically maintains the temperature of the superconducting coils at 4.3.degree. K. or below so that superconductivity takes place. Intermediate the two rotors and concentric therewith, is a thermal radiation or insulating shield, designed to minimize radiant heating of the cold inner rotor. The term "rotor" will be used to refer to the inner rotor, the outer rotor, and the insulating shield.
An inherent problem in the design of superconducting generators is the accommodation of the relatively large thermal deflections between the cold inner rotor and the relatively warm outer rotor and between the cold inner rotor and the insulating shield. The present invention accommodates these differential axial thermal expansions and contractions.
The outer damper shield and damper shield support serve two functions. First, they comprise the strongback outer thermal jacket of the super-cooled rotor. Second, they prevent back electromotive forces from the stator from penetrating to the superconducting coils. If penetration to the superconducting coils of the back electromotive forces occurs, the coils of the windings become heated. When they become heated above a critical temperature, they lose their superconductivity and the designed field is lost.
During normal operation, the inner rotor is first subjected to "cool-down". In cool-down, liquified helium is introduced into the vicinity of the superconducting coils. The inner rotor undergoes substantial thermal contraction in an axial direction. Taking the case of a superconducting rotor 132 inches long, a thermal contraction of 3/10 of an inch or more can occur. In a longer superconducting rotor on the order of 275 inches long, thermal contractions of as much as 7/10 of an inch or more can occur. Simultaneously, the insulating shield, which will be cooled to an intermediate temperature of about 100.degree. K., contracts axially, but normally in an amount less than that of the inner rotor.
At the same time this axial shrinkage is accommodated, any tendency of the inner rotor to move rotationally with respect to the outer rotor must be prevented. Otherwise, this relative movement between inner and outer rotors will generate undesired back electromotive heating of the superconducting coils and can result in the loss of their superconductivity.
Further, any tendency of the rotors to move out of concentric alignment must be avoided. Even a minute eccentricity of the rotors may result in substantial resonances and unbalanced forces during high-speed rotation. Therefore, the connection must have sufficient lateral (radial) stiffness and strength to maintain the rotors in concentric alignment.
In addition, the regions between the rotor elements are in a vacuum which adversely affects the operation of a sliding coupling. At low vacuum temperatures and at high rates of rotation, a rapid "fretting corrosion" of the sliding parts normally occurs. Also, in a vacuum, rubbing surfaces frequently gall and seize or weld.
In the past, it has been proposed to connect the rotor elements rigidly both axially and torsionally. However, this design leads to excessive axial stresses in large generators.
Prior art patents do not address themselves to the particular needs of a coupling between the rotors of a superconducting generator. There are, however, a number of prior art patents which disclose a variety of couplings designed to connect misaligned shafts in end-to-end relation. Typical of these are U.S. Pat. Nos. 3,798,924, 3,874,195, 3,759,064, 3,703,817, 1,947,052, and 3,405,760. None of the couplings disclosed in these patents is adapted to solve the problems encountered when connecting concentric structures of a superconducting rotor.
In general, the couplings disclosed in these patents provide a driving connection only between the shafts since the shafts are supported by independent bearings on each side of the coupling. These couplings are well adapted to accommodate misalignments between rotating shafts. However, they are generally incapable of accommodating appreciable axial movement between the shafts, particularly at the low temperatures encountered in super-cooled generators and they are even less capable of radially supporting a pair of shafts, especially when the weight of the rotary element is as large as that of the rotor of a generator.
Summary of the Invention
The present invention provides a flexible coupling for connecting pairs of concentric elements in a superconducting rotor. The coupling is preferably constructed of a relatively thin ring and its provides the sole support between the rotors at one or both ends of the superconducting rotor. When used to connect the inner rotor to the insulating shield, the ring is constructed of a material that retains flexibility at temperatures down to at least about 100.degree. K. The ring may be laminated to increase its flexibility and may comprise a number of joined ring segments. Spaced apart securing devices alternately affix the ring to the rotors which it connects. The spacing between the securing devices is sufficient to permit deflections of the ring in an axial direction.
Thus, the flexible coupling of the present invention provides a radially and torsionally rigid connection between pairs of concentric elements in a superconducting rotor. The coupling prevents vibrations, can withstand short-circuit torques, and permits relative axial movements between the rotors caused by thermal contractions and expansions thereof during cool-down and warm-up. The coupling of the present invention maintains the rotors in concentric alignment.
An improved superconducting rotor design is also provided which is capable of accommodating large relative axial deflections between the cold inner rotor and (1) the relatively warm outer rotor, and/or (2) the insulating shield.
Brief Description of the Drawings
FIG. 1a is a side-elevation section taken along the axis of a superconducting rotor constructed in accordance with the present invention and illustrates the connection between the concentric rotors;
FIG. 1b is an enlarged, fragmentary view, in section, of the right end of the superconducting rotor of FIG. 1a, and shows another embodiment of the invention;
FIG. 1c is an enlarged, fragmentary view, in section, of the right end of the superconducting rotor shown in FIG. 1a, and shows a further embodiment of the invention;
FIG. 1d is an enlarged fragmentary view, in section of the left-end of the superconducting rotor shown in FIG. 1a, showing the connection between the inner and outer rotors in detail;
FIG. 2 is a plan view of a flexible coupling ring constructed according to the present invention;
FIG. 3 is an isometric view of a coupling constructed according to the invention connecting the inner rotor and the insulating shield;
FIG. 4 is a side-elevation, with parts broken away, taken along lines 4--4 of FIG. 3; and
FIG. 5 is a sectional view taken along lines 5--5 of FIG. 4.
Description of the Preferred Embodiments
Referring to FIG. 1a, a rotor 2 is disposed within a stator (not shown), and is driven by a stub shaft 6 and has at its end opposite the stub shaft a cryogenic transfer system 8. Rotor 2 revolves at high speed about its axis 4 to generate electricity in windings disposed in the stator.
Cryogenic transfer system 8 transfers liquid helium to and from the interior core space 10 of an inner rotor 12. This system is fully described in an article entitled, "A Relatively Rotatable Cryogenic Transfer System", dated July 13, 1972, in a technical publication available at the Massachusetts Institute of Technology, marked MT-125J. In addition to and adjacent transfer system 8, rotor 2 includes conventional collector rings 14 which transfer current to super-cooled field windings 16 disposed in inner rotor 12.
Inner rotor 12 includes torque tubes 18 and 20 which are disposed at respective ends of the inner rotor 12. Torque tube 18 has a flange 22 and torque tube 20 has a flange 24.
Surrounding inner rotor 12 and concentric therewith is a cylindrical insulating shield 26. The insulating shield minimizes the radiant heating of cold inner rotor 12 by the warmer outer rotor 32. An annulus 28 which surrounds inner rotor 12 and an annulus 30 which surrounds insulating shield 26 are maintained in a vacuum state during operation of the generator.
Surrounding insulating shield 26 is an outer rotor 32 which is co-axial with axis 4. A damper shield 34 is juxtaposed between and it is supported by outer rotor 32 on its inner side and by a damper support 36 on its outer side.
During operation of the generator, space 10 of rotor 12 and field windings 16 are cooled down to a temperature of approximately 4.3.degree. K. Field windings 16 thus become superconducting. Insulating shield 26 is cooled to a temperature of about 100.degree. K. Torque tubes 18 and 20 exhibit a temperature gradient along their axial lengths. For example, during operation, points 38 and 40 of the torque tubes are at approximately the same temperature as field windings 16. Points 42 and 44 are at approximately room temperature. Between points 38 and 42 and between 40 and 44 on the respective torque tubes, the temperature rises from about 4.degree. K. to room temperature moving axially outward from points on the torque tubes closest to intermediate point 46. To effect the described temperature gradient the interiors 18' and 20' of torque tubes 18 and 20 are thermally insulated from space 10 by providing thermally insulating barriers at each end of space 10 (not shown in the drawings). The exact proportions of the superconducting rotor elements and the couplings and the design of the cooling apparatus within inner rotor 12 are not shown. Outer rotor 32 is at room temperature or above (300.degree. K. plus).
Thus, in general, it can be said that during "cool down" inner rotor 12 and insulating shield 26 undergo axial thermal contraction and since the former contracts more than the latter, there is also a relative thermal contraction between the two. Outer rotor 32 does not undergo thermal contraction although it may expand relative to the axis if it becomes heated above room temperature during operation.
Referring to FIGS. 1a-2, the present invention provides a flexible coupling 48 for connecting flange 22 of inner rotor 12 to an end wall 33 of outer rotor 32. Coupling 48 preferably includes a ring 48a , best shown in FIG. 2, having spaced apart apertures 52-57 located intermediate an outer periphery 64' and an inner diameter 66' of the ring.
Referring to FIG. 1d, coupling 48 includes means, such as bolt sets, each of which consists of a bolt 68, a spacer 69, and a nut 68'. Three equally spaced bolt sets secure ring 48a to flange 22 of inner rotor 12, and three equally spaced bolt sets secure rings 48a to end wall 33 of outer rotor 32. Spacers 69 and 71, space ring 48a from flange 22 and end wall 33, respectively. Bolts 68 and 70 are secured by nuts 68' and 70'. In this manner, end wall 33 of outer rotor 32 is secured to ring 48a at three spaced points around the latter and inner rotor 12 is secured at alternative points about ring 48a midway between the outer rotor attachments.
Axial deflection between the inner and outer rotors is accommodated by out-of-plane bending of ring 48a which causes a wave-like deformation of the ring while the concentricity of the inner and outer rotors is maintained.
Instead of employing nuts to secure the bolts to ring 48a, the ring can be provided with bosses 62-67 that surround the ring apertures and the apertures can be threaded for direct engagement by the bolts to eliminate the need for the spacers and separate nuts. The bosses additionally strengthen the ring at the points where the greatest stresses occur.
The ring can be constructed of multiple laminations to enhance its axial deformability. Alternatively, a series of overlying, separate rings can be employed.
Coupling 48 must maintain inner rotor 12 and outer rotor 32 torsionally rigid during operation, that is, it must prevent relative angular movements between the inner and the outer rotors. Otherwise, undesired back electromotive heating can cause a temperature rise in the superconducting coils which in turn can lead to a loss of superconductivity. Additionally, coupling 48 must be radially rigid, that is, it must maintain the concentricity of the inner and outer rotors to avoid vibrations.
For coupling 48 to have these characteristics, ring 48a must have an axial thickness and a radial width which assure the necessary torsional and radial rigidity, while at the same time ring 48a must retain the ability to deform out of the ring plane to accommodate relative axial contractions between the rotors. An axial thickness of about 0.3 to 0.4 inch and radial width of about 4 inches for a ring having an outside diameter of about 25 inches and constructed of titanium accommodates axial deflections of between 0.4 inch to 0.7 inch. The ring can also be made out of aluminum, aluminum alloy, ferro alloy, titanium alloy, or reinforced composite.
Referring again to FIGS. 1a and 3-5, the present invention also provides a coupling 72 for connecting torque tube 18 of inner rotor 12 to insulating sheild 26. Normally shield 26 operates at approximately 100.degree. K.; however, abnormal conditions can cause larger thermal differences between the insulating shield and the interior of the rotor 10 which is at approximately 4.degree. K. during operation. Therefore, insulating shield 26 must be attached in such a way that axial and radial expansions thereof resulting from temperature differentials of up to 350.degree. K. can be accommodated. Coupling 72 must also be capable of transmitting some torque and it must be radially rigid to avoid vibrations.
FIGS. 1a, 1d, 3, 4, and 5 show the construction of coupling 72. A plurality of, e.g., two rings 73, each constructed of three 120.degree. ring segments 76 are secured to torque tube 18 with three right-angle brackets 74 each of which is attached, e.g., bolted to one of the ring segments 76. The brackets are further secured, e.g., bolted to the outer surface of torque tube 18. A rigid, generally L-shaped, circular flange 78 is shrunk fit into the end of shield 26. The flange defines a flat end-face 84.
Three pairs of lap plates 80 secure the ends of ring segments 76 to each other and secure rings 73 to the flat end face 84 of flange 78. It will be observed that a narrow gap 88 may be formed between each pair of adjoining ring segments 76, each set of aligned gaps may form a channel 86 between the inner and the outer lap plates, as best illustrated in FIG. 4. Bolts 92 and nuts 94 tighten the lap plates 80 and the ring segments 76 against each other and against face 84 of flange 78.
The laminated structure of the ring of coupling 72 yields greater flexibility and facilitates the accommodation of axial and radial expansions and contractions of insulating shield 26 with respect to inner rotor 12. Rings 73 of coupling 72 are separated from torque tube 18 by a space 98.
The ring of coupling 72 must have an axial thickness and a radial width so that it has the requisite radial and torsional rigidity and the capability to deform out-of-plane between brackets 74 at operating temperatures between 90.degree.-130.degree. K. to accommodate axial movement of the inner rotor with respect to the insulating shield. For example, in a typical large rotor in which rings 73 have a mean diameter of 22 inches, the rings have a combined axial thickness of 0.6-0.8 inches and a radial width of 1.6 inches when made of steel alloy.
As previously described, torque tube 18 has a temperature gradient in an axial direction so that the temperature increases moving in an axial direction indicated by arrow A. Insulating shield 26 has a length relative to inner rotor 12 so that coupling 72 is secured to torque tube 18 at a position where the normal operating temperature is between 90.degree.-130.degree. K.
For the actual construction of a superconducting rotor, the above described flexible couplings can be employed in several combinations depending on the size of the generator, the operating temperature, the materials of which the rotor is constructed and the like. In the embodiment shown in FIG. 1A, flexible couplings 48 and 72 are employed at one end of the rotor while the inner and outer rotors and the insulating shield are rigidly secured to each other at the other end. It should be noted, however, that couplings 48 and 72 are the only structures which hold the inner and outer rotors and the insulating shield in concentric alignment at that end of the rotor.
FIGS. 1b and 1c show the use of couplings 48 and 72 and of coupling 72 only, respectively at the right-hand end of the rotors.
In practice, the inner rotor and the insulating shield may be assembled in a pre-stressed state so that couplings 48 and 72 deflect axially out-of-plane. In this manner, the maximum out-of-plane bending of the couplings is limited to almost one-half of what it would otherwise be.
It is to be understood that variations of the present invention will occur to those having skill in the art. For example, it is possible that several flexible couplings can be used in series for larger axial deflections encountered in longer rotors, and that any combination of flexible couplings can be used at one or both ends of the superconducting rotor. Variations of the disclosed flexible coupling for attaching concentric elements in the rotor of a superconducting generator are within the spirit and scope of the present invention.