Description:1
A)
TECHNICAL FIELD OF INVENTION 5
[001]
The preset invention generally relates to an air pressure control unit in a centrifugal compressor and particularly relates to a bevel gear integrated with a bearing unit for frictionless control of an angle of inlet guide vane to control an air pressure inside a centrifugal compressor.
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B)
BACKGROUND OF INVENTION
[002]
Inlet guide vanes (IGVs) in a centrifugal compressor are adjustable vanes located at the inlet that control airflow and pressure by altering the angle of the incoming air stream. This adjustment allows for optimizing compressor performance, particularly during off-design conditions, by reducing power 15 consumption and improving efficiency.
[003]
Conventionally, an angle of guide vanes is controlled through different mechanisms. One of such prior art mechanism discloses a compressor assembly has a fluid inlet positioned to facilitate the passage of a fluid. The compressor assembly includes a compressor housing defining a compressor inlet, a 20 compressor rotating element rotatably supported at least partially within the compressor housing, and an inlet guide vane assembly including a housing that defines a flow passage, a plurality of vanes, and a guide ring. Each of the plurality of vanes is rotatably supported by the housing and is coupled to the guide ring such that each of the vanes is rotatable simultaneously between a first position and 25 a second position to control the quantity of fluid that passes through the flow passage to the compressor rotating element.
2
[004]
However, the conventional centrifugal compressor has inlet guide vane 5 comprises a complex structure of bevel and bearing to facilitate the rotational motion of the bevel gear. This complex structure has separate housing for bearing and bevel gear that shall lead to high friction, assembly malfunction in case of minor mismatch during assembling the two housing together, inefficient control of vane angle etc. These phenomenon leads to reduction in compression efficiency 10 and increases losses in form of heat in a centrifugal compressor.
[005]
In the view of foregoing, there is a need for an integrated assembly structure for bevel gear and bearing with a linear and friction-less transfer of motion from a motor to guide vane.
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C)
OBJECT OF INVENTION
[006]
The primary objective of the present invention is to provide an integrated assembly structure for bevel gear and bearing with a linear and friction-less transfer of motion from a motor to guide vane.
[007]
Another objective of the present invention is to provide an integrated bevel 20 gear and bearing assembly for high precision control of an angular movement of inlet guide vane.
[008]
These and other objects and advantages of the embodiments herein will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings. 25
D)
SUMMARY OF INVENTION
3
[009]
The embodiments of the present invention provide an integrated assembly 5 of a bevel gear and a bearing housing in a centrifugal compressor to provide a frictionless motion transfer to an inlet guide vane. The assembly comprises a stepper motor, a worm gear, a bevel gear, a plurality of pinion gears, and an inlet guide vane. The stepper motor acts as an actuator and is connected to a controller for an actuation command. The worm gear is axially connected to a shaft of the 10 stepper motor. A tooth of the bevel gear is meshed with worm gear to convert a linear motion of stepper motor to a rotation motion. The bevel gear comprises a bevel wheel mounted on a bearing housing collectively mounted on a core. The plurality of pinion gears is orthogonally connected to a face plate of the bevel gear. The inlet guide vane comprising plurality of blades housed in the core and 15 mounted is a manner that a shaft of each blade is connected to one pinion gear. A linear motion transfer from the stepper motor to the inlet guide vane reduces a power loss.
[0010]
According to one embodiment of the present invention, a single housing of bearing and bevel gear leads to frictionless motion to remove a power transfer lag 20 leading to high efficiency compression.
[0011]
According to one embodiment of the present invention, the linear motion transfer leads to removal of synchronization lag leading to accurate control of an angular position of the vane.
[0012]
According to one embodiment of the present invention, an integrated 25 housing of the bevel gear, the bearing and the inlet guide vane reduces size at an end plate mounting by 10-12%.
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[0013]
According to one embodiment of the present invention, the integrated 5 housing and linear motion transfer leads to reduction of wear and tear of the said assembly and increase life cycle by 10-12%.
[0014]
According to one embodiment of the present invention, an angular movement of the vane in the inlet guide vane ranges from 0-60 degrees facilitating a low pass as well as high pass air inlet. 10
[0015]
According to one embodiment of the present invention, a sealing plate seals the bearing housing to the core. The sealing plate is mounted onto the core through a leakproof bolting mechanism.
[0016]
These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following 15 description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the 20 embodiments herein include all such modifications.
E)
BRIEF DESCRIPTION OF DRAWINGS
[0017]
The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the 25 accompanying drawings in which:
5
[0018]
FIG. 1a-1c discloses a top perspective view, a side perspective view and a 5 front view of an integrated bevel gear and bearing assembly for controlling inlet guide vane, according to one embodiment of the present invention.
[0019]
FIG. 1d illustrates a placement of bearing in a bevel wheel, according to one embodiment of the present invention.
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F)
DETAILED DESCRIPTION OF DRAWINGS
[0020]
In the following detailed description, a reference is made to the accompanying drawings that form a part hereof, and in which the specific embodiments that may be practiced is shown by way of illustration. The embodiments are described in sufficient detail to enable those skilled in the art to 15 practice the embodiments and it is to be understood that the logical, mechanical, electronic and other changes may be made without departing from the scope of the embodiments. The following detailed description is therefore not to be taken in a limiting sense.
[0021]
The inlet guide vanes are one of the most important components in modern 20 day centrifugal compressor used in multiple applications such as industrial cooling, aerospace systems, oil and gas etc. The inlet guide vanes control attack angle for an air entering into centrifugal compressor, thus any misalignment or delay in a command or ineffective angle of attack shall lead to failure of sufficient pressure in compressor leading to power loss or failure. Thus, an angular tilt of the 25 inlet guide vane should be controlled using a lossless assembly.
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[0022]
To provide such lossless assembly, the present invention proposes an 5 integrated bevel gear and ball bearing assembly. As shown in FIG. 1a-1d, the assembly 100 comprises a stepper motor 101, a worm gear 102, a bevel gear 103, a plurality of pinion gears 104, and an inlet guide vane 105. The stepper motor 101 acts as an actuator and is connected to a controller for an actuation command. The worm gear 102 is axially connected to a shaft of the stepper motor 101. A 10 tooth of the bevel gear 103 is meshed with the worm gear 102 to convert a linear motion of the stepper motor 101 to a rotational motion. The bevel gear 103 comprises a bevel wheel 106 mounted on a bearing housing 107 collectively mounted on a core. The plurality of pinion gears 104 is orthogonally connected to a face plate of the bevel gear 103. The inlet guide vane 105 comprising plurality 15 of blades housed in the core and mounted is a manner that a shaft of each blade is connected to one pinion gear 104. A linear motion transfer from the stepper motor 101 to the inlet guide vane 105 reduces a power loss. A sealing plate 108 seals the bearing housing 107 to the core. The sealing plate 108 is mounted onto the core through a leakproof bolting mechanism. 20
[0023]
According to an exemplar embodiment of the present invention, a method of operation of the said assembly comprises a control signal sent by the compressor control unit (controller) to the stepper motor. The stepper motor generates precise rotational motion leading to a motor shaft which is further transferred to the connected worm gear. The worm gear drives the bevel wheel, 25 rotating it with the help of bearing balls in the guided path which minimizes friction, and ensures smooth movement. The bevel wheel adjusts the inlet guide
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vane (IGV) blade angles to optimize an airflow entering the compressor. The inlet 5 guide vane and the compressor are enabled with feedback mechanism that ensures real-time correction and fine-tuning.
[0024]
The compressor behaviour in various airflow conditions is undermentioned:
a.
Low Airflow Demand: IGV blades adjust to a closed position to 10 reduce airflow.
b.
High Airflow Demand: IGV blades open to maximize airflow, controlled by the bevel wheel rotation.
c.
Dynamic Adjustments: Real-time adjustments occur smoothly without backlash or misalignment issues. 15
G) ADVANTAGES OF INVENTION
[0025]
The present invention finds application in many real world applications by providing following advantages over the conventional compressor with inlet guide vane: 20
[0026]
A) Integration of bearing balls into the bevel gear significantly reduces friction during rotational motion.
[0027]
B) The guided ball-bearing pathway eliminates mechanical play or backlash between components.
[0028]
C) The guided path for the bearing balls ensures perfect alignment 25 between the bevel wheel and associated components.
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[0029]
D) Smooth and backlash-free operation ensures precise angular 5 adjustments of IGV blades.
[0030]
E) The integration of ball-bearing functionality within the bevel gear reduces the need for separate bearing assemblies.
[0031]
F) Fewer independent components and the sealed ball-bearing assembly reduce wear and tear. 10
[0032]
G) Friction reduction and proper alignment enhance the lifespan of mechanical components.
[0033]
H) The sealing plate prevents bearing ball dislodgment and protects against contaminants like dust and debris.
[0034]
I) Reduced energy losses from friction and optimized rotational motion. 15
[0035]
J) Bearing balls ensure uninterrupted, smooth rotation of the bevel gear.
[0036]
K) Integration with stepper motors and worm gears allows for real-time adjustment of IGV angles.
[0037]
L) Fewer components and simplified design reduce manufacturing complexity. 20
[0038]
M) Reduced energy consumption and improved efficiency contribute to sustainability.
[0039]
It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, 25 those skilled in the art will recognize that the embodiments herein can be
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practiced with modification within the spirit and scope of the claims presented in 5 the complete specification or non-provisional application. , Claims:1
CLAIMS: 5
We Claim:
1.
An integrated assembly of a bevel gear and a bearing housing in a centrifugal compressor to provide a frictionless motion transfer to an inlet guide vane, the assembly comprises:
a stepper motor, wherein the stepper motor acts as an actuator and is 10 connected to a controller for an actuation command;
a worm gear, wherein the worm gear is axially connected to a shaft of the stepper motor;
a bevel gear, wherein a tooth of the bevel gear is meshed with the worm gear to convert a linear motion of the stepper motor to a rotational motion, wherein 15 the bevel gear comprises a bevel wheel mounted on a bearing housing collectively mounted on a core;
a plurality of pinion gears, wherein the plurality of pinion gears is orthogonally connected to a face plate of the bevel gear; and
an inlet guide vane, wherein the inlet guide vane comprising plurality of 20 blades housed in the core and mounted is a manner that a shaft of each blade is connected to one pinion gear;
wherein, a linear motion transfer from the stepper motor to the inlet guide vane reduced a power loss.
2.
The assembly as claimed in claim 1, wherein a single housing of bearing and 25 bevel gear leads to frictionless motion to remove a power transfer lag leading to high efficiency compression.
2
3.
The assembly as claimed in claim 1, wherein the linear motion transfer leads 5 to removal of synchronization lag leading to accurate control of an angular position of the vane.
4.
The assembly as claimed in claim 1, wherein an integrated housing of the bevel gear, the bearing and the inlet guide vane reduces size at an end plate mounting by 10-12%. 10
5.
The assembly as claimed in claim 4, wherein the integrated housing and linear motion transfer leads to reduction of wear and tear of the said assembly and increase life cycle by 10-12%.
6.
The assembly as claimed in claim 1, wherein an angular movement of the vane in the inlet guide vane ranges from 0-60 degrees facilitating a low pass as 15 well as high pass air inlet.
7.
The assembly as claimed in claim 1, wherein a sealing plate seals the bearing housing to the core, wherein the sealing plate is mounted onto the core through a leakproof bolting mechanism.