Description:

FIELD OF THE INVENTION:
[001] This invention relates generally to compact and silent turbo generator. More particularly the invention relates to a method for designing a compact turbo-generator which occupies low space and results in noise reduction and absorption emitted by turbo-generator.

BACKGROUND/PRIOR ART OF THE INVENTION:
[002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[003] A turbo- generator converts rotational energy of the turbine into electrical energy. A rotating magnetic field generated by the rotor is converted in to current and voltage to the grid through a stator coil installed in a stator core.

[004] The generator operates in a high magnetic field at high current and heat is generated as per the following:
a. copper loss generated by electrical current flow in conductors,
b. iron loss generated by passage of the magnetic field through the core,
c. other electrical losses are generated in each component of the generator,
d. windage losses which include ventilation loss and friction loss are generated by rotation of the rotor and fan assembly.

[005] In order to remove the heat arising from these losses, fans are mounted on the rotor shaft, and cooling medium is circulated inside the generator.

[006] A turbo-generator is an equipment having a rotating mechanical member (rotor) and a fluid to exchange heat during its flow across various zones inside turbo-generator. Rotors emit noise by its nature and the noise should be reduced to allowable limits as a result of installation at a site. Also limiting the exposure to the noise of workers engaged to ensure working and maintenance of turbo-machinery at site.

[007] Turbo-generators are one of the most significant sources of noise at every site and occupy more space. Even a small noise reduction and occupied space reduction of turbo-generator will improve the environment in a power plant and its surroundings and is cost effective. Rotating speed of turbo-generator is around 3000 or 3600 RPM which leads to significant emission of noise from the fans employed inside the turbo-generator for ventilation purposes. The need for size and noise reduction has increased a lot recently and became a criteria compared by customers for placing an order on an original equipment manufacturer. Turbo-generators operate closer to habitat areas and some of them will serve in ships, submarines or petroleum platforms, so it is very important that optimum size is utilised like in the case of ships or sub-marines and emit less noise.

[008] Air-cooled generators are used in industrial power facilities because of their low maintenance costs and their simple operation and are operated during peak hours to supply daily load. Air-cooled generators usually generate more and it is a necessity to bring noise in to allowable limits by designing the source, absorption and cooling medium along with structural design to mitigate the noise.

[009] In a prior art, US6375416 B1, titled “Technique for reducing acoustic radiation in turbomachinery” an axial fan with a clearance between fan blades and the shroud. Fan and the shroud are two separate components and a clearance exists between them. But in present invention an integral shrouded axial fan is envisaged. Hub, vanes and shroud are integral part of the axial impeller fan.

[0010] In view of the above, there is requirement to devise an apparatus which can address the aforesaid shortcoming(s). Hence, the present invention has been introduced.

[0011] The information disclosed in this background of the disclosure section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.

OBJECTS OF THE INVENTION:
[0012] It is therefore the object of the present subject matter to provide compact and silent turbo generator, which can overcome the aforementioned and other drawbacks in prior arts.

[0013] Another object of present invention is to provide compact and silent turbo generator, which is designed compact in order to make use of optimum material, so that it can be manufactured at less cost without compromising on structural rigidity and strength.

[0014] Another objective of the present invention is to provide a silent turbo-generator, which can be installed in habituated areas and where there is a stringent noise limitation.

[0015] These and other objects and advantages of the present invention will be apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying drawings in which a preferred form of the present invention is illustrated.

SUMMARY OF THE INVENTION:
[0016] One or more drawbacks of conventional systems and process are overcome, and additional advantages are provided through the apparatus/composition and a method as claimed in the present disclosure. Additional features and advantages are realized through the technicalities of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered to be part of the claimed disclosure.

[0017] The analyses on vibration and strength by using the analysis model of a stator frame is performed to optimize the stator frame structure with the optimum mass of the generator. A sound-insulation configuration that can adequately reduce noise from a thin-walled stator frame is necessary.

[0018] The noise generated by turbo-generator can be broadly classified into two categories.
a. electromagnetic-vibration sound,
b. aerodynamic sound due to fluid flow.

[0019] Electro-magnetic vibration sound is generated when the stator core and stator coils are vibrated by rotating magnetic fields. The noise generated by this electromagnetic vibration is transmitted as solid-borne sound to the stator frame, where it becomes a noise source. In the case of a two-pole turbine generator, a double magnetic vibration is generated per revolution, so this vibrational frequency becomes about twice the rotational frequency.

[0020] Aerodynamic sound due to fluid flow is generated by rotation of fans attached to the ends of the rotor and rotation of the rotor itself as well as by cooling air flow circulating inside of the generator. Since a generator produces heat through various kinds of losses, internal fluid is circulated around the fans at the rotor ends. As a result of this circulation, aerodynamic sound is generated by the flow of cooling air inside the generator and the rotor itself also generates aerodynamic sound through its rotation.

[0021] Said object is achieved according to the invention by the features of principal claim. Further, particularly advantageous embodiments of the invention are disclosed in the sub-claims.

[0022] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

[0023] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure.

[0024] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS:
[0025] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods or structure in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which:

[0026] Figure 1 illustrates the cross-sectional view of clamping plate with embedded fingers.

[0027] Figure 2 illustrates the cross-sectional view of End-shield bearings assembly.

[0028] Figure 3 illustrates the cross-sectional view of Pedestal encapsulating coupling.

[0029] Figure 4A and 4B illustrates Compact rotor overhang.

[0030] Figure 5 illustrates the cross sectional view of Flanged cooler duct and cooler assembly integrated with turbo-generator.

[0031] Figure 6 illustrates the Strengthened enclosure for mounting control equipment.

[0032] Figure 7 illustrates the Water cooled stator winding.

[0033] Figure 8 illustrates the Shrouded axial fans.

[0034] Figure 9A and 9B illustrates the Assembled rotor.

[0035] Figure 10A and 10B illustrates the Compact aero-dynamic air guide ring.

[0036] Figure 11 illustrates the sectional view of Modular enclosure assembly and enclosure wall.
[0037] Figure 12 illustrates the exploded isometric view of turbo-generator.

[0038] Figure 13 illustrates the Cross-sectional view of turbo-generator.

[0039] The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S) OF THE PRESENT INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS:

[0040] While the embodiments of the disclosure are subject to various modifications and alternative forms, specific embodiment thereof have been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.

[0041] The present invention makes a disclosure regarding a technology pertinent to reduced size of turbo-generator and improving the noise reduction and absorption emitted by turbo-generator.

[0042] The Present invention relates to the compact and silent turbo-generator equipped with a clamping plate with embedded fingers (06), end-shield mounted bearings (09), en-capsulated rotor coupling inside top pedestal, compact rotor overhang, Modular enclosure (04) for mounting of control equipment on top of turbo-generator, compact aero-dynamic air guide ring (07), compact air cooler duct (11) without compromising on structural rigidity.
[0043] The Present invention further relates to the compact and silent turbo-generator equipped with water-cooled stator (02) for reducing fan capacity thus reducing the noise, shrink fitted shrouded fans (12) , aerodynamic air-guide ring (11) profile suiting to shrouded fans, modular acoustic enclosure in three parts fitted in all 3 directions, air-cooled rotor with compact rotor overhang for silent operation.

[0044] Now reference may be made to Figure-1 illustrating the design of clamping plate with embedded fingers (06). Usually additional fingers are welded to the clamping plate (06) for creating a clamping pressure on the core assembly and they occupy an additional 50 to 70 mm axially. The same is achieved by the embedded fingers in the clamping plate (06) resulting in reduction of axial space occupied by turbo-generator.

[0045] Now referring to Figure-2 showing the end-shield bearing assembly where bearing (09) is mounted on the end-shield plate (08) of the stator frame (01) and is occupying less space axially as a portion of bearing is inside stator frame (01) and there is not axial gap between stator frame (01) and bearings (09) as in case of pedestal mounted bearing.

[0046] Figure-3 illustrates the bearing pedestal encapsulating the coupling of the turbo-generator. Coupling outer diameter is acting as a seal ring step for the pedestal seal-ring and coupling side step outer diameter is acting as a seal ring step for the bearing shell seal-ring. Such arrangement is fulfilling the requirement of proper sealing of the circulating oil inside the bearings pedestal and occupying a compact space by reducing the axial length of the turbo-generator there by eliminating the coupling overhang. Necessary seal-rings are provided both on bearing shell and bearing pedestal to avoid oil leakage from the bearing.

[0047] Figure-4 illustrates the compact rotor overhang where axial shrouded fan (12) is placed strategically very near to retaining ring so that most of the air circulated due to the pressure head developed by rotation of fan is pumped in to the rotor of the turbo-generator. As the stator cooling is taken care by water cooling arrangement, this approach works. Due to the reduced length of rotor overhang, axial length of the turbo-generator is reduced.

[0048] Figure-5 illustrates a flanged air cooler duct (11) with cooler elements assembly to the duct and is bolted to the turbo-generator forming an integral part of the turbo-generator. Cooler duct is sized and the cooler elements are strategically located in such a way that the pressure head developed by the fan is sufficient to overcome the resistance offered to the flow due to this arrangement. Cooler elements are designed in such a way that it is bolted to the cooler duct from the front and back ends.

[0049] Figure-6 illustrates a rigid and strengthened enclosure assembly (04) capable of withstanding the control equipment mounted on top of the turbo-generator. Control equipment is bolted on to the plurality of pads located at the top of the enclosure.

[0050] Figure-7 illustrates a water cooled stator winding arrangement where heat generated by stator copper, laminations packets is carried away by water circulating inside the stator winding. Due to this, heat load to be catered by air is reduced and lesser size fan i.e. small outer diameter of fan is sufficient to dissipate the heat generated by rotor assemblies. Reduced diameter of the fan leads to lesser noise.

[0051] Figure-8 illustrates an integral shrouded axial fan (12) where a hub having a cylindrical inner surface for shrink fitting on the rotor, a plurality of circumferentially equally spaced thin vanes designed for pumping air into the turbo-alternator extending from hub towards the shroud, an aerodynamically designed shroud for enclosing the air passing through the shrouded axial fan (12).

[0052] Figure-9 illustrates the assembled rotor with shrouded fans (12) mounted close to the retaining ring.

[0053] Figure-10 illustrates a compact aero-dynamic air guide ring (07) designed in a compact way occupying very minimum space for guiding air into the shrouded fan (12) with minimum flow turbulences.

[0054] Figure-11 illustrates a modular enclosure assembly (04) consisting of three parts one central enclosure and two axial enclosures to attenuate noise generated inside the turbo-alternator. Axial enclosure are bolted to the stator frame (01) and central enclosure with the help of long nuts extending along the length of the axial enclosures. Enclosure walls are further divided in to three zone a. Enclosure plate, b. Empty space (air gap) and c. Rock-wool covered with a two layers of perforated sheet at both ends as shown in the sectional view in figure 10.

[0055] Figure-12 illustrates the Modular enclosure assembly (04) and enclosure wall sectional view.

[0056] Figure-13 illustrates the Cross-sectional view of turbo-generator.

[0057] The advantage of present Invention is that it utilizes optimum space and emits less noise.

[0058] The material above has been given as an example without restricting scope of the invention to the same. Thus, other materials readily apparent to a person skilled in the art are within scope of the invention.

[0059] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the “invention” may in some cases refer to certain specific embodiments only. In other cases, it will be recognized that references to the “invention” will refer to subject matter recited in one or more, but not necessarily all, of the claims.

[0060] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.

[0061] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particulars claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogues to “at least one of A, B and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B”.

[0062] The above description does not provide specific details of manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.

[0063] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.
[0064] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.

[0065] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

Claims:WE CLAIM :
1. A compact and silent turbo-generator comprising:
a Stator frame (01);
a Water cooled Stator core assembly (02);
a Rotor assembly (03);
a Modular enclosure assembly (04) for mounting control equipment;
a Thrust cum journal bearing (05);
a Clamping plate integrated pressing finger (06);
an Aerodynamic air guide ring (07);
an End-shield plate (08);
an End-shield mounted bearing (09);
a bearing sealing cover (10);
a Flanged cooler duct assembly (11);
a Shrouded axial fan (12);
wherein there is provision of a clamping plate with embedded fingers (06), end-shield mounted bearings (09), en-capsulated rotor coupling inside top pedestal, compact rotor overhang, Modular enclosure (04) for mounting of control equipment on top of turbo-generator, compact aero-dynamic air guide ring (07), compact air cooler duct (11);
water-cooled stator (02) for reducing fan capacity thus reducing the noise, shrink fitted shrouded fans (12) , aerodynamic air-guide ring (11) profile suiting to shrouded fans, modular acoustic enclosure in three parts fitted in all 3 directions, air-cooled rotor with compact rotor overhang for silent operation.

2. The turbo-generator as claimed in claim 1, wherein bearing (09) is mounted on the end-shield plate (08) of the stator frame (01) and is occupying less space axially as a portion of bearing is inside stator frame (01) and there is no axial gap between stator frame (01) and bearings (09).

3. The turbo-generator as claimed in claim 1 or 2, wherein Coupling outer diameter acts as a seal ring step for the pedestal seal-ring and coupling side step outer diameter acts as a seal ring step for the bearing shell seal-ring, wherein seal-rings are provided both on bearing shell and bearing pedestal to avoid oil leakage from the bearing.

4. The turbo-generator as claimed in claims 1-3 comprises rotor overhang where axial shrouded fan (12) is placed in proximity to retaining ring that most of the air circulated due to the pressure head developed by rotation of fan is pumped in to the rotor of the turbo-generator, in which the stator cooling is taken care by water cooling arrangement and due to the reduced length of rotor overhang, axial length of the turbo-generator is reduced.

5. The turbo-generator as claimed in claims 1-4 comprises a flanged air cooler duct (11) with cooler elements assembly to the duct and is bolted to the turbo-generator forming an integral part of the turbo-generator, wherein Cooler duct is sized and the cooler elements are located that the pressure head developed by the fan is sufficient to overcome the resistance offered to the flow due to this arrangement, in which Cooler elements are designed that it is bolted to the cooler duct from the front and back ends.

6. The turbo-generator as claimed in claims 1-5, wherein an enclosure assembly (04) capable of withstanding the control equipment is mounted on top of the turbo-generator, in which Control equipment is bolted on to the plurality of pads located at the top of the enclosure.

7. The turbo-generator as claimed in claims 1-6 comprises a water cooled stator winding arrangement where heat is generated by stator copper, laminations packets is carried away by water circulating inside the stator winding, due to which, heat load to be catered by air is reduced and lesser size fan is sufficient to dissipate the heat generated by rotor assemblies.
8. The turbo-generator as claimed in claims 1-7 comprises an integral shrouded axial fan (12) where a hub having a cylindrical inner surface for shrink fitting on the rotor, a plurality of circumferentially equally spaced thin vanes designed for pumping air into the turbo-alternator extending from hub towards the shroud and an aerodynamically designed shroud for enclosing the air passing through the shrouded axial fan (12).

9. The turbo-generator as claimed in claims 1-8 comprises assembled rotor with shrouded fans (12) mounted close to the retaining ring, and a compact aero-dynamic air guide ring (07) designed in a compact way occupying very minimum space for guiding air into the shrouded fan (12) with minimum flow turbulences.

10. The turbo-generator as claimed in claims 1-9, wherein a modular enclosure assembly (04) comprising of three parts one central enclosure and two axial enclosures to attenuate noise generated inside the turbo-alternator, in which Axial enclosure are bolted to the stator frame (01) and central enclosure with the help of long nuts extending along the length of the axial enclosures, in which Enclosure walls are divided in to three zone a. Enclosure plate, b. Empty space (air gap) and c. Rock-wool covered with two layers of perforated sheet at both ends.