METHOD FOR OPERATING A TRAIN SYSTEM FOR A MECHANICAL DRIVEN EQUIPMENT
20230366452 · 2023-11-16
Inventors
Cpc classification
F02C7/36
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/34
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2260/4031
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2220/76
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H3/724
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2270/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D15/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2260/40311
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H3/725
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D15/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F16H3/72
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A method of operating a train system for driving a mechanical driven equipment is disclosed. The train system comprises a hybrid gearbox connected between a power source and a load to be driven. The hybrid gearbox includes a lay shaft gear, which transmission ratio between the power source and the load and a motor-generator unit can be adjusted, to adjust the transmission speed ratio, arranged to balance the power generated by the power source and transmitted to the load.
Claims
1. A method for operating a train system comprising the steps of: generating power by a power source; transmitting the power generated by the power source through a drive arrangement including: an input shaft connected to the power source; an output shaft; and a hybrid gearbox comprising layshaft gearbox, connected to the input shaft and to the output shaft, and comprising a star carrier configured to adjust the transmission speed ratio of the layshaft gearbox between the input shaft and the output shaft, and a speed ratio motor-generator unit, configured to control the rotation of the star carrier; driving an equipment connected to the output shaft; and, operating the speed ratio motor-generator unit to start up the power source, and then to decouple the load from the power source, to adjust the rotation of the star carrier to set the transmission speed ratio of the layshaft gearbox so as to adjust the speed and the torque at the output shaft when the power sources is operated at constant speed j),
2. The method of claim 1, wherein the power source is a single-shaft gas turbine, wherein the operating step comprises the sub-steps of: operating the speed ratio motor generator unit as a motor to bring the gas turbine to its crank speed; switching-off the speed ratio motor generator unit to decouple the single-shaft gas turbine to accelerate and to reach its nominal speed, so that the star carrier is free to spin; and, operating the speed ratio motor-generator unit as generator and slow-down the star carrier to increase the output shaft speed from stand-still condition.
3. The method of claim 2, further comprising the step of operating the speed ratio motor-generator unit as motor increasing the speed of the star carrier in an opposite direction than the operating step.
4. The method of claim 2, further comprising the step of blocking the output shaft during the start-up phase of the power source by a power balance motor-generator unit associated to the output shaft.
5. The method according to claim 1, wherein the power source is an electric motor, wherein the operating step comprises the sub-steps of: operating the speed ratio motor generator unit as a motor to bring the electric motor to a predefined speed to ovoid sub-synchronous torsional interactions with the train torsional natural frequencies; switching-off the speed ratio motor generator unit to decouple the electric motor to accelerate and to reach its nominal speed, so that the star carrier is free to spin; and, operating the speed ratio motor-generator unit as generator and slow-down the star carrier to increase the output shaft speed from stand-still condition.
6. The method according to claim 1, wherein the power source is a reciprocating engine, wherein the operating step comprises the sub-steps of: operating the speed ratio motor generator unit as a motor to bring the reciprocating engine to the minimum operating speed; switching-off the speed ratio motor generator unit to decouple the reciprocating engine to accelerate and to reach its nominal speed, so that the star carrier is free to spin; and, operating the speed ratio motor-generator unit as generator and slow-down the star carrier to increase the output shaft speed from stand-still condition.
7. A computer program, comprising instructions which, when the program is executed by a computer, causes the computer to carry out the operating step of the method of claim 1.
8. A computer-readable storage medium, comprising the instructions which, when executed by a computer, cause the computer to carry out the operating step of the method of claim 1.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] A more complete appreciation of the disclosed embodiments of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0020]
[0021]
[0022]
[0023]
[0024]
[0025]
[0026]
[0027]
DETAILED DESCRIPTION OF EMBODIMENTS
[0028] In mechanically driven equipment, a power source, such as a gas turbine, an electric motor, a diesel engine, a gas engine and the like, has to be connected to a load. The connection takes place by a transmission system, which can vary its transmission speed ratio, to vary the driven equipment speed, according to any possible operating circumstances, such as at the startup phase. The transmission system comprises a variable transmission gearbox. The transmission speed ratio of the variable speed gearbox is adjusted by a motor-generator unit, integrated in an annular way with the star carrier of the variable speed gearbox, which can be operated either as a motor or as a generator, to adjust the speed ratio of the gearbox thus allowing the decoupling of the power source from the load, until the power source itself reaches the so called crank speed, preventing any nonlinear power transmission during the above mentioned start-up phase.
[0029] Referring now to the drawings,
[0030] In particular, the train system T comprises a power source 2, a drive arrangement 1, connected through an input shaft 3 to the power source 2, and a load L, in its turn connected to the drive arrangement 1 through an output shaft 5. Also, the drive arrangement 1 comprises a hybrid gearbox 4, configured to transmit the torque from the input shaft 3 to the output shaft 5.
[0031] The drive arrangement 1 also comprises a control unit 7, which is a computer, and a power balance motor-generator unit 6, which is associated with the output shaft 5. The control unit 7 is operatively connected to the hybrid gearbox 4, and to the second motor-generator unit 6, to adjust the power transmitted to the load L, in terms of torque C.sub.o and rotational speed ω.sub.o. Furthermore, the control unit 7 is connectable to an electricity grid or battery packs N, as better explained below.
[0032] The power source 2 can be of any type used in the field of mechanically driven equipment. In particular, it can be a gas turbine, of double-shaft type, thus capable of varying its rotation speed, or single-shaft type, thus operating at a fixed speed. Alternatively, the power source 2 can also be an electric motor, a steam turbine, an expander, a diesel engine, or a gas engine. The power source 2 is capable of delivering a torque, indicated with C.sub.i to rotate the input shaft 3 at a rotational speed ω.sub.i.
[0033] The hybrid gearbox 4 comprises a layshaft gearbox 41 and a speed ratio motor-generator unit 42. The structure of the embodiment of the layshaft gearbox 41 is described in the following. Then an embodiment as to how the speed ratio motor-generator unit 42 is associated with the layshaft gearbox 41 and operates it is also disclosed.
[0034] Referring also to
[0035] The body 4131 of the star carrier 413 houses the input sun wheel 411 and the compound star wheel shafts 412. Each compound star wheel shaft 412 is pivoted about the body 4131 of the star carrier 413.
[0036] The layshaft gearbox 41 comprises also an output sun wheel 414, connected to the output shaft 5, and meshed with the second gear stage 4122 of each compound star wheel shafts 412. The output sun wheel 414 is also housed within the body 4131 of the star carrier 413.
[0037] In the embodiment illustrated in
[0038] In the embodiment illustrated in
[0039] Also, in the embodiment illustrated in
[0040] The embodiment of the speed ratio motor-generator unit 42 of
[0041] In operation, by the speed ratio motor-generator unit 42 is possible rotating (or controlling the rotation) of the star carrier 413, with respect to the input sun wheel 411 and the output sun wheel 414, thus, adjusting the rotation speed ω.sub.o and the torque C.sub.o of the output shaft 5, which is connected, as said above, to the output sun wheel 414.
[0042] Since the speed ratio motor-generator unit 42 is arranged directly around the star carrier 413, high compactness of the assembly is obtained. Furthermore, as can be seen, the layshaft gearbox 41 is not blocked, but its movement is controlled, namely, the relative rotation with respect to the input 3 or the output 5 shaft, by means of the speed ratio motor-generator unit 42. Furthermore, since the layshaft gearbox 41, or more precisely the star carrier 413, is not blocked, it is possible not to transmit the torque to the output shaft 5 when the speed ratio motor-generator unit 42 is switched-off, so that the power source 2 does not encounter any resistant torque of the load L. As will be seen below, this aspect avoids the insertion of clutches in the kinematic chain and allows high design freedom.
[0043] The speed ratio motor-generator unit 42 is a low voltage motor-generator unit that can operate both as an electric motor and as a generator, as disclosed above, to control the rotation of the star carrier 413. When the speed ratio motor-generator unit 42 is in generator mode, the drive arrangement 1 is delivering electric current to a grid N or battery systems recovering part of the driver output power, according to the following balance equation
C.sub.iω.sub.i=C.sub.cω.sub.c+C.sub.oω.sub.o
[0044] Where c.sub.C and ω.sub.C are the torque and the rotation speed respectively, and their product is the power delivered to the grid N or the battery pack.
[0045] When the speed ratio motor-generator unit 42 is in motor mode, the drive arrangement 1 is absorbing electric current from a grid or battery systems superimposing its power to the driver output power, according to the following equation:
C.sub.iω.sub.i+C.sub.cω.sub.c=C.sub.oω.sub.o
[0046] The control unit 7 is connected to the speed ratio motor-generator unit 42 and controls and adjusts its rotation. In particular, as will be better described below, by adjusting the rotation of the star carrier 413 by means of the speed ratio motor-generator unit 42, the torque and speed transmitted to the load L can be adjusted accordingly.
[0047] The drive arrangement 1 includes, as mentioned above, the power balance motor-generator unit 6, which is an electric motor associated with the output shaft 5, to adjust its rotation. The power balance motor-generator unit 6 can be of various types. In embodiments, the power balance motor-generator unit 6 comprises or is constituted of a plurality of permanent magnets 4211, installed on the outside diametral surface of the output shaft 5, or it can be of the same speed ratio motor-generator unit 42 technology.
[0048] Also, the power balance motor-generator unit 6 is a low voltage motor-generator machine capable of operating either as an electric motor, thus acting on the movement of the output shaft 5, or as a generator, thus absorbing (at least part of) the power on the input shaft 3, thus generating electric current. The operation shift from electric motor or generator of the power balance motor-generator unit 6 is controlled by the control unit 7, as better defined below.
[0049] To describe the operation of the drive arrangement 1, the operation of the hybrid gearbox 4 of
[0050] The operation of the hybrid gearbox 4 is as follows. Referring to
[0051] Accordingly, if the output shaft 5 is blocked while the input shaft 3 rotates at a certain rotation speed ω.sub.i, the star carrier 413 will rotate in the direction according to arrow E.
[0052] The operation of the drive assembly 1 is coordinated by the control unit 7, which can be configured as Active Front-End Variable Frequency Drive. In some embodiments, the control unit 7 may be realized or implemented as a cloud computing system, a computer network, or other installations capable of processing data by running appropriate computer programs.
[0053] In some embodiments, and particularly referring to
[0054] Based of the above, the operation of the drive assembly 1 is now described in different configurations, in order to better appreciate the performance and illustrate the operating method of the same. More specifically, the configuration of the drive assembly 1 according to
[0055] The method of operating the train system T, and in particular, the drive assembly 1, allows the latter to operate both with single-shaft gas turbines or with any other fixed speed driver, like synchronous or induction electric motors, as power source 2, which, as known, cannot change the rotation speed, as well as with double-shaft gas turbines, steam turbines, expanders, VFD electric motors, diesel and gas engines as power source 2. The operating method of the drive assembly 1 is described in case of the power source 2 is a single-shaft gas turbine, and in case of the power source 2 is a double-shaft gas turbine or any variable speed driver, discussing the technical and design advantages in any of the cases.
[0056] If the power source 2 is a single-shaft gas turbine, the drive assembly 1 can start-up the gas turbine from stand-still condition up to its crank speed, and disconnect the load L during the gas turbine 2 acceleration phase from its crank speed to the gas turbine nominal speed (thus decoupling the load L from the power sources), then it will rump-up the load L to bring the driven equipment to its operating speed and finally regulate the driven equipment speed within its operative speed range.
[0057] By means of the drive assembly 1, and referring again to
[0058] Then the speed ratio motor-generator unit 42 is switched-off, so that the single-shaft gas turbine 2 can accelerate to reach its nominal speed without any resistant torque coming from the load L. In this phase the output shaft 5 is decoupled from the input shaft 3 (and then from the power source 2) so that the star carrier 413 is left free to spin (usually called “free spinning mode”) and the torque transmitted to the load L is virtually zero.
[0059] In some embodiments, the output drive shaft 5 can be also blocked by means of the power balance motor-generator unit 6, which, as said, is controlled by the control unit 7. In this way, during the acceleration of the gas turbine 2, it is ensured that it is only the layshaft gearbox 41, and in particular, the rotation of the star carrier 413, able to compensate the speed increase of the gas turbine 2 and of the input shaft 3. In this configuration, the power balance motor-generator unit 6 allows the total control of torque transmission by the rotation of the star carrier 413.
[0060] The torque is then gradually transmitted to the load L by means of said control unit 7, which allows the rotation of the output shaft 5 by means of the speed ratio motor-generator unit 42. The speed ratio motor-generator unit 42 acts as generator and slow-down the star carrier 413 from its “free spinning mode”. With the power source 2 at its nominal running speed any reduction of star carrier 413 speed from its “free spinning mode” will results in an increase of the output shaft 5 speed from stand-still condition (the power balance motor-generator unit 6 will be switched-off to keep the output shaft 5 free to rotate or act as an helper if requested). The star carrier 413 speed will be further reduced from its “free spinning mode” up to zero speed by the action of the speed ratio motor-generator unit 42, which continue to act as generator, and then the star carrier 413 speed will be increased in opposite rotation direction (in the direction according to arrow D of
[0061] The layshaft gearbox 41 will be cinematically designed in order to bring the driven equipment to an operating point inside its operative speed range when the star carrier 413 speed is zero, so that the speed ratio motor-generator unit 42 will be able to regulate the driven equipment speed within its operative speed range, alternatively acting as generator, up to a maximum speed of the star carrier 413 in the direction according to arrow E, which will correspond to the driven equipment at minimum operative speed (MOS); or acting as motor up to a maximum speed in the direction according to arrow D, which will correspond to the driven equipment at maximum continuous speed (MCS).
[0062] Referring to
[0063] Referring to
[0064] Also, the method 8 for operating the train system T further comprises the sub step of operating 844 the speed ratio motor-generator unit 42 as motor, to increase the speed of star carrier 413 in an opposite direction then the step 843, so as to further increase the speed of the output shaft 5.
[0065] Finally, a blocking step 85 of the output shaft 5 during the start-up phase of the power source 2 by a power balance motor-generator unit 6 associated to the output shaft 5 can be included.
[0066] The drive assembly 1 disclosed herein is capable of adapting its operation also in case of a double-shaft gas turbine as power source 2. In particular, in this case, a double-shaft gas turbine optimizes its efficiency when operates at the maximum power and speed. In this case, in fact, the corresponding pollution (in particular the emitted CO.sub.2) is proportionally minimized per kilowatt (kW) generated. Therefore, operating the double-shaft gas turbine to the maximum power and speed, the rotational speed ω.sub.i of the input shaft 3 is fixed. The output shaft 5 rotational speed ω.sub.o can be adjusted by the star carrier 413 by means of the speed ratio motor-generator unit 42.
[0067] The power balance motor-generator unit 6 adjusts, by means of the control unit 7, the power absorbed by the load L, if operated as a generator, absorbing part of the torque transmitted to the output shaft 5. Therefore, part of the power generated by the power source 2 can be recovered by the power balance motor-generator unit 6 and transformed in electrical energy. The electrical energy generated by the power balance motor-generator unit 6 can be then either injected into the electricity grid N or injected into a battery system for future use, thus balancing the power to be transmitted to the load L and, at the same time, recovering the energy produced in excess by the power source 2.
[0068] Further, in case, for example, the load L requires additional power at different operating speed, the control unit 7 can either increase the speed output shaft 5 rotational speed ω.sub.o by adjusting the rotation of the star carrier 413, and/or reduce the torque (and therefore the power) absorbed by the power balance motor-generator unit 6.
[0069] Further, in case, for example, the load L requires a different power at constant operating speed, the control unit 7 can adjust the torque (and therefore the power) absorbed by the power balance motor-generator unit 6, or deliver, if needed a net power to the output shaft 5, acting as motor, to compensate the overall power balance.
[0070] Referring to
[0071] Referring to
[0072] Referring to
[0073] In case of the drive source 2 is an electric motor, synchronous or induction electric motor, at the start it is necessary provide a peak power to overcome the inertia of the load L. This requires that the electric motor is oversized in terms of power, just to compensate for this power need in the start-up phase. This causes an increase in the cost of the component.
[0074] In case of the drive source 2 is a synchronous electric motor, its pulsating torque at the start-up will cross the train TNF's (typically the first and second train torsional frequencies), thus resulting in a heavy torque response, in resonance, which can limit the number of start-ups due to fatigue phenomena.
[0075] The hybrid gearbox 4, will be able to start-up the electric motor through the operation of the speed ratio motor-generator unit 42 decoupling the load L thus avoiding to oversize the electric motor as power source 2 and at the same time avoiding the torsional interaction with train torsional natural frequencies. In fact, exciting the train torsional natural frequencies results dangerous torque responses at the torque transmission devices, such as couplings and shafts.
[0076] The same method steps can be applied for starting up a reciprocating engine, namely a gas engine or a diesel engine, avoiding to install a dedicated starting device.
[0077] While aspects of the invention have been described in terms of various specific embodiments, it will be apparent to those of ordinary skill in the art that many modifications, changes, and omissions are possible without departing form the spirt and scope of the claims. In addition, unless specified otherwise herein, the order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments.
[0078] Reference has been made in detail to embodiments of the disclosure, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the disclosure, not limitation of the disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure. Reference throughout the specification to “one embodiment” or “an embodiment”or “some embodiments” means that the particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrase “in one embodiment” or “in an embodiment” or “in some embodiments” in various places 5 throughout the specification is not necessarily referring to the same embodiment(s). Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
[0079] When elements of various embodiments are introduced, the articles “a”, “an”, “the”, and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.