ROTARY MACHINE WITH IMPROVED SHAFT

Abstract

A rotary machine is disclosed, which includes a rotary shaft having a rotation axis, a first shaft end, and a second shaft end; a first bearing arrangement at the first shaft end; a second bearing arrangement at the second shaft end; a coupling flange mechanically connected to the first shaft end. The coupling flange is mechanically connected to the first shaft end by means of a first axial-contact coupling.

Claims

1. A rotary machine comprising: a rotary shaft comprising a rotation axis, a first shaft end, and a second shaft end; a first bearing arrangement at the first shaft end; a second bearing arrangement at the second shaft end; and a coupling flange mechanically connected to the first shaft end; wherein the coupling flange is mechanically connected to the first shaft end by means of a first axial-contact coupling.

2. The rotary machine of claim 1, wherein the first axial-contact coupling comprises a first Hirth joint.

3. The rotary machine of claim 1, wherein the coupling flange has an outer flange diameter greater than a diameter of the first shaft end.

4. The rotary machine of claim 1, wherein the rotary shaft supports centrifugal impellers, the rotary machine being a centrifugal compressor.

5. The rotary machine of claim 1, wherein the coupling flange comprises connection members for mechanical connection to a motion transmission joint.

6. The rotary machine of claim 1, wherein: the first shaft end overhangs beyond the first bearing arrangement and is provided with a first set of radial teeth formed on a first annular front surface and having a first diametrical outer dimension; and the coupling flange comprises a second set of radial teeth, configured and arranged for meshing with the first set of radial teeth and formed on a second annular front surface on the flange and having a second diametrical outer dimension; and wherein the first diametrical dimension and the second diametrical dimension are smaller than the outer flange diameter.

7. The rotary machine of claim 1, wherein a tie rod and ring nut arrangement axially presses the coupling flange against the rotary shaft.

8. The rotary machine of claim 1, wherein the first bearing arrangement comprises a radial bearing, and wherein the second bearing arrangement comprises a radial bearing and a thrust bearing in combination.

9. The rotary machine of claim 1, wherein the second bearing arrangement comprises a thrust bearing comprised of a thrust collar, mounted for co-rotating with the rotary shaft and co-acting with stationary pads circularly arranged about the rotation axis of the rotary shaft; and wherein the thrust collar is mechanically coupled to the second shaft end by means of a second axial-contact coupling.

10. The rotary machine of claim 9, wherein the second axial-contact coupling comprises a second Hirth joint.

11. The rotary machine of claim 9, wherein the thrust collar is mounted on a shaft portion overhanging from a radial bearing of the second bearing arrangement.

12. The rotary machine of claim 9, wherein: the second shaft end overhangs beyond a radial bearing of the second bearing arrangement and is provided with a third set of radial teeth formed on a third annular front surface provided at the second shaft end and having a third diametrical outer dimension; the thrust collar comprises a fourth set of radial teeth, configured and arranged for mechanical coupling with the third set of radial teeth and formed on a fourth annular front surface formed on the thrust collar and having a fourth diametrical outer dimension; and wherein the third diametrical dimension and the fourth diametrical dimension are smaller than an outer diameter of the thrust collar.

13. A rotary machine comprising: a rotary shaft comprising a rotation axis, a first shaft end and a second shaft end; a first bearing arrangement at the first shaft end; and a second bearing arrangement at the second shaft end; wherein the second bearing arrangement comprises a thrust bearing comprised of a thrust collar, mounted for co-rotating with the rotary shaft and co-acting with stationary pads circularly arranged about the rotation axis of the rotary shaft; and wherein the thrust collar is mechanically coupled to the second shaft end by means of an axial-contact coupling.

14. The rotary machine of claim 13, wherein the axial-contact coupling comprises a Hirth joint.

15. A rotary machine shaft comprising: a first shaft end and a second shaft end; a first bearing portion, at the first shaft end, configured and arranged for support in a first radial bearing, the first shaft end extending beyond the first bearing portion; a second bearing portion, at the second shaft end, configured and arranged for support in a second radial bearing, the second shaft end extending beyond the second bearing portion; and a first surface of a first axial-contact coupling formed on one of the first shaft end and second shaft end.

16. The rotary machine shaft of claim 15, wherein the first surface of the first axial-contact coupling comprises a respective set of radial teeth of a Hirth joint.

17. The rotary machine shaft of claim 15, further comprising a first surface of a second axial-contact coupling formed on the other one of the first shaft end and second shaft end.

18. The rotary machine shaft of claim 17, wherein the first surface of the second axial-contact coupling comprises a respective set of radial teeth of a Hirth joint.

19. The rotary machine shaft of claim 15, further comprising at least one of: a coupling flange mechanically connectable to one of the first shaft end and the second shaft end, the coupling flange comprised of a second surface of the first axial-contact coupling, co-acting with the first surface of the first axial-contact coupling; and a thrust collar mechanically connectable to one of the first shaft end and the second shaft end, the thrust collar comprised of a second surface of the second axial-contact coupling, co-acting with the first surface of the second axial-contact coupling.

20. The rotary machine shaft of claim 19, wherein: the second surface of the first axial-contact coupling comprises a set of radial teeth of a Hirth joint; and/or the second surface of the second axial-contact coupling comprises a set of radial teeth of a Hirth joint.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] 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:

[0017] FIG. 1 schematically illustrates a motor-compressor unit, wherein the subject matter disclosed herein can be incorporated;

[0018] FIG. 2 illustrates a sectional view of an exemplary centrifugal compressor which can be used in a unit according to FIG. 1, and which is comprised of a rotary shaft and relevant impellers, as well as end bearing arrangements for the shaft;

[0019] FIG. 3 illustrates an enlargement of a first end of the rotary shaft of FIG. 2;

[0020] FIG. 3A illustrates an enlargement of a detail of FIG. 3;

[0021] FIG. 4 illustrates an enlargement of a second end of the rotary shaft of FIG. 2;

[0022] FIG. 4A illustrates an enlargement of a detail of FIG. 4.

DETAILED DESCRIPTION

[0023] The following detailed description of exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. Additionally, the drawings are not necessarily drawn to scale. Also, the following detailed description does not limit embodiments of the invention. Instead, the scope of the invention is defined by the appended claims.

[0024] 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 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.

[0025] The following description specifically relates to applications of the subject matter disclosed herein in combination with turbomachines, such as in particular centrifugal compressors. However, the scope of the disclosure is not limited to such machinery. Those skilled in the art will appreciate that applications to other rotary machines and equipment are possible, where similar problems arise in connection with the natural frequencies of the rotating components and which can be at least partly alleviated by using the teaching of the present disclosure.

[0026] In FIG. 1 a motor-compressor unit 1 is schematically shown, which includes a compressor 3, e.g. a centrifugal, high-speed compressor, and a driver, e.g. an electric motor 5. The centrifugal compressor 3 comprises a rotary shaft 7 supported in a compressor casing 9 for rotation around a rotation axis A-A by means of a first bearing arrangement 10 and a second bearing arrangement 11. Reference numbers 13 and 15 indicate a compressor inlet and a compressor outlet, respectively. The rotary shaft 7 is mechanically coupled to the electric motor 5 by means of a motion transmission joint 17, for instance a flexible motion transmission joint.

[0027] In FIG. 1 the compressor 9 is represented schematically. A possible embodiment of a centrifugal compressor which can be used in the unit 1 of FIG. 1 is shown in some more detail in a sectional view in FIG. 2. By way of example only the compressor 9 of FIG. 2 comprises two sections in a back-to-back configuration. Each section comprises a plurality of stages, the impellers whereof are arranged in a back-to-back relationship in order to reduce the axial thrust on the shaft.

[0028] As better shown in FIG. 2, the rotary shaft 7 can be comprised of one or more shaft portions 7X, 7Y, which can be axially and torsionally locked to one another.

[0029] In the exemplary embodiment disclosed herein, referring to FIG. 2 with continuing reference to FIG. 1, a plurality of impellers 21 are mounted on the rotary shaft 7 between the first bearing arrangement 10 and the second bearing arrangement 11. In a manner known to those skilled in the art and not described in detail herein, diffusers 23 and return channels 23, schematically shown in FIG. 2, are provided in the casing 9, which define a flow path for the fluid processed by compressor 3. A first shaft end 7A is supported in the first bearing arrangement 10 and a second shaft end 7B is supported in the second bearing arrangement 11.

[0030] In the exemplary embodiment of FIG. 2, the first shaft end 7A is arranged at the drive end side of the compressor 3, i.e. the side of the compressor which is mechanically coupled to the electric motor 5. The second shaft end 7B is arranged at the non-drive end side of the compressor 3, i.e. the side opposite the electric motor 5.

[0031] Sealing members, such as dry-gas sealing arrangements schematically shown at 25, 27 are provided in the compressor casing 9, to reduce or prevent fluid leakages from the interior of compressor 3 towards the bearing assemblies 10 and 11.

[0032] Referring now to FIGS. 3 and 3A, with continuing reference to FIGS. 1 and 2, according to some embodiments the first bearing arrangement 10 comprises a first radial bearing, for instance a hydrodynamic radial bearing 10A, which is located adjacent the first shaft end 7A. The rotary shaft 7 comprises a bearing portion 7C forming a journal co-acting with bearing shoes of the radial bearing that surround the journal. The first shaft end 7A projects with an overhanging terminal portion beyond the radial bearing 10A and the journal 7C.

[0033] A coupling flange 31 is mechanically connected to the first shaft end 7A. The coupling flange 31 has an outer flange diameter D31 which is larger than the outer diameter D7A of the first shaft end 7A. Connection members 33, such as bolts or the like, can be circularly arranged about the rotation axis A-A of the compressor 9, for mechanically connecting the coupling flange 31 to the motion transmission joint 17. This latter can be comprised of a rigid central bush-shaped member 17A, which is connected, through axially spaced resilient members 17B, 17C, to respective end rings 17D, 17E. The ring 17D is in turn mechanically coupled to the coupling flange 31.

[0034] The coupling flange 31 is mechanically coupled to the first shaft end 7A by means of an axial-contact coupling. According to the embodiment shown in FIGS. 3 and 3A, the axial-contact coupling is comprised of a Hirth joint 35. The mechanical axial-contact coupling embodied by the Hirth joint is best shown in the enlargement of FIG. 3A, where the first shaft end 7A and the coupling flange 31 are shown in isolation and separate from one another.

[0035] In the embodiment of FIGS. 3, 3A, the first shaft end 7A is provided with a first annular front surface 37, whereon a first set of radial teeth 39 is formed. The coupling flange 31 is in turn comprised of a second set of radial teeth 41 formed on a second annular front surface 43. The radial teeth 39 and 41 mesh with one another, forming the Hirth joint 35. The outer diameter of the first annular front surface 37 and the outer diameter of the second front surface 43 can be identical, as shown in the exemplary embodiment illustrated in the figures, where said outer diameter is labeled D35. The outer diameter D35 is smaller than the outer diameter of the outer flange diameter D31.

[0036] The coupling flange 31 can be mounted on the first shaft end 7A by means of a tie rod 45 and a ring nut 47 (FIG. 3). The end portions of the tie rod 45 are threaded. A first end portion is treadedly engaged in a threaded axial hole of shaft 7, while a second end portion of the tie rod 45 is threadedly engaged by the ring nut 47. The tie rod 45 and ring nut 47 axially press the radial teeth 39 and the radial teeth 41 in meshing engagement with one another.

[0037] The axial-contact coupling provided by the Hirth joint 35 in combination with the coupling flange 31 provide a mechanical coupling between the rotary shaft 7 and the motion transmission joint 17. By means of the axial-contact mechanical coupling between shaft 7 and motion transmission joint 17, the shaft end 7A is made substantially shorter than shaft ends of the current art, which are required for mechanical coupling using a radial interference involving conical interference surfaces.

[0038] According to some embodiments, compared with current art couplings, the other dimensions being the same, the use of a Hirth joint can reduce the length of the shaft portion overhangingly projecting beyond the first bearing arrangement 10 by around 38%, which in turn reduces the overhanging mass (i.e. the mass of the shaft end portion projecting in an overhanging fashion from the first bearing arrangement 10) by around 49%. An increase of the fourth natural frequency of the rotary shaft 7 can thus be obtained, such that the centrifugal compressor 3 can rotate at a higher speed without reaching the fourth critical speed. Similar results can be achieved also with other axial-contact couplings, e.g. using simple friction surfaces, rather than a Hirth joint. This latter, however, is particularly advantageous since the teeth of the Hirth joint allow a high torque to be transmitted through the joint.

[0039] Referring now to FIG. 4, with continuing reference to FIG. 2, adjacent the second shaft end 7B the rotary shaft 7 is supported by the second bearing arrangement 11, which can comprise a second radial bearing, for instance a hydrodynamic radial bearing 11A. The rotary shaft 7 can be comprised of a bearing portion 7D forming a journal which co-acts with shoes of the hydrodynamic radial bearing 11A. The second shaft end 7B projects with an overhanging terminal portion beyond the radial bearing 11A and the journal 7D.

[0040] The second bearing arrangement 11 can further comprise a thrust bearing, i.e. an axial bearing, labeled 11B. The thrust bearing comprises a thrust collar 51 mounted on the second end 7B of rotary shaft 7 for co-rotation with rotary shaft 7, and co-acting with stationary pads 53, 55 supported in a bearing housing. The thrust collar 51 is mechanically coupled to the second shaft end 7B by means of a respective axial-contact coupling. According to embodiments, the axial-contact coupling comprises a Hirth joint 56. The thrust collar 51 has an outer diameter D51, which can be larger than the diameter of the shaft end 7B.

[0041] FIG. 4A illustrates an enlargement of the thrust collar 51 and of the terminal portion of the shaft end 7B in a disassembled condition. As best shown in FIG. 4A, according to some embodiments the Hirth joint 56 comprises a set of radial teeth 57 formed on an annular front surface 59 provided at the second shaft end 7B. The Hirth joint 56 further comprises a further set of radial teeth 61 formed on a further annular front surface 63 formed on the thrust collar 51. The sets of radial teeth 57, 61 are configured for meshing with one another and mounted in meshing engagement by means of a tie rod 65 and a nut 67, which threadedly engages the tie rod 65, such that the radial teeth 57 and the radial teeth 61 are pressed in mechanical engagement with one another.

[0042] The Hirth joint 56 has an outer diameter D56 which is larger than the outer diameter D51 of the thrust collar 51.

[0043] By using an axial-contact coupling, instead of a radial interference coupling of the current art, for coupling the thrust collar 51 to the second shaft end 7B, the length of the shaft end portion, which overhangingly projects beyond the second bearing arrangement 11, becomes substantially shorter.

[0044] According to some embodiments, compared with current art couplings, the other dimensions being the same, the use of an axial-contact coupling, e.g. provided by a Hirth joint for connecting the thrust collar 51 to the rotary shaft 7 can reduce the length of the shaft portion projecting beyond the second bearing arrangement 11 by around 23%, which in turn reduces the overhanging mass (i.e. the mass of the shaft end portion projecting in an overhanging fashion from the second bearing arrangement 11) by around 19%. An increase of the fourth natural frequency of the rotary shaft 7 can thus be obtained.

[0045] Even though in the embodiment described herein two axial-contact couplings, both embodied by Hirth joints 35, 56 are used in order to reduce the overhanging mass on both the drive end side and the non-drive end side of the centrifugal compressor 3, those skilled in the art will understand that advantages in terms of rotor dynamic and increase of the natural speeds of the higher order (above the first critical speed) of the rotary shaft 7 can be achieved also if only one axial-contact coupling is used, e.g. on the first shaft end 7A, or else only on the second shaft end 7B, the other shaft end being provided with a radial interference coupling using a conical interference connection according to the current art. Best performances are obtained, if both the first shaft end 7A and the second shaft end 7B are provided with axial-contact couplings for connecting the coupling flange 31 and the thrust collar 51 to the rotary shaft ends 7A and 7B, respectively.

[0046] It shall also be understood that, while in the above description and in the drawings both axial-contact couplings are embodied by Hirth joints, in other embodiments two different axial-contact couplings can be used instead, for instance a Hirth joint at one end and an axial friction contact at the other.

[0047] While the disclosed embodiments of the subject matter described herein have been shown in the drawings and fully described above with particularity and detail in connection with several exemplary embodiments, it will be apparent to those of ordinary skill in the art that many modifications, changes, and omissions are possible without materially departing from the novel teachings, the principles and concepts set forth herein, and advantages of the subject matter recited in the appended claims. Hence, the proper scope of the disclosed innovations should be determined only by the broadest interpretation of the appended claims so as to encompass all such modifications, changes, and omissions. In addition, the order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments.