SYSTEM AND METHOD TO ALIGN VARIABLE DIFFUSER VANE WITH DIRECTION OF FLOW OF WORKING FLUID
Embodiments of systems and methods permit use of variable diffuser vanes in multi-stage compressor devices. These embodiments deploy a flow sensor to identify the direction of flow for a working fluid that transits the stages of the compressor device. In one embodiment, the flow sensor generates a signal, which a controller processes to align a variable diffuser vane with the direction of flow of the working fluid. This configuration pre-empts the operational difficulties of previous designs by providing independent control over the diffuser vanes in the individual stages of the multi-stage compressor device.
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The subject matter disclosed herein relates to compressor devices (e.g., centrifugal compressors) and, in particular, to diffusers and diffuser vanes for a compressor device.
Compressor devices (e.g., centrifugal compressors) use a diffuser assembly to convert kinetic energy of a working fluid into static pressure by slowing the velocity of the working fluid through an expanding volume region. An example of a diffuser assembly typically utilizes several diffuser vanes in circumferential arrangement about an impeller. The design (e.g., shapes and sizes) of the diffuser vanes, in combination with the preferred orientation of the leading edge and the trailing edge of the diffuser vanes with respect to the flow of the working fluid, often determine how the diffuser vanes are affixed in the diffuser assembly.
To add further improvement and flexibility to the design, some examples of a diffuser assembly incorporate variable diffuser vanes. These types of diffuser vanes move to change the orientation of the leading edge and the trailing edge. This feature helps to tune operation of the compressor device. Known designs for variable diffuser vanes rotate about an axis that resides in the lower half, i.e., closer to the leading edge than the trailing edge of the diffuser vanes.
Some configurations of compressor devices do not comport with use of variable diffuser vanes. Multi-stage compressors, for example, often forego use of variable diffuser vanes because of problems with maintaining desired flow and pressure rates for the working fluid; namely, that use of variable diffuser vanes can reduce the operating range of the multi-stage compressor device.
BRIEF DESCRIPTION OF THE INVENTIONThis disclosure describes embodiments of systems and methods that permit use of variable diffuser vanes in multi-stage compressor devices. These embodiments deploy a flow sensor in combination with a variable diffuser vane to align the variable diffuser vane with the direction of flow of the working fluid. This configuration pre-empts the operational difficulties of previous designs by providing independent control over the diffuser vanes in the individual stages of the multi-stage compressor device.
Reference is now made briefly to the accompanying drawings, in which:
Where applicable like reference characters designate identical or corresponding components and units throughout the several views, which are not to scale unless otherwise indicated.
DETAILED DESCRIPTION OF THE INVENTIONEmbodiments of the compressor device 100 find use in a variety of settings and industries including automotive industries, electronics industries, aerospace industries, oil and gas industries, power generation industries, petrochemical industries, and the like. During one implementation, the shaft 128 transfers power from the drive unit 126 to rotate the first impeller 110 and the second impeller 112. Rotation of the first impeller 110 draws a working fluid (e.g., air) through the inlet 102. In the first stage 106, the first impeller 110 compresses the working fluid. The compressed working fluid flows into the first diffuser assembly 114, which allows the working fluid to expand before the working fluid enters the second stage 108. In the second stage 108, the working fluid undergoes compression and expansion by, respectively, the second impeller 112 and the second diffuser assembly 116. In one embodiment, the compressor device 100 can couple at the outlet 104 with industrial piping to expel the working fluid under pressure and/or with certain designated flow parameters as desired.
Examples of the diffuser vanes 118, 120 can move (e.g., rotate) from one position (e.g., a first position) to another position (e.g., a second position), and vice versa. Movement between the first position and the second position allows the diffuser vanes 118, 120 to align with the direction of flow of the working fluid. This feature avoids flow separation of the working fluid from the surfaces of the diffuser vane 118, 120.
The flow sensors 122, 124 monitor the direction of flow of the working fluid upstream of the diffuser vanes 118, 120. As the direction of the flow changes, e.g., due to changes in operation of the compressor device 100, the flow sensor 122 will generate a signal. Examples of the signal convey information to indicate the extent, direction, and other characteristics relevant to the direction of the flow. The controller 132 can process this signal and, in response, generate an output to impart changes to the position of the diffuser vanes 118, 120. In one example, the output encodes instructions to move the actuators 134, 136 which in turn causes the diffuser vanes 118, 120 to change position, e.g., from the first position to the second position.
As shown in
The controller 132 can comprise computers and computing devices with processors and memory that can store and execute certain executable instructions, software programs, and the like. The controller 132 can be a separate unit, e.g., part of a control unit that operates the compressor device 100 and other equipment. In other examples, the controller 132 integrates with the compressor device 100, e.g., as part of the hardware and/or software configured on such hardware. In still other examples, the controller 132 can be located remote from the compressor device 100, e.g., in a separate location where the controller 132 can issue commands and instructions using wireless and wired communication, e.g., via the network 124.
Examples of the system 130 orient one or both of the diffuser vanes 118, 120 to modify flow and expansion that occurs as the working fluid transits the corresponding diffuser assemblies 114, 116. By utilizing separate flow sensors 122, 124 to measure the direction of flow upstream of the respective diffuser vanes 118, 120, the system 130 can account for variations in flow that occur from stage to stage, e.g., from stage 106 to stage 108. The system 130 can use the information about the direction of flow to instruct the actuators 134, 136 to place the diffuser vanes 118, 120 in different positions relative to one another. This feature effectively decouples operation of the compressor device 100 in the first stage 106 from the second stage 108, which allows the diffuser vanes 118, 120 to operate independent of one another and, in one example, independent of additional stages without having an adverse effect on overall performance of the compressor device 100.
In one embodiment, the first signal (e.g., at step 202) and the second signal (e.g., at step 204) indicate the position of the first flow sensor and the second flow sensor. To illustrate,
The flow sensor 304 can move and, in one example, the directional element 308 rotates relative to the base element 306 to indicate the direction of flow F. Examples of the base element 306 can secure to components of the diffuser assembly 300. These components can include wall members, frame member, and other structure (e.g., volute) that can position the flow sensor 304 in the flow of the working fluid. For example, the flow base element 306 can reside a bore and/or counter bore in such structure to position the directional element 308 in the flow path. Examples of the base element 306 can include a pin and/or other bearing element, which receives the directional element 308. The pin acts as a pivot about which the directional element 308 can freely rotate. When placed in the path of flow F, the directional element 308 will align with the direction of the flow F. In one example, the base element 306 can comprise a rotary potentiometer and/or other like devices that can measure angular displacement. The rotary potentiometer can couple with the directional element 308 to register changes in the position of the directional element 308 in response to the direction of flow F.
With reference to
Examples of the first signal and/or the second signal can encode information to identify the position and/or the relative change in position of the directional element 308. In one example, the first signal and the second signal may encode an angular position to each of the first sensor position 322 and the second sensor position 324. Examples of the angular position can utilize a radial scale that covers 360°, wherein the first position 322 and the second position 324 assume different values on the radial scale, e.g., 0° for the first position 322 and 300° for the second position 324. In other examples, the first signal and the second signal my encode an angular offset to each of the first sensor position 322 and the second sensor position 324. The angular offset can define a value, e.g., a radial value, on the radial scale by which the first sensor position 322 and the second sensor position 324 deviate relative to a fixed or home position. For purposes of the present example of
The steps for identifying a first position (e.g., at step 206) for the diffuser vane 302 can use the information in the first signal and the second signal to align the diffuser vane 302 with the direction of flow F. In this connection,
Implementations in which the trailing edge 314 rotates the leading edge 312 are advantageous to accommodate the first flow direction F1 and the second flow direction F2. As shown in the example of
In the example of
Examples of the diffuser vane 302 can comprise various materials and combinations, compositions, and derivations thereof. These materials include metals (e.g., steel, stainless steel, aluminum), metal alloys, high-strength plastics, composites, and the like. Material selection may depend on the type and composition of the working fluid. For example, working fluids with caustic properties may require that the diffuser vanes comprise relatively inert materials and/or materials that are chemically inactive with respect to the working fluid, and/or have one or more coatings and/or surface treatments that provide prevent corrosion, erosion, or other degradation of the surface of the diffuser vanes.
Geometry for the diffuser vane 302 is determined as part of the design, build, and fitting of the compressor device for the application. The geometry can include airfoil shapes, e.g., the shape shown in
Referring back to the method 200 of
In view of the foregoing discussion, one or more of the steps of the methods 200 and 400 can be coded as one or more executable instructions (e.g., hardware, firmware, software, software programs, etc.). These executable instructions can be part of a computer-implemented method and/or program, which can be executed by a processor and/or processing device. Examples of the controller 132 (
In one embodiment, the controller 500 includes a processor 502, memory 504, and control circuitry 506. Busses 508 couple the components of the controller 500 together to permit the exchange of signals, data, and information from one component of the controller 500 to another. In one example, the control circuitry 506 includes sensor driver circuitry 510 which couples with one or more sensors (e.g., first flow sensor 512 and second flow sensor 514) and motor drive circuitry 516 that couples with a drive unit 518. The control circuitry 506 also includes an actuator drive circuitry 520, which couples with one or more actuators (e.g., first actuator 522 and second actuator 524), and a radio circuitry 526 that couples to a radio 528, e.g., a device that operates in accordance with one or more of the wireless and/or wired protocols for sending and/or receiving electronic messages to and from a peripheral device 530 (e.g., a smartphone). As also shown in
This configuration of components can dictate operation of the controller 500 to analyze data, e.g., information encoded by the signals from sensors 512, 514 and/or drive unit 518, to identify appropriate changes to the diffuser vanes and/or other changes to other operating properties (e.g., motor speed) of the compressor device. For example, the controller 500 can provide signals (or inputs or outputs) to align diffuser vanes in various stages of the compressor device with the direction of flow, independent of the other stages and without disrupting operation (e.g., output pressure) of the compressor device.
The controller 500 and its constructive components can communicate amongst themselves and/or with other circuits (and/or devices), which execute high-level logic functions, algorithms, as well as executable instructions (e.g., firmware instructions, software instructions, software programs, etc.). Exemplary circuits of this type include discrete elements such as resistors, transistors, diodes, switches, and capacitors. Examples of the processor 502 include microprocessors and other logic devices such as field programmable gate arrays (“FPGAs”) and application specific integrated circuits (“ASICs”). Although all of the discrete elements, circuits, and devices function individually in a manner that is generally understood by those artisans that have ordinary skill in the electrical arts, it is their combination and integration into functional electrical groups and circuits that generally provide for the concepts that are disclosed and described herein.
The structure of the components in the controller 500 can permit certain determinations as to selected configuration and desired operating characteristics that an end user convey via the graphical user interface or that are retrieved or need to be retrieved by the device. For example, the electrical circuits of the controller 500 can physically manifest theoretical analysis and logical operations and/or can replicate in physical form an algorithm, a comparative analysis, and/or a decisional logic tree, each of which operates to assign the output and/or a value to the output that correctly reflects one or more of the nature, content, and origin of the changes that occur and that are reflected by the inputs to the controller 500 as provided by the corresponding control circuitry, e.g., in the control circuitry 506.
In one embodiment, the processor 502 is a central processing unit (CPU) such as an ASIC and/or an FPGA that is configured to instruct and/or control operation one or more devices. This processor can also include state machine circuitry or other suitable components capable of controlling operation of the components as described herein. The memory 504 includes volatile and non-volatile memory and can store executable instructions in the form of and/or including software (or firmware) instructions and configuration settings. Each of the control circuitry 506 can embody stand-alone devices such as solid-state devices. Examples of these devices can mount to substrates such as printed-circuit boards and semiconductors, which can accommodate various components including the processor 502, the memory 504, and other related circuitry to facilitate operation of the controller 500.
However, although
Moreover, as will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.
Any combination of one or more computer readable medium(s) may be utilized. The computer readable medium may be a computer readable signal medium or a computer readable storage medium. Examples of a computer readable storage medium include an electronic, magnetic, electromagnetic, and/or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
A computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms and any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language and conventional procedural programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
Aspects of the present invention are described herein with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
Accordingly, a technical effect of embodiments of the systems and methods disclosed herein is to change the position of one or more diffuser vanes to align with the direction of flow of the working fluid.
As used herein, an element or function recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural said elements or functions, unless such exclusion is explicitly recited. Furthermore, references to “one embodiment” of the claimed invention should not be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
Claims
1. A system, comprising:
- a compressor device comprising a first diffuser vane, a second diffuser vane downstream of the first diffuser vane, and a flow sensor assembly comprising a first flow sensor upstream of the first diffuser vane and a second flow sensor upstream of the second diffuser vane; and
- a controller coupled with the first flow sensor and the second flow sensor, the controller comprising a processor, memory, and one or more executable instructions stored on the memory and configured to be executed by the processor, the executable instructions comprising instructions for: receiving a first signal from the first flow sensor encoding information that identifies a first direction of flow for a working fluid upstream of the first diffuser vane; receiving a second signal from the second flow sensor encoding information that identifies a second direction of flow for the working fluid upstream of the second diffuser vane; identifying a first position for the first diffuser vane and the second diffuser vane, the first position aligning the first diffuser vane and the second diffuser vane with, respectively, the first direction and the second direction of the working fluid; and generating an output encoding instructions to move the first diffuser vane and the second diffuser vane to the first position.
2. The system of claim 1, wherein the compressor device comprises a first actuator coupled with the first diffuser vane and a second actuator coupled with the second diffuser vane, and wherein the first actuator and the second actuator operate in response to the output.
3. The system of claim 1, wherein the first flow sensor and the second flow sensor comprise a directional element and a base element coupled to the directional element, and wherein the information of the first signal and the second signal reflects an angular position of the directional element.
4. The system of claim 3, wherein the base element comprises a rotary potentiometer that measures the angular position of the directional element.
5. The system of claim 1, wherein the compressor device comprises a first impeller upstream of the first diffuser vane and a second impeller downstream of the first diffuser vane and upstream of the second diffuser vane.
6. The system of claim 1, wherein the first diffuser vane and the second diffuser vane rotate in response to the output.
7. The system of claim 1, wherein the first diffuser vane and the second diffuser vane have an airfoil shape that converges at the leading edge to a tip with a center axis, wherein the tip has a curvilinear outer surface defined by a radius from the center axis, and wherein the first diffuser vane and the second diffuser vane rotate about a rotation axis that is found within an area defined by the radius.
8. The system of claim 7, wherein the rotation axis is coaxial with the center axis of the tip.
9. The system of claim 1, wherein the executable instructions comprise instructions for:
- comparing the first direction and the second direction to, respectively, a first reference direction and a second reference direction; and
- selecting a first increment by which to move the first diffuser vane and a second increment by which to move the second diffuser vane, the first increment defining the relative position of the first direction with respect to the first reference direction and the second increment defining the relative position of the second direction with respect to the second reference direction,
- wherein the instructions cause the first diffuser vane and the second diffuser vane to move from the first position to a second position, and wherein the second position is defined relative to the first position for the first diffuser vane by the first increment and for the second diffuser vane by the second increment.
10. A compressor device, comprising:
- a first diffuser vane;
- a second diffuser vane downstream of the first diffuser vane;
- a flow sensor assembly comprising a first flow sensor upstream of the first diffuser vane and a second flow sensor downstream of the first diffuser vane and upstream of the second diffuser vane, the first flow sensor and the second flow sensor comprising a base element and a directional element coupled with the base element, wherein the directional element can move between a first position and a second position to align with a flow of a working fluid.
11. The compressor device of claim 10, wherein the base element provides a pivot about which the directional element can rotate between the first position and the second position.
12. The compressor device of claim 10, wherein the base element comprises a rotary potentiometer.
13. The compressor device of claim 10, wherein the first diffuser vane and the second diffuser vane comprise a vane body with a leading edge and a trailing edge and a rotation axis spaced apart from the leading edge and the trailing edge along a chord length that defines the straight-line distance between the leading edge and the trailing edge
14. The compressor device of claim 10, wherein the first diffuser vane and the second diffuser vane rotate about the leading edge.
15. The compressor device of claim 10, wherein the vane body has an airfoil shape that converges at the leading edge to a tip with a center axis, wherein the tip has a curvilinear outer surface defined by a radius from the center axis, and wherein the first diffuser vane and the second diffuser vane rotate about a rotation axis that is found within an area defined by the radius.
16. The compressor device of claim 16, wherein the rotation axis is coaxial with the center axis of the tip.
17. The compressor device of claim 10, further comprising a controller coupled with the first flow sensor and the second flow sensor, the controller comprising a processor, memory, and one or more executable instructions stored on the memory and configured to be executed by the processor, the executable instructions comprising instructions for:
- receiving a first signal from the first flow sensor encoding information that identifies a first direction of flow for a working fluid upstream of the first diffuser vane;
- receiving a second signal from the second flow sensor encoding information that identifies a second direction of flow for the working fluid upstream of the second diffuser vane;
- identifying a first position for the first diffuser vane and the second diffuser vane, the first position aligning the first diffuser vane and the second diffuser vane with, respectively, the first direction and the second direction of the working fluid; and
- generating an output encoding instructions to move the first diffuser vane and the second diffuser vane to the first position.
18. The compressor device of claim 17, wherein the executable instructions comprise instructions for:
- comparing the first direction and the second direction to, respectively, a first reference direction and a second reference direction; and
- selecting a first increment by which to move the first diffuser vane and a second increment by which to move the second diffuser vane, the first increment defining the relative position of the first direction with respect to the first reference direction and the second increment defining the relative position of the second direction with respect to the second reference direction,
- wherein the instructions cause the first diffuser vane and the second diffuser vane to move from the first position to a second position, and wherein the second position is defined relative to the first position for the first diffuser vane by the first increment and for the second diffuser vane by the second increment.
19. A controller for operating a compressor device, said controller comprising:
- a processor;
- memory; and
- executable instructions stored on the memory and configured to be executed by the processor, the executable instructions comprising instructions for: receiving a first signal from the first flow sensor encoding information that identifies a first direction of flow for a working fluid upstream of the first diffuser vane; receiving a second signal from the second flow sensor encoding information that identifies a second direction of flow for the working fluid upstream of the second diffuser vane; identifying a first position for the first diffuser vane and the second diffuser vane, the first position aligning the first diffuser vane and the second diffuser vane with, respectively, the first direction and the second direction of the working fluid; and generating an output encoding instructions to move the first diffuser vane and the second diffuser vane to the first position.
20. The controller of claim 19, further comprising instructions for:
- comparing the first direction and the second direction to, respectively, a first reference direction and a second reference direction, wherein the first reference direction and the second reference direction comprise a value for the first direction and the second direction at a time t, and wherein the first position; and
- selecting a first increment by which to move the first diffuser vane and a second increment by which to move the second diffuser vane, the first increment defining the relative position of the first direction with respect to the first reference direction and the second increment defining the relative position of the second direction with respect to the second reference direction,
- wherein the instructions cause the first diffuser vane and the second diffuser vane to move from the first position to a second position, and wherein the second position is defined relative to the first position for the first diffuser vane by the first increment and for the second diffuser vane by the second increment.
Type: Application
Filed: Aug 31, 2012
Publication Date: Mar 6, 2014
Applicant: Dresser Inc. (Addison, TX)
Inventor: Dale Eugene Husted (Centerville, IN)
Application Number: 13/601,822
International Classification: F01D 17/20 (20060101); F01D 9/04 (20060101);