Chiller Compressor Rolling Bearings with Squeeze Film Dampers

Abstract

A centrifugal compressor (22) comprises: a case (160) having a suction port (24) and a discharge port (26); an impeller (162, 164) mounted for rotation about an impeller axis (500) by a plurality of bearings (80, 82); and a motor (34) coupled to the impeller to drive rotation of the impeller about the impeller axis. The bearings each comprise: an inner race (200); an outer race (202); and rolling elements (204) between the inner race and outer race. The outer race of each bearing is mounted for radial displacement relative to the case and is surrounded by an associated chamber (224); and the chambers are coupled to a port (92) on the compressor.

Description

CROSS-REFERENCE TO RELATED APPLICATION

Benefit is claimed of U.S. Patent Application Ser. No. 61971838, filed Mar. 28, 2014, and entitled “Centrifugal Compressor Bearings”, the disclosure of which is incorporated by reference herein in its entirety as if set forth at length.

BACKGROUND

The disclosure relates to vapor compression systems. More particularly, the disclosure relates to centrifugal compressors in vapor compression systems.

One example of a vapor compression system involves a chiller. The exemplary chiller involves a two-stage centrifugal compressor driven by an electric motor. The main refrigerant flowpath through the exemplary system passes sequentially from an outlet of the compressor through a condenser, an economizer (e.g., a flash tank economizer), an expansion device, and a cooler, returning from the cooler to the compressor inlet. An economizer line may extend from the economizer to an interstage of the compressor.

Exemplary compressors include centrifugal compressors. Exemplary centrifugal compressors include two-stage centrifugal compressors. There are two forms of common two-stage centrifugal compressors. The so-called in-line form places two impellers one behind the other at a first end of the motor. In contrast, the so-called back-to-back form has a first impeller at a first end of the motor and a second impeller at a second end of the motor.

Typical compressor configurations support the motor shaft with a pair of bearings, one at each end of the motor. One or two impeller stages are mounted distally of the bearings. Thus, the in-line configuration has a longer shaft cantilever than does an equivalent back-to-back configuration. The asymmetry of the in-line configuration also imposes various mechanical loads on the compressor. As a result, in-line compressors are more susceptible to resonance problems than back-to-back compressors.

For a typical back-to-back compressor, operation is typically below the first critical speed. Inexpensive bearings can thus be used with an in-line compressor. For example, ceramic hybrid bearings may be used (i.e., bearings with metallic races and ceramic rolling elements). In contrast, the in-line configuration will have a lower first critical speed than a corresponding back-to-back configuration. The operational envelope of the in-line compressor may include this critical speed. Expensive magnetic bearings may be used to provide the required damping for an in-line compressor to withstand resonance associated with operation of the first critical speed. Thus, the cost of the magnetic bearings may be several thousand dollars higher than would ceramic hybrid bearings.

SUMMARY

One aspect of the disclosure involves a centrifugal compressor comprising: a case having a suction port and a discharge port; an impeller mounted for rotation about an impeller axis by a plurality of bearings; and a motor coupled to the impeller to drive rotation of the impeller about the impeller axis. The bearings each comprise: an inner race; an outer race; and rolling elements between the inner race and outer race. The outer race of each bearing is mounted for radial displacement relative to the case and is surrounded by an associated chamber; and the chambers are coupled to a port on the compressor.

In one or more embodiments of any of the foregoing embodiments, the impeller is coaxial with the motor and mounted to a shaft of the rotor for said rotation about the impeller axis.

In one or more embodiments of any of the foregoing embodiments, the centrifugal compressor is an in-line compressor with a first said impeller and a second said impeller; and a first said bearing is between the motor and the first impeller and second impeller.

In one or more embodiments of any of the foregoing embodiments, each of the chambers is bounded by: a portion of the case; the outer race; and a pair of o-rings.

In one or more embodiments of any of the foregoing embodiments, at least one orifice is between the port and the chambers.

In one or more embodiments of any of the foregoing embodiments, each of the bearings further comprises an anti-rotation means coupling the outer race to the case.

In one or more embodiments of any of the foregoing embodiments, a drain port is coupled to the chambers.

Another aspect of the disclosure involves a refrigeration system comprising the centrifugal compressor and further comprising: a heat rejection heat exchanger coupled to the compressor to receive refrigerant from the discharge port; an expansion device; and a heat absorption heat exchanger coupled to the compressor to deliver refrigerant to the suction port.

In one or more embodiments of any of the foregoing embodiments, a bearing supply flowpath to said port bypasses the expansion device.

In one or more embodiments of any of the foregoing embodiments, the system has subcooling means for subcooling refrigerant flowing along the bearing supply flowpath.

In one or more embodiments of any of the foregoing embodiments, the subcooling means comprises a heat exchanger.

In one or more embodiments of any of the foregoing embodiments, the heat exchanger is a refrigerant-refrigerant heat exchanger having a first leg along the bearing supply flowpath and a second leg in heat exchange with the first leg.

In one or more embodiments of any of the foregoing embodiments, the second leg is along a branch flowpath branching off from and returning to a main flowpath and the subcooling means further comprises a second expansion device along the branch flowpath upstream of the second leg.

In one or more embodiments of any of the foregoing embodiments, a filter is between the subcooling means and the port.

In one or more embodiments of any of the foregoing embodiments, at least one orifice in the compressor restricts flow through the bearing supply flowpath.

In one or more embodiments of any of the foregoing embodiments, the system has a drain flowpath from the chambers.

In one or more embodiments of any of the foregoing embodiments, a pressure control valve is in the drain flowpath.

In one or more embodiments of any of the foregoing embodiments, the drain flowpath extends to the heat absorption heat exchanger to merge with a main flowpath.

In one or more embodiments of any of the foregoing embodiments, a method for using the system comprises running the compressor to drive refrigerant along a main flowpath proceeding sequentially from the compressor to the heat rejection heat exchanger, the expansion device, and the heat absorption heat exchanger to return to the compressor; and diverting refrigerant from the main flowpath to the chambers.

In one or more embodiments of any of the foregoing embodiments, the method further comprises subcooling the diverted refrigerant prior to delivery to the chambers.

The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a chiller system.

FIG. 2 is a partially schematic view of a compressor of the system of FIG. 1.

Like reference numbers and designations in the various drawings indicate like elements.

DETAILED DESCRIPTION

FIG. 1 shows a vapor compression system 20 having an improved compressor bearing configuration and operation. As is discussed further below, the compressor features a damped mechanical bearing configuration using relatively inexpensive mechanical bearings (e.g., ceramic hybrid bearings) in place of magnetic bearings. The exemplary vapor compression system 20 is a chiller used to cool a flow of water or other heat transfer liquid. The chiller comprises a compressor 22 having an inlet or suction port 24 defining suction conditions and an outlet or discharge port 26 defining discharge conditions. An exemplary compressor is a two-stage centrifugal compressor having a first stage shown as 28, a second stage shown as 30, and an interstage shown as 32. Each stage comprises a centrifugal impeller. The two impellers are co-driven by an electric motor 34 (e.g., directly or via a gearbox). As is discussed further below, the exemplary two-stage compressor is an in-line compressor directly driven by the motor.

The system 20 has a main refrigerant flowpath 35 proceeding through the stages of compression between the inlet 24 and the outlet 26 and proceeding downstream via a discharge line from the outlet 26 to the inlet 36 of a heat exchanger 38. In normal operation, the heat exchanger 38 is a heat rejection heat exchanger, more particularly a condenser rejecting heat from the refrigerant flowing therethrough to an external flow of a heat transfer fluid. An exemplary flow of heat transfer fluid is cooling water or air. An exemplary flow 40 of heat transfer fluid enters an inlet 42 of the condenser 38 and exits an outlet 44 (e.g., a water loop of the heat exchanger).

The main refrigerant flowpath 35 proceeds further downstream to an expansion device 56 having an inlet 58 and an outlet 60. The main refrigerant flowpath 35 passes further downstream from the expansion device outlet 60 to an inlet 62 of a second heat exchanger (a heat absorption heat exchanger (e.g., cooler)) 64. The cooler absorbs heat from a flow 70 of heat transfer fluid (e.g., water) entering an inlet 72 and exiting an outlet 74 (e.g., a water loop of the heat exchanger). The cooler has a refrigerant outlet 76 along the main refrigerant flowpath with a suction line 78 connecting the outlet 76 to the compressor inlet 24 to complete the main refrigerant flowpath 35.

As so far described, this is representative of one of several exemplary prior art configurations to which one or more of the further modifications may be applied. Alternative vapor compression systems may have other features, including basic variations such as economizers, suction line heat exchangers, hot gas bypass, multiple heat absorption heat exchangers, and the like and more extreme variations including multiple compressors, Heat rejection heat exchangers, and the like.

FIG. 1 further shows several additional flowpath branches which may be used to supply fluid to compressor bearings 80 and 82. The fluid fills chambers surrounding the bearings to act in a squeeze film damper role, damping radial excursions/vibration of the bearings. Such dampers are used in other arts such as turbine engines and turbochargers.

The bearings support a motor rotor and the impellers for rotation about a rotor axis 500. A supply flowpath 90 branches off from the main flowpath 35 upstream of the expansion device 56. In this example, the flowpath 90 is formed by appropriate conduits extending from an upstream end at a sump of the heat rejection heat exchanger 38. The flowpath 90 extends to a port 92 on the compressor (supply port). As is discussed further below, the flowpath continues through a manifold 94. The port 92 may be along a casting (or other structural component) of the housing or may be along piping/tubing secured thereto. Similarly, the manifold may include such piping or tubing.

FIG. 1 further shows a return flowpath 100 returning from the bearings to the main flowpath 35. The exemplary return flowpath 100 may contain one or more branches. In this example, a return manifold 102 is coupled to a return port 104 on the compressor. A line from the return port 104 extends back to return refrigerant to the main flowpath 35 (e.g., at a port 108 on the shell of the heat absorption heat exchanger 64). A pressure control device 110 (e.g., a spring-loaded pressure control valve (PCV) or an electronically controlled pressure control valve) is located along the flowpath 100 and maintains the bearings at a pressure difference above a pressure of the evaporator. The exemplary difference is 3 psi to 5 psi (21 kPa to 34 kPa), more broadly 2 psi to 10 psi (14 kPa to 69 kPa).

The refrigerant is delivered along the supply flowpath 90 as a liquid. Thus it is bypassed from upstream of the expansion device. However, it may be desirable to subcool this refrigerant. Subcooling and the pressure difference may serve to help avoid vaporization or cavitation of the liquid refrigerant. Cavitation would reduce damping and, thereby, allow severe shaft vibrations and associated damage.

An exemplary means for subcooling the refrigerant comprises a heat exchanger 120 for extracting heat from refrigerant passing along the supply flowpath 90. The exemplary heat exchanger 120 is a refrigerant-refrigerant heat exchanger having a first leg 122 along the supply flowpath 90 and a second leg 124 in heat exchange communication with the first leg 122 to absorb heat from the first leg. In order to provide cooled refrigerant to the second leg 124, a second bypass flowpath 140 is provided. The leg 124 is along the second bypass flowpath. The exemplary second bypass flowpath 140 extends from an upstream end along the main flowpath 35 upstream of the expansion device 56 (e.g., also from the sump of the heat rejection heat exchanger 38). The exemplary second bypass flowpath 140 further returns to the main refrigerant flowpath 35. The exemplary return of the second bypass flowpath 140 is at a port 146 on the vessel of the heat absorption heat exchanger 64. To cool refrigerant flowing along the second bypass flowpath 140, an exemplary expansion device 144 is along the second bypass flowpath 140. The exemplary expansion device 144 is an electronic expansion valve (EXV) or a thermal expansion valve (TXV) discussed further below. In operation, refrigerant leaving the expansion device 144 is at a temperature reduced below that entering the device. This reduced temperature refrigerant flows downstream and, in the second leg 124 of the heat exchanger 120 absorbs heat from refrigerant flowing through the first leg 122 so as to provide the subcooling noted above.

The expansion device 144 may be operated to provide a desired amount of subcooling to the refrigerant being delivered to the bearings. The exemplary control is based upon a sensor (e.g., a TXV bulb or by electronic temperature sensor used by a controller to control an EXV). An exemplary sensor is located downstream of the exit of the supply flowpath 90 from the heat exchanger 120. In this example, a filter 126 is located along the supply flowpath 90. In the particular example, the filter 126 is located between the heat exchanger 120 and the supply port 92. The exemplary heat exchanger 120 is a brazed plate heat exchanger or a shell and tube heat exchanger. The exemplary temperature sensor used to control the expansion device 144 may be located, for example, between the filter 126 and the heat exchanger 120.

FIG. 2 partially schematically shows exemplary locations of the impeller stages. It further shows a case (housing) assembly 160 of the compressor containing the first stage impeller 162 and the second stage impeller 164 mounted to the shaft 166 of the motor 34. Between the inlet 24 and the inlet 167 of the first stage impeller, the case contains a controllable inlet guide vane (IGV) array 168. Downstream of the second stage impeller outlet 169, the case defines a discharge plenum 170 along which the discharge port (not shown) is located. Between the outlet 172 of the first stage impeller and the inlet 174 of the second stage impeller, components of the housing assembly define one or more passageways including diffuser passageways 176 extending radially outward to a turn 178 which turns back radially inward and joins with return passageways (return) 180 extending radially inward and then turning axially to meet the inlet 174.

FIG. 2 further shows each of the bearings 80, 82 as comprising an inner race 200, an outer race 202, and a circumferential array of rolling elements (e.g., rollers or balls) 204 in rolling engagement radially between the inner race and outer race. The inner race is secured to the motor shaft 166. The outer race is compliantly mounted relative to an adjacent portion of the case. The outer race has an outer diameter or OD surface 220 spaced apart from an adjacent inner diameter (ID) surface 222 of the case. A chamber 224 is formed between the outer race OD surface 220 and case ID surface 222. The exemplary chamber is axially bounded by seals such as o-rings 226, 228 compliantly engaging both the surfaces 220 and 222. The exemplary rolling elements 204 are ceramic. The bearings may be ceramic hybrid bearings wherein the races are steel. Chamber dimensions may be calculated based upon known engineering principles from the use of squeeze film dampers in other arts such as turbine engines and turbochargers. Exemplary chamber heights or radial spans are 0.25 mm to 1.25 mm, more narrowly 0.5 mm to 1.0 mm. Exemplary longitudinal spans (lengths) of the chambers are 10 mm to 40 mm, more narrowly 15 mm to 30 mm. Exemplary refrigerants are hydrofluorocarbons (HFC), chlorofluorocarbons (CFC), and hydrofluoro-olefins (HFO), and the refrigerant charge may comprise a by weight majority (or consist essentially of such as 90%+ or 95%+by weight) of one or more such refrigerants with minor amounts of lubricant and/or other additives, if any.

FIG. 2 further shows exemplary means for preventing relative rotation of the outer race and case. The exemplary means comprises an anti-rotation pin 240 radially spanning the chamber. The exemplary pin 240 is secured to one of the outer race and case and radially floats in the other (e.g., accommodated in a bore in the other for radial movement but restraining all but slight axial movements, if any).

FIG. 2 further shows the supply flowpath 90 having a means for regulating supply flow. Exemplary means comprises one or more orifices 250. In the exemplary embodiment there are an exemplary two orifices 250 respectively located in branches of the manifold leading to the two chambers 224.

FIG. 1 further shows a controller 400. The controller may receive user inputs from an input device (e.g., switches, keyboard, or the like) and sensors (not shown, e.g., pressure sensors and temperature sensors at various system locations). The controller may be coupled to the sensors and controllable system components (e.g., valves, the bearings, the compressor motor, vane actuators, and the like) via control lines (e.g., hardwired or wireless communication paths). The controller may include one or more: processors; memory (e.g., for storing program information for execution by the processor to perform the operational methods and for storing data used or generated by the program(s)); and hardware interface devices (e.g., ports) for interfacing with input/output devices and controllable system components. As is discussed above, in a first exemplary embodiment the control is fully conventional in control of any baseline system it replaces.

As noted above, some systems may involve active control with additional routines which may be programmed or otherwise configured into the controller. Such systems may include the pressure regulating valve 110 being controlled by the controller to provide a desired fixed pressure or a pressure otherwise programmed or calculated by the controller. The expansion device 144 is an electronic expansion valve (EXV) similarly controlled by the controller to provide a fixed temperature of refrigerant delivered to the bearings or based upon programmed and/or calculated parameters. The control routine may provide cooling sufficient to avoid cavatation while providing means to optimize efficiency and optionally controlling damping levels and may be superimposed upon the controller's normal programming/routines (not shown, e.g., providing the basic operation of a baseline system to which the foregoing control routine is added).

The use of “first”, “second”, and the like in the description and following claims is for differentiation within the claim only and does not necessarily indicate relative or absolute importance or temporal order. Similarly, the identification in a claim of one element as “first” (or the like) does not preclude such “first” element from identifying an element that is referred to as “second” (or the like) in another claim or in the description.

Where a measure is given in English units followed by a parenthetical containing SI or other units, the parenthetical's units are a conversion and should not imply a degree of precision not found in the English units.

One or more embodiments have been described. Nevertheless, it will be understood that various modifications may be made. For example, when applied to an existing basic system, details of such configuration or its associated use may influence details of particular implementations. Accordingly, other embodiments are within the scope of the following claims.

Claims

1. (canceled)

2. The system of claim 9 wherein:

the impeller is coaxial with the motor and mounted to a shaft (166) of the rotor for said rotation about the impeller axis.

3. The system of claim 9 wherein:

the centrifugal compressor is an in-line compressor with a first said impeller and a second said impeller; and

a first said bearing is between the motor and the first impeller and second impeller.

4. The system of claim 9 wherein:

each of the chambers is bounded by: a portion of the case; the outer race; and a pair of o-rings (226, 228).

5. The system of claim 9 further comprising:

at least one orifice (250) between the port and the chambers.

6. The system of claim 9 wherein each of the bearings further comprises:

an anti-rotation means (240) coupling the outer race to the case.

7. The system of claim 9 further comprising:

a drain port (104) coupled to the chambers.

8. (canceled)

9. A refrigeration system (20) comprising:

a centrifugal compressor (22) comprising: a case (160) having a suction port (24) and a discharge port (26); an impeller (162, 164) mounted for rotation about an impeller axis (500) by a plurality of bearings (80, 82), the bearings each comprising: an inner race (200); an outer race (202); and rolling elements (204) between the inner race and outer race; and a motor (34) coupled to the impeller to drive rotation of the impeller about the impeller axis, wherein: the outer race of each bearing is mounted for radial displacement relative to the case and is surrounded by an associated chamber (224); and the chambers are coupled to a port (92) on the compressor;

a heat rejection heat exchanger (38) coupled to the compressor to receive refrigerant from the discharge port;

an expansion device (56);

a heat absorption heat exchanger (64) coupled to the compressor to deliver refrigerant to the suction port; and

a bearing supply flowpath (90) to said port (92) bypassing the expansion device (56).

10. The system of claim 9 further comprising:

subcooling means (120, 144) for subcooling refrigerant flowing along the bearing supply flowpath.

11. The system of claim 10 wherein:

the subcooling means comprises a heat exchanger (120).

12. The system of claim 11 wherein:

the heat exchanger (120) is a refrigerant-refrigerant heat exchanger having a first leg (122) along the bearing supply flowpath and a second leg (124) in heat exchange with the first leg.

13. The system of claim 11 wherein:

the second leg is along a branch flowpath (140) branching off from and returning to a main flowpath (35); and

the subcooling means further comprises a second expansion device (144) along the branch flowpath (140) upstream of the second leg.

14. The system of claim 10 further comprising a filter (126) between the subcooling means and the port.

15. The system of claim 10 wherein:

at least one orifice (250) in the compressor restricts flow through the bearing supply flowpath.

16. The system of claim 10 further comprising:

a drain flowpath (100) from the chambers.

17. The system of claim 16 further comprising:

a pressure control valve (110) in the drain flowpath.

18. The system of claim 16 wherein:

the drain flowpath extends to the heat absorption heat exchanger to merge with a main flowpath (35).

19. A method for using a refrigeration system, the refrigeration system comprising:

a centrifugal compressor (22) comprising: a case (160) having a suction port (24) and a discharge port (26); an impeller (162, 164) mounted for rotation about an impeller axis (500) by a plurality of bearings (80, 82), the bearings each comprising: an inner race (200); an outer race (202); and rolling elements (204) between the inner race and outer race; and a motor (34) coupled to the impeller to drive rotation of the impeller about the impeller axis;

a heat rejection heat exchanger (38) coupled to the compressor to receive refrigerant from the discharge port;

an expansion device (56); and

a heat absorption heat exchanger (64) coupled to the compressor to deliver refrigerant to the suction port,

wherein:

the outer race of each bearing is mounted for radial displacement relative to the case and is surrounded by an associated chamber (224); and

the chambers are coupled to a port (92) on the compressor,

the method comprising:

running the compressor to drive refrigerant along a main flowpath proceeding sequentially from the compressor to the heat rejection heat exchanger, the expansion device, and the heat absorption heat exchanger to return to the compressor; and

diverting refrigerant from the main flowpath to the chambers.

20. The method of claim 19 further comprising:

subcooling the diverted refrigerant prior to delivery to the chambers.

21. The method of claim 19 further comprising:

draining refrigerant from the chambers by a drain port (104) coupled to the chambers.

22. The method of claim 19 the diverting comprises:

passing refrigerant through at least one orifice (250) located between the port and the chambers.