CN117006063A

CN117006063A - Integrated bearing system for dynamically supporting a shaft in a pump system

Info

Publication number: CN117006063A
Application number: CN202310370845.9A
Authority: CN
Inventors: 大卫·拉朱·亚玛丝; 拉温德拉·山卡尔·加尼格尔; 亚当·约瑟夫·旺勒; 莫汉·坎奈亚·拉朱; 朴拉琪·阿南德·塔普; 桑托什·库马尔·帕特耐克; 布兰登·W·米勒; 丹尼尔·A·尼加斯; 凯文·爱德华·辛德利特; 施什尔·帕雷什·沙
Original assignee: General Electric Co
Current assignee: General Electric Co
Priority date: 2022-05-03
Filing date: 2023-04-10
Publication date: 2023-11-07

Abstract

Disclosed herein are pump systems that pressurize fluid within a closed loop transmission bus. Examples of pump systems disclosed herein include: a pump including an impeller to increase kinetic energy of fluid flowing through the impeller; an electric motor including a rotor shaft connected to the impeller to provide torque to the rotor shaft; a first bearing supporting the rotor shaft in a first operating speed range, the first bearing coupled to the inner race; a second bearing supporting the rotor shaft in a second operating speed range, the rotor shaft being coupled to the outer race; and one or more diagonal bracing elements configured to: engaging the inner race with the outer race over a first operating speed range; and separating the inner race from the outer race in a second operating speed range.

Description

Integrated bearing system for dynamically supporting a shaft in a pump system

Technical Field

The present disclosure relates generally to fluid pumps and, more particularly, to an integrated bearing system that dynamically supports a shaft in a pump system.

Background

An aircraft typically includes various accessory systems that support the operation of the aircraft and/or its gas turbine engines. For example, such accessory systems may include lubrication systems that lubricate components of the engine, engine cooling systems that provide cooling air to engine components, environmental control systems that provide cooled air to the cabin of an aircraft, and the like. Thus, during operation of these accessory systems, heat is added or removed from the fluid (e.g., oil, air, etc.).

Drawings

FIG. 1 is a side view of an example aircraft.

FIG. 2 is a schematic cross-sectional view of an example gas turbine engine of an aircraft.

FIG. 3 is a schematic diagram of an example thermal management system for transferring heat between fluids.

FIG. 4 illustrates an example heat transfer bus pump.

FIG. 5 illustrates a first example radial coupling fluid pump system according to teachings disclosed herein.

FIG. 6 illustrates a second example radial coupling fluid pump system according to teachings disclosed herein.

FIG. 7 illustrates a third example radial coupling fluid pump system according to teachings disclosed herein.

FIG. 8 is a flow chart illustrating operation of the radially coupled fluid pump system.

FIG. 9 illustrates an example integrated bearing system for dynamically supporting a rotating shaft in an example pump system in accordance with the teachings of the present disclosure.

FIG. 10 illustrates an example integrated bearing system for dynamically supporting a rotating shaft in an example pump system in accordance with the teachings of the present disclosure.

FIG. 11 illustrates an example sprag clutch for engaging and disengaging bearings in an example integrated bearing system according to the teachings of this disclosure.

Fig. 12A illustrates an example engaged state of an example sprag element of an example integrated bearing system according to the teachings of the present disclosure.

Fig. 12B illustrates an example split state of an example sprag element of an example integrated bearing system according to the teachings of the present disclosure.

FIG. 13 illustrates an example load path supported by an example integrated bearing system during operation of an example pump system in accordance with the teachings of the present disclosure.

FIG. 14 is a flow chart illustrating example operation of an example integrated bearing system of an example pump system.

Fig. 15 illustrates a first example barrier tank according to the teachings disclosed herein.

Fig. 16 illustrates an example inner shell layer that may be used in the first example barrier can of fig. 15.

Fig. 17A shows a cross-section of a first example barrier can after a first example manufacturing operation.

Fig. 17B shows a cross-section of the first example barrier can after a second example manufacturing operation.

Fig. 17C shows a cross-section of the first example barrier can after a third example manufacturing operation.

Fig. 18 is a flow chart illustrating an example method of manufacturing the first example barrier tank of fig. 15 and 17A-C.

Fig. 19 illustrates a second example barrier tank according to the teachings disclosed herein.

Fig. 20A shows a first example fiber of the second example barrier can of fig. 19.

Fig. 20B shows a second example fiber of the second example barrier can of fig. 19.

Fig. 20C shows a third example fiber of the second example barrier can of fig. 19.

Fig. 20D shows a fourth example fiber of the second example barrier can of fig. 19.

Fig. 21 shows an enlarged view of a portion of the second example barrier can of fig. 19.

Fig. 22A is a flow chart illustrating an example method of manufacturing the second example barrier tank of fig. 19, 20A-D, and 21.

Fig. 22B is a flow chart illustrating another example method of manufacturing the second example barrier tank of fig. 19, 20A-D, and 21.

FIG. 23 illustrates an example pump system including a first example oil separator in accordance with the teachings disclosed herein.

FIG. 24 illustrates another example pump system including a second example oil separator according to teachings disclosed herein.

FIG. 25 illustrates another example pump system including a second example oil separator and a third example oil separator in accordance with the teachings disclosed herein.

FIG. 26 illustrates another example pump system including a planetary gearbox according to teachings disclosed herein.

Fig. 27 shows a cross section of the planetary gearbox of fig. 26.

FIG. 28 illustrates another example pump system including a bearing assembly according to teachings disclosed herein.

Fig. 29 is a schematic representation of the support provided by the bearing assembly of fig. 28.

Fig. 30A illustrates a first example rotary separator that may be used in the pump systems of fig. 23-26 and 28.

Fig. 30B illustrates a second example rotary separator that may be used in the pump systems of fig. 23-26 and 28.

Fig. 30C illustrates a third example rotary separator that may be used in the pump systems of fig. 23-26 and 28.

Fig. 31A shows a first example stationary separator that may be used in the pump systems of fig. 23-26 and 28.

Fig. 31B illustrates another example orientation of the first example stationary separator of fig. 31A.

Fig. 31C shows a second example stationary separator that may be used in the pump systems of fig. 23-26 and 28.

Fig. 32 is a schematic representation of a first example layout that may be associated with the pump systems of fig. 23-26 and 28.

Fig. 33 is a schematic representation of a second example layout that may be associated with the pump systems of fig. 23-26 and 28.

Fig. 34 is a schematic representation of a third example layout that may be associated with the pump systems of fig. 23-26 and 28.

Fig. 35 is a schematic representation of a fourth example layout that may be associated with the pump systems of fig. 23-26 and 28.

FIG. 36 illustrates a first example axial-flux motor-driven pump system for pressurizing fluid in a closed-loop system in accordance with the teachings of the present disclosure.

FIG. 37 illustrates a second example axial flux motor driven pump system for pressurizing fluid in a closed loop system in accordance with the teachings of the present disclosure.

The figures are not drawn to scale. In general, the same reference numerals will be used throughout the drawings and the accompanying written description to refer to the same or like parts.

Detailed Description

"comprising" and "including" (and all forms and tenses thereof) are used herein as open-ended terms. Thus, whenever a claim uses any form of "comprising" or "including" (e.g., includes, comprises, has, etc.) as a prelude or in any type of claim statement, it is to be understood that additional elements, terms, etc. may be present without exceeding the scope of the corresponding claim or statement. As used herein, when the phrase "at least" is used as a transitional term, for example, in the preamble of a claim, it is open-ended as if the terms "comprising" and "including" were open-ended. The term "and/or" when used in the form of, for example, A, B and/or C, refers to any combination or subset of A, B, C, such as (1) a alone, (2) B alone, (3) C alone, (4) a and B, (5) a and C, (6) B and C, or (7) a and B and C. As used herein in the context of describing structures, components, items, objects and/or things, the phrase "at least one of a and B" is intended to refer to an embodiment that includes any of the following: (1) at least one A, (2) at least one B or (3) at least one A and at least one B. Similarly, as used herein in the context of describing structures, components, items, objects and/or things, the phrase "at least one of a or B" is intended to refer to an embodiment that includes any of the following: (1) at least one A, (2) at least one B or (3) at least one A and at least one B. As used herein in the context of describing the performance or execution of a process, instruction, action, activity, and/or step, the phrase "at least one of a and B" is intended to refer to an embodiment that includes any of the following: (1) at least one A, (2) at least one B or (3) at least one A and at least one B. Similarly, as used herein in the context of describing the performance or execution of a process, instruction, action, activity, and/or step, the phrase "at least one of a or B" is intended to refer to an embodiment that includes any of the following: (1) at least one A, (2) at least one B or (3) at least one A and at least one B.

As used herein, singular references (e.g., "a," "an," "first," "second," etc.) do not exclude a plurality. As used herein, the terms "a" or "an" object refer to one or more of the object. The terms "a" (or "an"), "one or more" and "at least one" can be used interchangeably herein. Moreover, although individually listed, a plurality of means, elements or method acts may be implemented by e.g. the same entity or object. Additionally, although individual features may be included in different examples or claims, these may possibly be combined, and the inclusion in different examples or claims does not imply that a combination of features is not feasible and/or advantageous.

As used herein, unless otherwise indicated, the term "above" describes the relationship of two parts relative to the earth. The first portion is above the second portion if at least one of the second portion is between the earth and the first portion. Likewise, as used herein, a first portion is "below" a second portion when the first portion is closer to the earth than the second portion. As described above, the first portion may be above or below the second portion, with one or more of the following: with other portions therebetween, without other portions therebetween, with the first portion and the second portion in contact, or without the first portion and the second portion in direct contact with each other.

As used in this disclosure, any portion (e.g., layer, film, region, zone, or plate) is stated to be in any way on (e.g., positioned on, located on, disposed on, or formed on, etc.) another portion, indicating that the indicated portion is in contact with, or above, the other portion, with one or more intervening portions therebetween.

As used herein, unless otherwise indicated, connective references (e.g., attachment, coupling, connection, and engagement) may include intermediate members between elements referred to by connective references and/or relative movement between those elements. Thus, a connective reference does not necessarily infer that two elements are directly connected and/or in fixed relation to each other. As used herein, stating that any portion "contacts" another portion is defined to mean that there is no intermediate portion between the two portions.

Unless specifically stated otherwise, descriptors such as "first," "second," "third," etc. as used herein do not assign or otherwise indicate any meaning of priority, physical order, arrangement in a list, and/or ordering in any way, but are used merely as labels and/or arbitrary names to distinguish between elements in order to facilitate an understanding of the disclosed examples. In some examples, the descriptor "first" may be used to refer to an element in the detailed description, while a different descriptor (such as "second" or "third") may be used in the claims to refer to the same element. In this case, it should be understood that such descriptors are only used to clearly identify those elements that might otherwise share the same name, for example.

Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as "about," "approximately," and "substantially," are not to be limited to the precise value specified. In at least some cases, the approximating language may correspond to the precision of an instrument for measuring the value or the precision of a method or machine for constructing or manufacturing a component and/or system. For example, the approximating language may refer to being within a ten percent margin.

The terms "forward" and "aft" refer to relative positions within the gas turbine engine, pump, or carrier, and refer to the normal operating attitude of the gas turbine engine, pump, or carrier. For example, with respect to a gas turbine engine, reference is made to a location closer to the engine inlet and then to a location closer to the engine nozzle or exhaust. Further, with respect to the pump, forward refers to a position closer to the inlet of the pump, and then to a position closer to the end of the pump opposite the inlet.

The terms "upstream" and "downstream" refer to the relative direction with respect to flow in a path. For example, "upstream" refers to the direction from which fluid flows, and "downstream" refers to the direction in which fluid flows, relative to fluid flow.

As used herein, the phrase "communication," including variations thereof, includes direct communication and/or indirect communication through one or more intermediary components, and does not require direct physical (e.g., wired) communication and/or constant communication, but additionally includes selective communication at periodic intervals, scheduled intervals, aperiodic intervals, and/or disposable events.

As used herein, "processor circuitry" is defined to include (i) one or more dedicated circuits configured to perform certain operations and comprising one or more semiconductor-based logic devices (e.g., electrical hardware implemented by one or more transistors), and/or (ii) one or more general-purpose semiconductor-based circuits programmed with instructions to perform certain operations and comprising one or more semiconductor-based logic devices (e.g., electrical hardware implemented by one or more transistors). Examples of processor circuits include a programmable microprocessor, a Field Programmable Gate Array (FPGA) that can instantiate instructions, a Central Processing Unit (CPU), a Graphics Processor Unit (GPU), a Digital Signal Processor (DSP), an XPU, or a microcontroller and integrated circuit such as an Application Specific Integrated Circuit (ASIC). For example, the XPU may be implemented by a heterogeneous computing system that includes multiple types of processor circuits (e.g., one or more FPGAs, one or more CPUs, one or more GPUs, one or more DSPs, etc., and/or combinations thereof) and Application Programming Interfaces (APIs) that may assign computing tasks to any of the multiple types of processing circuits that are best suited for performing the computing tasks.

As used herein, the term "substantially orthogonal" in the context of describing the position and/or orientation of a first object relative to a second object includes the term orthogonal, and more broadly includes the meaning that the first object is positioned and/or oriented relative to the second object at an absolute angle of no more than five degrees (5 °) from orthogonal. For example, a first axis that is substantially orthogonal to a second axis is positioned and/or oriented at an absolute angle of no more than five degrees (5 °) from orthogonal relative to the second axis.

As used herein, "radially" is used to express a point or points along a radial vector that originates at the central axis of the rotating body and points perpendicularly outward from the central axis. In some examples, two gears are referred to as radially connected or coupled, meaning that the two gears are in physical contact with each other at one or more points along the circumferential outer edge surface of the gears via interlocking gear teeth. In some examples, the two pulleys are referred to as radially connected or coupled, meaning that the two pulleys are in physical contact with the drive belt at one or more points along the circumferential outer edge surface of the pulleys.

Centrifugal fluid pumps move fluid through a system by converting rotational kinetic energy of an impeller into hydrodynamic energy of a flowing fluid. In other words, the angular velocity of the impeller is proportional to the flow rate of the flowing fluid exiting the pump. The impeller is provided with rotational kinetic energy variation from a motor that applies mechanical work to an impeller shaft coupled to the impeller and to a rotor of the motor. The rotor is provided with a change in mechanical work (i.e., mechanical power) over a period of time from a stator in the motor that applies an electromagnetic force to the rotor in the form of torque. If the motor supplies a constant amount of electrical energy to the stator, the rotor will supply a constant amount of mechanical energy to the impeller. In this case, the mechanical power supplied by the motor to the pump will be equal to the quotient of the rotational kinetic energy and the amount of time the power is supplied. In a rotating system, such as a centrifugal fluid pump, the mechanical power of the impeller is equal to the product of torque and angular velocity. If the rotor of the motor and the impeller shaft of the centrifugal fluid pump are axially coupled (e.g. by a magnetic coupling), the torque and angular velocity of the rotor will be transferred to the impeller via the coupling shaft and will have the same value.

In some examples of fluid pump systems, a motor shaft (e.g., a rotor) may be axially coupled to an impeller shaft via a magnetic coupling. The magnetic coupling transfers torque between the two shafts without physical contact between the shafts. In some examples, the magnetic coupling may be in the form of an inner hub secured to the first shaft (e.g., the impeller shaft) and an outer hub secured to the second shaft (e.g., the rotor shaft). In the example outer hub, a series of magnets (e.g., bar magnets) are positioned to surround the example inner hub, with each magnet having an opposite charge to the previous magnet in the series. In the inner hub, a similar series of magnets are positioned about the rotational axis of the first shaft. In some examples, the outer hub and the inner hub have the same number of magnets. Because oppositely charged magnets attract each other via a magnetic field, rotation of the outer hub causes the inner hub to rotate at the same rate as the outer hub is positioned around the inner hub. In other words, the example inner hub and the example outer hub are rotatably interlocked. This type of magnetic coupling may be referred to as a coaxial magnetic coupling. Because there is no physical contact between the inner hub and the outer hub of the coaxial magnetic coupling, the containment barrier (containment barrier) can be secured to the housing surrounding the inner hub such that no fluid can flow from the inner hub side to the outer hub side.

Example aircraft and engines in which examples disclosed herein may be implemented

For the drawings disclosed herein, like numbers refer to like elements throughout. Referring now to the drawings, FIG. 1 is a side view of one embodiment of an aircraft 10. As shown, in several embodiments, the aircraft 10 includes a fuselage 12 and a pair of wings 14 (one shown), with the pair of wings 14 extending outwardly from the fuselage 12. In the illustrated embodiment, a gas turbine engine 100 is supported on each wing 14 to propel an aircraft through the air during flight. Additionally, as shown, the aircraft 10 includes a vertical stabilizer 16 and a pair of horizontal stabilizers 18 (one shown). However, in alternative embodiments, the aircraft 10 may include any other suitable configuration, such as any other suitable number or type of engines.

Furthermore, aircraft 10 may include a thermal management system 200, thermal management system 200 being configured to transfer heat between fluids supporting operation of aircraft 10. More specifically, aircraft 10 may include one or more accessory systems configured to support operation of aircraft 10. For example, in some embodiments, such accessory systems include lubrication systems that lubricate components of engine 100, cooling systems that provide cooling air to components of engine 100, environmental control systems that provide cooled air to the cabin of aircraft 10, and the like. In such embodiments, thermal management system 200 is configured to transfer heat from one or more other fluids supporting operation of aircraft 10 (e.g., fuel supplied to engine 100) to one or more fluids supporting operation of aircraft 10 (e.g., oil of a lubrication system, air of a cooling system and/or an environmental control system, etc.), and/or to transfer heat from one or more fluids supporting operation of aircraft 10 (e.g., oil of a lubrication system, air of a cooling system and/or an environmental control system, etc.) to one or more other fluids supporting operation of aircraft 10 (e.g., fuel supplied to engine 100). However, in alternative embodiments, thermal management system 200 may be configured to transfer heat between any other suitable fluid that supports operation of aircraft 10.

The configuration of the aircraft 10 described above and shown in fig. 1 is provided only for placing the present subject matter in an exemplary field of use. Thus, the present subject matter may be readily adapted for any manner of aircraft and/or any other suitable heat transfer application.

FIG. 2 is a schematic cross-sectional view of an embodiment of a gas turbine engine 100. In the illustrated embodiment, engine 100 is configured as a high bypass turbofan engine. However, in alternative embodiments, engine 100 may be configured as a propeller fan engine, a turbojet engine, a turboprop engine, a turboshaft gas turbine engine, or any other suitable type of gas turbine engine.

In general, engine 100 extends along an axial centerline 102 and includes a fan 104, a Low Pressure (LP) spool 106, and a High Pressure (HP) spool 108 at least partially encased by an annular nacelle 110. More specifically, fan 104 may include a fan rotor 112 and a plurality of fan blades 114 (one shown) coupled to fan rotor 112. In this regard, the fan blades 114 are circumferentially spaced apart and extend radially outward from the fan rotor 112. In addition, the LP and HP spools 106, 108 are positioned downstream of the fan 104 along the axial centerline 102. As shown, LP spool 106 is rotatably coupled to fan rotor 112, allowing LP spool 106 to rotate fan blades 114. Additionally, a plurality of outlet guide vanes or struts 116 are circumferentially spaced apart from one another and extend radially between an outer casing 118 surrounding the LP rotor 106 and HP rotor 108 and the nacelle 110. Thus, the struts 116 support the nacelle 110 relative to the housing 118 such that the housing 118 and the nacelle 110 define a bypass airflow passage 120 positioned therebetween.

The casing 118 generally surrounds or encases the compressor section 122, the combustion section 124, the turbine section 126, and the exhaust section 128 in serial flow order. In some examples, the compressor section 122 may include a Low Pressure (LP) compressor 130 of the LP spool 106 and a High Pressure (HP) compressor 132 of the HP spool 108, the HP compressor 132 being positioned downstream of the LP compressor 130 along the axial centerline 102. Each compressor 130, 132, in turn, may include one or more rows of stator vanes 134 interleaved with one or more rows of compressor rotor blades 136. Accordingly, the compressors 130, 132 define a compressed air flow path 133 extending therethrough. Moreover, in some examples, turbine section 126 includes a High Pressure (HP) turbine 138 of HP spool 108 and a Low Pressure (LP) turbine 140 of LP spool 106, LP turbine 140 being positioned downstream of HP turbine 138 along axial centerline 102. Each turbine 138, 140, in turn, may include one or more rows of stator vanes 142 interleaved with one or more rows of turbine rotor blades 144.

Additionally, the LP spool 106 includes a Low Pressure (LP) shaft 146, while the HP spool 108 includes a High Pressure (HP) shaft 148, the HP shaft 148 being positioned concentrically about the LP shaft 146. In such an embodiment, HP shaft 148 rotatably couples turbine rotor blades 144 of HP turbine 138 and compressor rotor blades 136 of HP compressor 132 such that rotation of turbine rotor blades 144 of HP turbine 138 rotatably drives compressor rotor blades 136 of HP compressor 132. As shown, the LP shaft 146 is directly coupled to turbine rotor blades 144 of the LP turbine 140 and compressor rotor blades 136 of the LP compressor 130. Further, the LP shaft 146 is coupled to the fan 104 via a gearbox 150. In this regard, rotation of turbine rotor blades 144 of LP turbine 140 rotatably drives compressor rotor blades 136 and fan blades 114 of LP compressor 130.

In some examples, engine 100 may generate thrust to propel an aircraft. More specifically, during operation, air (indicated by arrow 152) enters an inlet portion 154 of engine 100. Fan 104 supplies a first portion of air 152 (indicated by arrow 156) to bypass airflow passage 120 and a second portion of air 152 (indicated by arrow 158) to compressor section 122. A second portion 158 of air 152 first flows through LP compressor 130, where compressor rotor blades 136 therein progressively compress second portion 158 of air 152. Next, the second portion 158 of the air 152 flows through the HP compressor 132, wherein the compressor rotor blades 136 therein continue to progressively compress the second portion 158 of the air 152 in the HP compressor 132. A compressed second portion 158 of the air 152 is then channeled to combustion section 124. In the combustion section 124, a second portion 158 of the air 152 is mixed with fuel and combusted to generate a high temperature, high pressure combustion gas 160. Thereafter, the combustion gases 160 flow through the HP turbine 138, and turbine rotor blades 144 of the HP turbine 138 extract a first portion of kinetic and/or thermal energy therefrom. This energy extraction rotates HP shaft 148, thereby driving HP compressor 132. The combustion gases 160 then flow through the LP turbine 140, wherein turbine rotor blades 144 of the LP turbine 140 extract a second portion of kinetic and/or thermal energy therefrom. This energy extraction rotates the LP shaft 146, thereby driving the LP compressor 130 and the fan 104 via the gearbox 150. The combustion gases 160 then exit the engine 100 through the exhaust section 128.

As described above, aircraft 10 may include thermal management system 200 for transferring heat between fluids supporting operation of aircraft 10. In this regard, thermal management system 200 may be positioned within engine 100. For example, as shown in FIG. 2, thermal management system 200 is positioned within housing 118 of engine 100. However, in alternative examples, thermal management system 200 may be positioned at any other suitable location within engine 100.

Further, in some examples, engine 100 defines a third flow path 170. In general, the third flow path 170 extends from the compressed air flow path 133 defined by the compressor section 122 to the bypass airflow passage 120. In this regard, the third flow path 170 allows a portion of the compression of the compressed air 158 from the compressor section 122 to bypass the combustion section 124. More specifically, in some examples, the third flow path 170 may define concentric or non-concentric channels with respect to the compressed air flow path 170 downstream of one or more of the compressors 130, 132 or the fans 104. The third flow path 170 may be configured to selectively remove a portion of the compressed air 158 from the compressed air flow path 170 via one or more variable guide vanes, nozzles, or other actuatable flow control structures. Additionally, as will be described below, in some embodiments, the thermal management system 200 may transfer heat to the air flowing through the third flow path 170. However, the fluid within the thermal management system 200 (e.g., a heat exchange fluid, such as a supercritical fluid (e.g., supercritical carbon dioxide (scco) ₂ ) Etc.) limits the rate at which thermal energy is transferred between the air and the heat exchange fluid. Additionally, it is advantageous for thermal management system 200 to generate pressure and/or flow rate with components (e.g., pump systems) that minimize and/or otherwise reduce the physical size of thermal management system 200 and/or components (e.g., pump systems) included therein. Further, the thermal management system 200 may ensure that the heat exchange fluid is free of contaminants when transferring thermal energy.

The configuration of the gas turbine engine 100 described above and shown in FIG. 2 is provided only for placing the present subject matter in an exemplary field of use. Thus, the present subject matter may be readily adapted to any manner of gas turbine engine configuration, including other types of aircraft-based gas turbine engines, marine-based gas turbine engines, and/or land-based/industrial gas turbine engines.

The illustrations of examples disclosed herein may be implementedExample thermal management system

FIG. 3 is a schematic diagram of an example embodiment of a thermal management system 200 for transferring heat between fluids. In general, the thermal management system 200 will be discussed above and in the context of the aircraft 10 and the gas turbine engine 100 shown in FIGS. 1 and 2. However, the disclosed thermal management system 200 may be implemented within any aircraft having any other suitable configuration and/or any gas turbine engine having any other suitable configuration.

As shown, thermal management system 200 includes a heat transfer bus 202. Specifically, in several examples, the heat transfer bus 202 is configured as one or more fluid conduits through which a fluid (e.g., a heat exchange fluid) flows. As will be described below, the heat exchange fluid flows through the various heat exchangers such that heat is added to and/or removed from the heat exchange fluid. In this regard, the heat exchange fluid may be any suitable fluid, such as supercritical carbon dioxide. Further, in such an example, thermal management system 200 includes a pump 204, pump 204 configured to pump heat exchange fluid through heat transfer bus 202.

Additionally, the thermal management system 200 includes one or more heat source heat exchangers 206 arranged along the heat transfer bus 202. More specifically, heat source heat exchanger 206 is fluidly coupled to heat transfer bus 202 such that a heat exchange fluid flows through heat source heat exchanger 206. In this regard, heat source heat exchanger 206 is configured to transfer heat from the fluid supporting operation of aircraft 10 to the heat exchange fluid, thereby cooling the fluid supporting operation of aircraft 10. Thus, the heat source heat exchanger 206 adds heat to the heat exchange fluid. Although fig. 3 shows two heat source heat exchangers 206, the thermal management system 200 may include a single heat source heat exchanger 206 or three or more heat source heat exchangers 206.

Heat source heat exchanger 206 may correspond to any suitable heat exchanger that cools a fluid supporting operation of aircraft 10. For example, in one embodiment, at least one of the heat exchangers 206 is a heat exchanger of a lubrication system of the engine 100. In this example, the heat exchanger 206 transfers heat from the oil that lubricates the engine 100 to a heat transfer fluid. In another example, at least one of the heat exchangers 206 is a heat exchanger of a cooling system of the engine 100. In this example, the heat exchanger 206 transfers heat from cooling air discharged from the compressor section 122 (or compressor discharge plenum) of the engine 100 to a heat transfer fluid. However, in alternative examples, heat source heat exchanger 206 may correspond to any other suitable heat exchanger that cools a fluid supporting operation of aircraft 10.

Further, the thermal management system 200 includes a plurality of radiator heat exchangers 208 arranged along the heat transfer bus 202. More specifically, the radiator heat exchanger 208 is fluidly coupled to the heat transfer bus 202 such that a heat exchange fluid flows through the radiator heat exchanger 208. In this regard, radiator heat exchanger 208 is configured to transfer heat from the heat exchange fluid to other fluids supporting operation of aircraft 10, thereby heating the other fluids supporting operation of aircraft 10. Thus, the radiator heat exchanger 208 removes heat from the heat exchange fluid. Although fig. 3 shows two radiator heat exchangers 208, the thermal management system 200 may include three or more radiator heat exchangers 208.

Radiator heat exchanger 208 may correspond to any suitable heat exchanger that heats a fluid supporting operation of aircraft 10. For example, at least one of the heat exchangers 208 is a heat exchanger of a fuel system of the engine 100. In such an example, fuel system heat exchanger 208 transfers heat from the heat transfer fluid to fuel supplied to engine 100. In another embodiment, at least one of the heat exchangers 208 is a heat exchanger in contact with the air 156 flowing through the bypass airflow passage 120 of the engine 100. In this example, the heat exchanger 208 transfers heat from the heat exchange fluid to the air 156 flowing through the bypass airflow passage 120.

In several examples, the one or more heat exchangers 208 are configured to transfer heat to the air flowing through the third flow path 170. In this example, the heat exchanger 208 is in contact with the air flow flowing through the third flow path 170. Accordingly, heat from the heat exchange fluid flowing through the heat transfer bus 202 may be transferred to the air flow through the third flow path 170. The use of the third flow path 170 as a heat sink for the thermal management system 200 provides one or more technical advantages. For example, the third flow path 170 provides greater cooling than other bleed air sources because a greater volume of air flows through the third flow path 170 than other bleed air flow paths. In addition, the air flowing through the third flow path 170 is cooler than the air flowing through the other bleed air flow paths and the compressor bleed air. Additionally, the air in the third flow path 170 is pressurized, allowing the heat exchanger 208 to be smaller than heat exchangers that rely on other radiators within the engine. Furthermore, in embodiments where engine 100 is non-ducted, using third flow path 170 as a radiator does not increase the resistance on engine 100, as opposed to using ambient air (e.g., a heat exchanger in contact with air flowing around engine 100). However, in alternative embodiments, radiator heat exchanger 208 may correspond to any other suitable heat exchanger that heats a fluid supporting operation of aircraft 10.

Furthermore, in several embodiments, thermal management system 200 includes one or more bypass conduits 210. Specifically, as shown, each bypass conduit 210 is fluidly coupled to the heat transfer bus 202 such that the bypass conduit 210 allows at least a portion of the heat exchange fluid to bypass one of the heat exchangers 206, 208. In some examples, the heat exchange fluid bypasses one or more of the heat exchangers 206, 208 to adjust the temperature of the heat exchange fluid within the heat transfer bus 202. The flow of the example heat exchange fluid through bypass conduit 210 is controlled to regulate the pressure of the heat exchange fluid within heat transfer bus 202. In the example shown in fig. 3, each heat exchanger 206, 208 has a corresponding bypass conduit 210. However, in alternative embodiments, any number of heat exchangers 206, 208 may have corresponding bypass conduits 210, so long as at least one bypass conduit 210 is present.

Additionally, in several examples, thermal management system 200 includes one or more heat source valves 212 and one or more heat sink valves 214. In general, each heat source valve 212 is configured to control the flow of heat exchange fluid through bypass conduit 210, bypass conduit 210 bypassing heat source heat exchanger 206. Similarly, each radiator valve 214 is configured to control the flow of heat exchange fluid through bypass conduit 210, bypass conduit 210 bypassing radiator heat exchanger 208. In this regard, each valve 212, 214 is fluidly coupled to the heat transfer bus 202 and the corresponding bypass conduit 210. Thus, each valve 212, 214 may be moved between fully and/or partially open and/or closed positions to selectively block heat exchange flow through its corresponding bypass conduit 210.

The valves 212, 214 are controlled based on the pressure of the heat exchange fluid within the heat transfer bus 202. More specifically, as indicated above, in some cases, the pressure of the heat exchange fluid flowing through the heat transfer bus 202 may fall outside of a desired pressure range. When the pressure of the heat exchange fluid is too high, the thermal management system 200 may cause accelerated wear. In this regard, when the pressure of the heat exchange fluid within the heat transfer bus 202 exceeds a maximum pressure value or otherwise increases a pressure value, one or more heat source valves 212 open. In this case, at least a portion of the heat exchange fluid flows through bypass conduit 210 instead of heat source heat exchanger 206. Thus, less heat is added to the heat exchange fluid through the heat source heat exchanger 206, thereby reducing the temperature and, therefore, the pressure of the fluid. In several embodiments, the maximum pressure value is between 3800 and 4000 pounds per square inch or less. In some embodiments, the maximum pressure value is between 2700 and 2900 pounds per square inch, such as 2800 pounds per square inch. In other embodiments, the maximum pressure value is between 1300 and 1500 pounds per square inch, such as 1400 pounds per square inch. Such maximum pressure values substantially prevent the thermal management system 200 from causing accelerated wear.

In some examples, the maximum pressure value is set prior to and/or during operation based on parameters associated with thermal management system 200 (e.g., materials used, pump 204 design, aircraft 10 design, gas turbine engine 100 design, heat exchange fluid, etc.). The example maximum pressure value may be adjusted relative to the pressure capacity of the heat transfer bus 202, the pump 204, the heat exchangers 206, 208, the bypass conduit 210, and/or the valves 212, 214. Some examples of pump 204 architectures that affect example maximum pressure capacities are described in more detail below.

Conversely, when the pressure of the heat exchange fluid is too low, the pump 204 may experience operability problems and increased wear. Accordingly, when the pressure of the heat exchange fluid within the heat transfer bus falls below a minimum pressure value or otherwise reduced pressure value, one or more radiator valves 214 open. In this case, at least a portion of the heat exchange fluid flows through bypass conduit 210 instead of radiator heat exchanger 208. Accordingly, less heat is removed from the heat exchange fluid through the radiator heat exchanger 208, thereby increasing the temperature and thus the pressure of the fluid. In several embodiments, the minimum pressure value is 1070 pounds per square inch or more. In some embodiments, the minimum pressure value is between 1150 and 1350 pounds per square inch, such as 1250 pounds per square inch. In other embodiments, the minimum pressure value is between 2400 and 2600 pounds per square inch, such as 2500 pounds per square inch. Such a minimum pressure value is generally used when the heat exchange fluid is in a supercritical state (e.g., when the heat exchange fluid is carbon dioxide).

Accordingly, the thermal management system 200 may be configured to operate such that the pressure of the heat transfer fluid is maintained within a range extending between a minimum pressure value and a maximum pressure value. In some examples, the range extends from 1070 pounds per square inch to 4000 pounds per square inch. Specifically, in one example, the range extends from 1250 pounds per square inch to 1400 pounds. In another embodiment, the range extends from 2500 pounds per square inch to 2800 pounds.

Thus, operation of the pump 204 and valves 212, 214 allows the disclosed thermal management system 200 to maintain the pressure of the heat exchange fluid within the heat transfer bus 202 within a particular range of values as the thermal load placed on the thermal management system 200 changes.

Further, the example pump 204 drives the heat exchange fluid through the heat management system 200. In some examples, thermal management system 200 includes one pump 204 or multiple pumps 204 depending on a desired flow rate of the heat exchange fluid in heat transfer bus 202, a pressure differential (delta pressure) across pumps 204, and/or kinetic energy loss. For example, the pump 204 may increase the output head to accelerate the flow of the heat exchange fluid to the first flow rate. As the heat exchange fluid passes through the heat transfer bus 202, the example kinetic energy of the heat exchange fluid dissipates due to friction, temperature changes, and the like. Due to the kinetic energy loss, the heat exchange fluid decelerates to the second flow rate at a point upstream of the pump 204. If the example second flow rate is lower than the desired operating flow rate of the heat exchange fluid, the pump 204 may have a different architecture that outputs a higher first flow rate, or one or more additional pumps 204 may be included in the thermal management system 200. Variations of the example pump 204 architecture are described in more detail below.

Fig. 4 illustrates an example heat transfer bus pump 400 (e.g., a magnetically driven pump, a sealed electric pump, a fluid pump, a scco 2 pump, the pump 204 of fig. 3, etc.). In the example shown in fig. 4, the heat transfer bus pump 400 drives a fluid (e.g., a heat exchange fluid, such as scco 2, etc.) through one or more fluid conduits 402 that are connected to a flow line (e.g., the heat transfer bus 202 of fig. 3). Specifically, fluid flows through the inlet tube 404 and encounters the impeller 406 (e.g., a compressor wheel), the impeller 406 rotates to drive the fluid through a compressor collector 408 (e.g., a volute), the compressor collector 408 being fluidly coupled to the fluid conduit 402. Further, the fluid conduit 402 may supply fluid to one or more heat exchangers (e.g., the heat source exchanger 206 and/or the radiator exchanger 208 of fig. 3). Accordingly, the heat transfer bus pump 400 may pump fluid to manage thermal energy of the working fluid associated with the aircraft 10 of fig. 1, the gas turbine engine 100 of fig. 2, and/or any other suitable system.

In the example shown in fig. 4, the heat transfer bus pump 400 includes a motor 410, the motor 410 being positioned in a motor housing 412. As discussed in further detail below, the motor 410 indirectly drives rotation of the impeller 406. In fig. 4, motor 410 is an induction motor that is operably coupled to a Variable Frequency Drive (VFD) (not shown) via a feed through connector 414, feed through connector 414 being coupled to motor housing 412. The VFD may be operatively coupled to a control circuit, such as a Full Authority Digital Engine Control (FADEC) (not shown), that controls the rotational speed of the motor 410. For example, the control circuit may operate the motor 410 based on the pressure and/or temperature of the fluid in the fluid conduit 402 and/or the heat transfer bus pump 400. In some examples, the control circuit may operate motor 410 based on the pressure and/or temperature of the fluid-affected working fluid. Additionally or alternatively, the control circuit may operate the motor 410 based on vibration measurements obtained by an accelerometer operatively coupled to the heat transfer bus pump 400 and/or the fluid conduit 402.

In fig. 4, motor housing 412 is at least partially surrounded by cooling jacket 416 to prevent overheating of motor 410. The rear end of the motor housing 412 is coupled to a rear bearing housing 418. The front end of the motor housing 412 is coupled to the intermediate bearing housing 420 via bolts 422. Further, the intermediate bearing housing 420 is coupled to a coupling housing 424 opposite the motor housing 412 via bolts 426. The coupling housing 424 is coupled to a front bearing housing 428 opposite the intermediate bearing housing 420 via bolts 430. Further, front bearing housing 428 is coupled to back plate 432 and compressor collector 408 on an opposite side of back plate 432 via bolts 434.

In the example shown in fig. 4, the rotor 436 of the motor 410 is fixedly coupled to a shaft 438. Thus, motor 410 drives rotation of shaft 438. The rear end of the shaft 438 is supported by a first roller bearing 440 (e.g., a first rolling element bearing), the first roller bearing 440 being coupled to the rear bearing housing 418. Specifically, the first roller bearing 440 is coupled to the rear bearing housing 418 via a first bearing cup 442 and a bearing shim 444 positioned between the first roller bearing 440 and the rear bearing housing 418. In the example shown in fig. 4, a preload spring 446 is positioned between the first bearing cup 442 and the bearing spacer 444. Similarly, the front end of the shaft 438 is supported by a second roller bearing 448 (e.g., a second rolling element bearing), the second roller bearing 448 being coupled to the intermediate bearing housing 420. Specifically, the second roller bearing 448 is coupled to the intermediate bearing housing 420 via a second bearing cup 449. The first roller bearing 440 and the second roller bearing 448 are filled with an oil lubricant (e.g., grease, motor oil, etc.) to reduce resistance to rotation of the shaft 438 and to reduce wear encountered by the bearings 440, 448 as the shaft 438 rotates.

In the example shown in fig. 4, the forward end of the shaft 438 extends at least partially through the intermediate bearing housing 420. The rear end of the first magnetic coupling 450 (e.g., a female magnetic coupling) is positioned about the front end of the shaft 438. To couple the shaft 438 and the first magnetic coupling 450, a retaining bolt 451 is inserted through the rear end of the first magnetic coupling 450 and the front end of the shaft 438. Specifically, the width of the head 453 of the retaining bolt 451 is greater than the width of the aperture 455 in the first magnetic coupling 450 through which the retaining bolt 451 extends. As a result, the shaft 438 drives the rotation of the first magnetic coupling 450.

In the example shown in fig. 4, the first magnetic coupling 450 is positioned around a barrier can 452 (e.g., a shield). To couple the barrier can 452 to the front bearing housing 428, a barrier can retainer 454 (e.g., a retainer ring) is positioned around a flange 456 of the barrier can 452 and coupled to a rear end of the front bearing housing 428 via bolts 458. Further, an O-ring 459 is positioned between flange 456 of barrier can 452 and barrier can retainer 454. The barrier canister 452 hermetically seals the rear end of the front bearing housing 428 and thereby prevents fluid spillage. Thus, the barrier canister 452 prevents fluid from flowing through the coupling housing 424 and mixing with other fluids (such as oil lubricant of the first roller bearing 440 and/or the second roller bearing 448), which would otherwise impede the safe transfer of thermal energy between the fluid and the working fluid. Additionally or alternatively, the barrier canister 452 may hermetically seal the motor housing 412 to prevent oil lubricant from mixing with and contaminating the fluid.

In the example shown in fig. 4, the barrier canister 452 is positioned around a second magnetic coupling 460 (e.g., a male magnetic coupling), the second magnetic coupling 460 being magnetically coupled to the first magnetic coupling 450. In particular, opposing magnetic poles of the first magnetic coupling 450 and the second magnetic coupling 460 are aligned on opposite sides of the barrier can 452 to magnetically couple the first magnetic coupling 450 to the second magnetic coupling 460. As a result, the first magnetic coupling 450 and the second magnetic coupling 460 are rotatably interlocked. Thus, the first magnetic coupling 450 may drive rotation of the second magnetic coupling 460. In some examples, the coupling housing 424 includes a vent 461 to enable fluid (e.g., hydrogen, air, etc.) to circulate into and out of the coupling housing 424. Further, when the barrier tank 452 generates heat energy due to encountering the rotating magnetic field generated by the first and second magnetic couplings 450 and 460, the fluid may absorb heat from the barrier tank 452 to prevent the barrier tank 452 from melting. In some examples, the fan drive fluid circulates through a vent 461 in the coupling housing 424. In some other examples, the vent 461 is open to the atmosphere or another fluid housing portion, which provides a fluid to absorb heat from the barrier can 452.

In the example shown in fig. 4, the second magnetic coupling 460 is coupled to the pull rod 462 via the top cap 464. A pull rod 462 extends through the front bearing housing 428 and the back plate 432 to couple to the impeller 406. Additionally, the second magnetic coupling 460 is coupled to the shaft 466 and/or extends from the shaft 466, with the shaft 466 positioned about the pull rod 462. Similarly, a shaft 466 extends through the front bearing housing 428 and the backplate 432 to couple to the impeller 406. As a result, the pull rod 462 and the shaft 466 cause the impeller 406 to rotate with the second magnetic coupling 460 and pump fluid.

In the example shown in fig. 4, an axial portion 468 of shaft 466 is supported by journal bearing assembly 470. Further, a radial portion 472 of the shaft 466 is supported by a thrust bearing assembly 474. For example, journal bearing assembly 470 and/or thrust bearing assembly 474 may include foil bearings. In some examples, journal bearing assembly 470 and thrust bearing assembly 474 are coupled to forward bearing housing 428 via bolts. Additionally or alternatively, the thrust bearing assembly 474 may be coupled to one of the journal bearing assemblies 470.

In the example shown in fig. 4, the heat transfer bus pump 400 includes a secondary flow network having an inlet 475 in a front bearing housing 428. Specifically, in the secondary flow network, fluid enters the front bearing housing 428 and flows between the radial portion 472 of the shaft 466 and the thrust bearing assembly 474. Further, in the secondary flow network, a first portion of the fluid flows around the shaft 466 and into the compressor collector 408 between the impeller 406 and the backplate 432. A second portion of the fluid in the secondary flow network flows around the shaft 466 toward the barrier tank 452. The separation between the rear end of the second magnetic coupling 460 and the barrier canister 452 enables fluid to flow through the second magnetic coupling 460 and back toward the impeller 406 through the shaft 466. Further, the shaft 466 includes a conduit 476 that directs fluid flow therethrough between the backplate 432 and the impeller 406 such that the fluid enters the compressor collector 408. Thus, upon rotation of the motor 410 drive shaft 438, the impeller 406 pumps fluid through the fluid conduit 402.

In some examples, the heat transfer bus pump 400 includes a means for containing a fluid. For example, the means for receiving may be implemented by the compressor collector 408, the front bearing housing 428, and/or the backplate 432.

In some examples, the heat transfer bus pump 400 includes a means for compressing a fluid. For example, the means for compressing the fluid may be implemented by the impeller 406.

In some examples, the heat transfer bus pump 400 includes means for sealing the means for housing. For example, the means for sealing may be implemented by the barrier can 452.

Radially coupled pump system for pressurizing fluid in a closed loop system

As described above with reference to fig. 4, some example fluid pump systems and operation of centrifugal fluid pump systems have an electric motor axially aligned with an impeller (e.g., impeller 406). In such an example fluid pump, the torque and angular velocity of the motor shaft (e.g., rotor shaft 438) is transferred directly to the impeller shaft (e.g., impeller shaft 466) and ultimately to the impeller. For example, if a motor (e.g., motor 410) provides 2000 watts (W) of mechanical power to the rotor shaft and the rotor shaft rotates at an angular rate of 3600 revolutions per minute (rpm), the torque produced by the rotor is 5.31 newton meters (Nm). In this example, since the rotor is axially aligned with and coupled to the impeller via the impeller shaft, the impeller will also have an angular speed of 3600rpm (378 radians per second (rad/s)) and a torque of 5.31 Nm.

In some examples, an axially configured fluid pump, such as the heat transfer bus pump 400 of fig. 4 described above ("axially coupled pump 400"), is limited in the amount by which the impeller can convert to an angular velocity of the fluid flow rate. The example angular velocity of the impeller is limited based on the available mechanical power supplied by the motor to the pump system (e.g., axially coupled pump 400). In other words, the motor causes a first angular velocity of the rotor shaft that is substantially similar (e.g., within one percent) to a second angular velocity of the impeller. Thus, the power of the motor limits the flow rate of fluid (e.g., heat exchange fluid, such as supercritical fluid (e.g., supercritical carbon dioxide (scco 2)), etc.) exiting the pump 400. For example, the thermal management system 200 of fig. 3 on an aircraft (e.g., the aircraft 10 of fig. 1) may include an axially coupled pump 400 to pressurize fluid up to a first pressure (e.g., 1450 force pounds per square inch (psi), 1475psi, 1500psi, etc.), the first pressure being associated with a first angular velocity of the impeller (e.g., 4800rpm, 5000rpm, 5200rpm, etc.). However, the example axially coupled pump 400 described above may not be able to pressurize the example scco 2 to a pressure sufficient to maintain the supercritical state of the fluid due to thermal energy loss in the example thermal management system 200. A larger and higher power motor would have to be incorporated into the axially coupled pump 400, which would take up more space and add additional weight to the system. If the above-described example axially coupled pump 400 is capable of pressurizing the heat exchange fluid up to a second pressure associated with the first angular velocity of the impeller (e.g., 1550psi, 1575psi, 1600psi, etc.), the motor of the axially coupled pump 400 (e.g., motor 410) may need to be serviced or replaced after a first period of operation (e.g., one year).

In examples disclosed herein, the radially coupled pump system may output a higher angular velocity of the impeller using the same (e.g., substantially similar) motor and/or the same power output as the motor 410 of the axially coupled pump 400. In the examples disclosed herein, the radially coupled pump system may also utilize a smaller motor and/or a smaller power output that outputs the same (e.g., substantially similar) angular velocity of the impeller as the motor 410 of the axially coupled pump 400. In the examples disclosed herein, the radially coupled pump system may also reduce the axial length of the pump relative to the axially coupled pump 400, thereby saving space in a system (e.g., the thermal management system 200 of fig. 3) that uses the radially coupled pump system.

Fig. 5 illustrates a cross-sectional view of a radially coupled pump system 500 for a fluid (e.g., a heat exchange fluid, such as a supercritical fluid (e.g., scco 2, etc.)) in a pressurized system (e.g., thermal management system 200 of fig. 3). As shown in fig. 5, a radially coupled pump system 500 ("pump system 500") includes a pump 502 and an electric motor 504. In some examples, pump system 500 is used to pump the scco 2 through a thermal management system on an aircraft (e.g., aircraft 10 of fig. 1) and/or a gas turbine engine (e.g., gas turbine engine 100 of fig. 2). In some examples, motor 504 of pump system 500 includes stator 506, rotor 508, radial motor bearing 510, motor housing 512, cooling jacket 514, coupling housing 516, and drive wheel 518.

The example motor 504 of the pump system 500 shown in fig. 5 includes a stator 506 and a rotor 508. In some examples, the stator 506 includes field magnets (e.g., electromagnets or permanent magnets) that generate a magnetic field based on current (e.g., direct current or alternating current) through the various electromagnets of the stator 506. The example stator 506 generates a first set of magnetic fields that exert a force (e.g., lorentz force) on a second set of magnetic fields generated by the rotor 508. The example rotor 508 generates a second set of magnetic fields via permanent magnets or electromagnets. Since the stator 506 is stationary and fixed in position, this force causes the example rotor 508 to rotate and generate torque.

The example motor 504 of the pump system 500 includes radial motor bearings 510, the radial motor bearings 510 supporting the weight of the rotor shaft 508 and maintaining the rotor 508 in radial and/or axial alignment. The example radial motor bearing 510 supports radial loads (e.g., weight) and thrust loads of the rotor 508. In some examples, radial motor bearing 510 is a rolling element bearing, such as an angular contact ball bearing, a hybrid ceramic bearing, a tapered roller bearing, a deep groove single ball bearing, a double ball bearing, a spherical bearing, or the like. In some examples, radial motor bearing 510 uses a liquid lubricant (e.g., grease, oil, etc.) to reduce friction and wear in the rotating elements of radial motor bearing 510. In some examples, radial motor bearing 510 uses a solid lubricant (e.g., a silver coating) to reduce friction and wear of rotating elements of radial motor bearing 510. In some examples, radial motor bearing 510 is a foil bearing that uses pressurized air to form a non-contact barrier between the rotor shaft and the sleeve of radial motor bearing 510 at a sufficiently high rotational speed. Although motor 504 is shown in fig. 5 as including two radial motor bearings 510, one or more radial motor bearings 510 may be used in motor 504.

The example motor 504 of the pump system 500 includes a motor housing 512 to frame and/or otherwise support the stator 506, radial motor bearings 510, and the like. In some examples, the motor housing 512 is additively manufactured (e.g., via Direct Metal Laser Sintering (DMLS), three-dimensional printing, etc.) to accommodate the custom geometry and configuration of the stator 506, radial motor bearing 510, cooling jacket 514, etc.

Because the example stator 506 uses electromagnets to generate eddy currents, the example pump system 500 shown in fig. 5 includes a cooling jacket 514 to dissipate heat generated by the stator 506 during operation. In some examples, the cooling jacket 514 is mechanically secured to the motor housing 512 and includes cooling fins, vents, channels, etc. to transfer heat from the stator 506 to air, water, gas coolant, liquid coolant, etc. The example motor housing 512 shown in fig. 5 is an additive manufactured structure that includes a cooling jacket 514 as an additive manufactured portion of the motor housing 512 such that the cooling jacket 514 and the motor housing 512 are the same additive manufactured portion. The example cooling jacket 514 shown in fig. 5 is fabricated in conjunction with the motor housing 512 to surround the stator 506 and transfer heat from the stator 506 to air, water, gas coolant, liquid coolant, etc., via cooling fins, vents, channels, etc.

The example motor 504 of the pump system 500 includes a coupling housing 516 to support the radial motor bearings 510 and/or other portions of the pump system 500. Example portions of the pump system 500 supported by the coupling housing 516 are described in more detail below. In some examples, coupling housing 516 is manufactured separately from motor housing 512 and is secured to motor housing 512 via bolts, pins, interference fits, and/or adhesives. In some examples, the coupling housing 516 is additively manufactured as part of the motor housing 512 such that the coupling housing 516 and the motor housing 512 are the same additively manufactured part.

The example motor 504 of the pump system 500 includes a drive wheel 518 coupled to the rotor shaft 508. The example drive wheel 518 of the pump system 500 shown in fig. 5 is connected to the rotor shaft 508 via one or more bolts such that there is a direct torque transfer from the rotor shaft 508 to the drive wheel 518. For example, if the stator 506 generates a first torque to rotate the rotor 508 at a first angular velocity, the drive wheel 518 also rotates at the first angular velocity. The example drive wheel 518 is radially coupled to the driven wheel 520 to convert the first torque and the first angular velocity to a second torque and a second angular velocity output by the driven wheel 520.

The example pump 502 of the pump system 500 shown in fig. 5 includes a driven wheel 520, a radial coupling bearing 521, a coupling shaft 522, an impeller shaft 524, a magnetic coupling 526, an impeller 528, a radial pump bearing 530, a thrust shaft 532, a thrust bearing 534, a barrier can 536, an outer hub 538, an inner hub 540, and a backing plate 542. The drive wheel 518 and the driven wheel 520 of the pump system 500 shown in fig. 5 may be gears (e.g., spur gears, helical gears, double helical gears, etc.) that are radially connected via interlocking teeth, or pulleys that are radially connected via a drive belt. In some examples, the teeth of drive wheel 518 generate a force on the teeth of driven wheel 520. In some examples, the drive belt contacting drive wheel 518 generates a tension force on the outer surface of driven wheel 520. The example force, the tension, and/or the example first torque generated by drive wheel 518 and the example first angular velocity at which drive wheel 518 rotates are based on the mechanical power output of electric motor 504.

Equation 1 below represents the instantaneous mechanical power of drive wheel 518 and/or driven wheel 520 as a function of torque and angular velocity:

(equation 1) p=τω.

In equation 1, P is power, τ is torque, and ω is angular velocity. Due to conservation of power, and due to drive wheel 518 and driven wheel 520 Radial coupling via gear teeth and/or drive belt, so that the instantaneous power (P ₁ ) Instantaneous power (P) to driven wheel 520 ₂ ) Substantially similar (e.g., within 1%). Thus, assuming that there is no energy loss (e.g., 100% efficiency) between drive wheel 518 and driven wheel 520 due to heat, vibration, bending, friction, belt creep, etc., the transfer of torque and angular velocity between drive wheel 518 and driven wheel 520 may be expressed by equation 2 below:

P ₁ ＝P ₂

(equation 2) τ ₁ ω ₁ ＝τ ₂ ω ₂ 。

In equation 2, τ ₁ Is the torque output, ω, of the drive wheel 518 ₁ Is the angular velocity of the drive wheel 518, τ ₂ Is the torque output of driven wheel 520, ω ₂ Is the angular velocity of driven wheel 520.

The example drive wheel 518 generates a first torque (τ ₁ ) And example driven wheel 520 generates a second torque (τ ₂ ). Equation 3 below is used to determine the torque output of the rotating wheel:

(equation 3)In equation 3, F is the tangential force generated by drive wheel 518 and/or driven wheel 520, L is the length from the axis of rotation of drive wheel 518 and/or driven wheel 520 to the point where force (F) acts (e.g., the radius of drive wheel 518 and/or driven wheel 520), and D is the diameter of drive wheel 518 and/or driven wheel 520. The force F generated by drive wheel 518 is substantially similar (e.g., within 1%) to the force value F generated by driven wheel 520 due to newton's third law, with some losses due to heat, vibration, bending, friction, belt creep, etc. Thus, assuming no such loss occurs (e.g., 100% efficiency), equations 2 and 3 may be combined and simplified to equation 4 as shown below:

τ ₁ ω ₁ ＝τ ₂ ω ₂

(equation 4)

Equation 4 may be used to determine the angular velocity ω based on the drive wheel 518 ₁ Diameter D of drive wheel 518 ₁ And driven wheel 520 diameter D ₂ The angular velocities of driven wheel 520 and impeller 528 are determined. Thus, if drive wheel 518 has a larger diameter than driven wheel 520, impeller 528 rotates at a greater rate than rotor shaft 508 because impeller 528 is axially coupled to driven wheel 520 via impeller shaft 524, magnetic coupling 526, and the like.

In the example shown in fig. 5, the drive wheel 518 has a larger diameter than the driven wheel 520, according to equation 4, so that the second angular velocity is higher than the first angular velocity. Driven wheel 520 is secured (e.g., via one or more bolts) to coupling shaft 522. The example radial coupling bearing 521 supports the coupling shaft 522 and the weight generated by other portions connected to the coupling shaft 522. The example coupling shaft 522 is configured such that the coupling shaft 522 is axially coupled to the impeller shaft 524 via a magnetic coupling 526. The example impeller shaft 524 is also axially coupled to an impeller 528 via one or more fasteners (e.g., bolts, rods, interference fits, etc.). Since coupling shaft 522, magnetic coupling 526, and impeller shaft 524 connect driven wheel 520 to impeller 528, the second angular velocity of driven wheel 520 is directly transferred to impeller 528. In other words, impeller 528 and driven wheel 520 are rotatably interlocked and rotate at the same rate.

The example pump 502 of the pump system 500 includes radial pump bearings 530 to support radial loads generated by the impeller shaft 524. In some examples, radial pump bearing 530 is a rolling element bearing similar to radial motor bearing 510. In the example pump system 500 shown in fig. 5, the radial pump bearing 530 is a foil bearing. In some examples, radial pump bearing 530 includes a spring loaded foil liner inside the bearing sleeve. As the impeller shaft 524 begins to rotate, the example spring loaded foil liner supports the weight of the impeller shaft 524. As the second angular velocity of the impeller shaft 524 increases, the air pressure between the impeller shaft 524 and the spring loaded foil liner increases. As the second angular velocity continues to increase, the air pressure also increases until the air pressure pushes the spring loaded foil liner outward from the axis of rotation. The example air gap formed in radial pump bearing 530 between impeller shaft 524 and the sleeve of radial pump bearing 530 then supports the weight of impeller shaft 524.

The example radial pump bearing 530 does not use fluid lubrication (e.g., oil lubricant) that may contaminate the heat exchange fluid. However, the example radial pump bearing 530 (e.g., foil bearing) is unable to support the axial loads generated by the driven wheel 520, coupling shaft 522, and/or impeller shaft 524. The example motor housing 512 and back plate 542 shown in fig. 5 frame the thrust bearing 534 such that the thrust bearing 534 supports the thrust load generated by the impeller shaft 524. The example thrust shaft 532 is secured to the impeller shaft 524 and/or otherwise rigidly extends from the impeller shaft 524 perpendicular to the axis of rotation of the impeller shaft 524. As impeller shaft 524 rotates and transfers axial and/or thrust loads to thrust shaft 532, thrust bearing 534 counteracts the axial loads from thrust shaft 532 while allowing impeller shaft 524 to rotate with limited (e.g., less than 1%) energy loss. Although two thrust shafts 532 and one thrust bearing 534 are shown in fig. 5, there may be two or more thrust shafts 532 and/or one or more thrust bearings 534 in pump system 500. In some examples, the thrust bearing 534 may be a thrust ball bearing, a cylindrical thrust roller bearing, a tapered roller thrust bearing, a spherical roller thrust bearing, a magnetic bearing, or the like.

The example pump 502 of the pump system 500 shown in fig. 5 includes a magnetic coupling 526 to connect the coupling shaft 522 and the impeller shaft 524. The example magnetic coupling 526 includes an outer hub 538 and an inner hub 540, both the outer hub 538 and the inner hub 540 including permanent magnets of alternating polarity about an axis of rotation. The example inner hub 540 is a male component of the magnetic coupling 526 and fits within the outer hub 538 (e.g., a female component). The magnetic force of the permanent magnet causes coupling shaft 522 to transmit torque directly to impeller shaft 524 such that impeller shaft 524 and impeller 528 rotate at the same second angular velocity as driven wheel 520. The coupling shaft 522 is magnetically coupled to the impeller shaft 524 such that a gap exists between the male and female members. The example barrier canister 536 (e.g., the barrier canister 452) is designed to fit within the gap without physically and/or magnetically interfering with the magnetic coupling 526.

An example barrier canister 536 is secured in the magnetic coupling 526, the coupling housing 516, and/or the motor housing 512 to hermetically seal the driven wheel 520, the coupling shaft 522, and the motor 504 from fluids (e.g., heat exchange fluids such as supercritical fluids (e.g., scco 2, etc.)). The example barrier canister 536 also hermetically seals the radial motor bearing 510, the drive wheel 518, the driven wheel 520, and/or the example oil of the motor 504 used as a lubricant from contaminating the heat exchange fluid. In some examples, the barrier canister 536 is of the same structure, material, design, etc. as the barrier canister 452 of fig. 4. In some examples, the barrier canister 536 of fig. 5 is also secured to the coupling housing 516 and/or the motor housing 512 in the same manner as the barrier canister 452 of fig. 4, such as via flanges, barrier canister retainer rings, and/or bolts.

In some examples, the barrier can 536 includes an inner shell layer, an intermediate layer, and an outer layer. In some examples, the inner and outer layers are composed of various combinations of ceramic, polymer, or composite materials, while the intermediate layer is composed of metal electroformed on the inner mandrel. Some further examples of barrier cans 536 including materials, structures, designs, etc. are described in more detail in other portions of this document.

Disclosed herein is a radially coupled pump system 500. Examples disclosed herein include electric motor 504 to drive pump 502 via a drive wheel 518 axially coupled to rotor shaft 508. Examples disclosed herein further include driven wheel 520, driven wheel 520 being radially coupled to drive wheel 518 via a gearing arrangement or belt. Examples disclosed herein further include driven wheel 520 being axially coupled to impeller shaft 524 via magnetic coupling 526. Examples disclosed herein further include drive wheel 518 having a first diameter and driven wheel 520 having a second diameter that is less than the first diameter. Accordingly, examples disclosed herein further include driving wheel 518 rotating at a first angular velocity and driven wheel 520 rotating at a second angular velocity, the second angular velocity being greater than the first angular velocity. Examples disclosed herein allow motor 504 to be mounted above or below portions of pump 502 such that pump system 500 saves space in an axial direction relative to an axially coupled and aligned pump system (e.g., pump 400 of fig. 4). The examples disclosed herein operate motor 504 more efficiently relative to example pump 400 of fig. 4, increase the life of motor 504, increase the power density of pump system 500, and increase the maximum angular velocity of impeller 528, because motor 504 may output less mechanical power than motor 410 to achieve the same angular velocity as impeller 406.

Fig. 6 illustrates a cross-sectional view of a radially coupled pump system 600 for a fluid (e.g., a heat exchange fluid, such as a supercritical fluid (e.g., scco 2, etc.)) in a pressurized system (e.g., thermal management system 200 of fig. 3). As shown in fig. 6, a radially coupled pump system 600 ("pump system 600") includes a pump 602 and a motor 604. In some examples, pump system 600 is used to pump the scco 2 through a thermal management system on an aircraft (e.g., aircraft 10 of fig. 1) and/or a gas turbine engine (e.g., gas turbine engine 100 of fig. 2). In some examples, motor 604 of pump system 600 includes stator 606, rotor 608, radial motor bearing 610, motor housing 612, mounting rod 613, cooling jacket 614, and drive wheel 618.

The example motor 604 of the pump system 600 shown in fig. 6 includes a stator 606 and a rotor 608. In some examples, the stator 606 includes field magnets (e.g., electromagnets or permanent magnets) that generate a magnetic field based on current (e.g., direct current or alternating current) through the various electromagnets of the stator 606. The example stator 606 generates a first set of magnetic fields that exert a force (e.g., lorentz force) on a second set of magnetic fields generated by the rotor 608. The example rotor 608 generates a second set of magnetic fields via permanent magnets or electromagnets. Since the stator 606 is stationary and fixed in position, this force causes the example rotor 508 to rotate and generate torque.

The example stator 606 of the pump system 600 is structurally configured to be fixed in place inside the rotor 608. The example rotor 608 rotates at a first angular velocity with a first torque similar to the rotor 508 of fig. 5. However, rotor 608 encases stator 606, while stator 506 of FIG. 5 encases rotor 508. The example stator 606 is secured to a mounting bar 613. The example mounting bar 613 is secured to the motor housing 612 via one or more bolts. The example mounting bar 613 also supports the radial motor bearing 610 such that an inner sleeve of the radial motor bearing 610 is statically attached to the mounting bar 613.

The example motor 604 of the pump system 600 includes a radial motor bearing 610, the radial motor bearing 610 supporting the weight of the rotor shaft 608 and/or the drive wheels 618. The example radial motor bearing 610 also maintains radial and/or axial alignment of the rotor 608 and/or the drive wheel 618. The example radial motor bearing 610 supports radial loads (e.g., weight) and thrust loads generated by the rotor 608. In some examples, radial motor bearing 610 is a rolling element bearing, such as an angular contact ball bearing, a hybrid ceramic bearing, a tapered roller bearing, a deep groove single ball bearing, a double ball bearing, a spherical bearing, and the like. In some examples, radial motor bearing 610 uses a liquid lubricant (e.g., grease, oil, etc.) to reduce friction and wear in the rotating elements of radial motor bearing 610. In some examples, radial motor bearing 610 uses a solid lubricant (e.g., a silver coating) to reduce friction and wear of rotating elements of radial motor bearing 610. In some examples, radial motor bearing 610 is a foil bearing that uses pressurized air to form a non-contact barrier between the rotor shaft and the sleeve of radial motor bearing 610 at a sufficiently high rotational speed. Although the motor 604 shown in fig. 6 includes two radial motor bearings 610, one or more radial motor bearings 610 may be used in the motor 604.

The example motor 604 of the pump system 600 includes a motor housing 612 to frame and/or otherwise support a mounting bar 613, which mounting bar 613 in turn supports a stator 606, radial motor bearings 510, and the like. In some examples, the motor housing 612 is additively manufactured (e.g., via Direct Metal Laser Sintering (DMLS), three-dimensional printing, etc.) to accommodate custom geometries and configurations of the mounting rod 613, stator 606, radial motor bearing 610, cooling jacket 614, rotor 608, drive wheel 618, etc. The example motor housing 612 shown in fig. 6 may be additively manufactured to include mounting posts 613 and/or cooling jackets 614 in the same manufacturing portion. Alternatively, the motor housing 612 may be additively manufactured separately from the mounting bar 613 and/or cooling jacket 614 such that the geometry and tolerances of the motor housing 612 can be properly adapted to the various portions of the motor 604, including the mounting bar 613 and/or cooling jacket 614. Additionally or alternatively, the motor housing 612, mounting bar 613 and/or cooling jacket 614 may be manufactured separately via a subtractive manufacturing process.

Since the example stator 606 uses electromagnets to generate eddy currents, the example pump system 600 shown in fig. 6 includes a cooling jacket 614 to dissipate heat generated by the stator 606 during operation. In some examples, the cooling jacket 614 is mechanically secured to the stator 606 and/or the mounting bar 613 and includes cooling fins, vents, channels, etc. to transfer heat from the stator 606 to air, water, gas coolant, liquid coolant, etc. The example mounting bar 613 shown in fig. 6 may be an additive manufactured structure that includes a cooling jacket 614 as an additive manufactured portion of the mounting bar 613 such that the cooling jacket 514 and the mounting bar 613 are the same additive manufactured portion. The example cooling jacket 614 shown in fig. 5 may be manufactured in conjunction with the mounting bar 613 such that the stator 606 fits precisely around the cooling jacket 614 and/or is coupled to the cooling jacket 614. In some examples, the cooling jacket 614 is fabricated in conjunction with the stator 606 such that the cooling jacket 614 and the stator 606 are the same portion, and such that the cooling jacket 614 transfers heat from the stator 606 to air, water, gas coolant, liquid coolant, etc., via cooling fins, vents, channels, etc.

The example motor 604 of the pump system 600 includes a drive wheel 618 coupled to the rotor shaft 608. The example drive wheel 618 of the pump system 600 shown in fig. 6 is connected to the rotor shaft 608 such that there is a direct torque transfer from the rotor shaft 608 to the drive wheel 618. For example, if the stator 606 generates a first torque to rotate the rotor 608 at a first angular velocity, the drive wheel 618 also rotates at the first angular velocity. The example drive wheel 618 has a shell construction that surrounds the rotor 608 and is secured thereto via one or more fastening techniques (e.g., bolts, pins, interference fits, adhesives, etc.). In some examples, the drive wheel 618 is additively manufactured to include one or more components (e.g., permanent magnets) of the rotor 608. The example drive wheel 618 is radially coupled to the driven wheel 620 (e.g., via gearing or a transmission belt) to convert the first torque and the first angular velocity to a second torque and a second angular velocity output by the driven wheel 620.

The example pump 602 of the pump system 600 shown in fig. 6 includes a pump housing 615, a coupling housing 616, a driven wheel 620, a radial coupling bearing 621, a coupling shaft 622, an impeller shaft 624, a magnetic coupling 626, an impeller 628, a radial pump bearing 630, a thrust shaft 632, a thrust bearing 634, a barrier canister 636, an outer hub 638, an inner hub 640, and a back plate 642. The example pump 602 of the pump system 600 includes a coupling housing 616 to support a radial coupling bearing 621. The example radial coupling bearing 621 supports the coupling shaft 622 and the weight generated by other portions connected to the coupling shaft 622. In some examples, the coupling housing 616 is manufactured separately from the motor housing 612 and is secured to the motor housing 612 via bolts, fasteners, adhesives, or the like. In some examples, coupling housing 616 is additively manufactured as part of motor housing 612 such that coupling housing 616 and motor housing 612 are the same additively manufactured part.

The drive wheel 618 and the driven wheel 620 of the pump system 600 shown in fig. 6 are gears (e.g., spur gears, helical gears, double helical gears, etc.) that are radially connected via interlocking teeth, or pulleys that are radially connected via a drive belt. In some examples, the teeth of the drive wheel 618 generate a force on the teeth of the driven wheel 620. In some examples, the drive belt contacting the drive wheel 618 generates a tension force on the outer surface of the driven wheel 620. The example force, the tension, and/or the example first torque generated by the drive wheel 618 and the example first angular velocity of the drive wheel 618 as it rotates are based on the mechanical power output of the motor 604. As described above, equation 1 represents the instantaneous mechanical power of the drive wheels 618 and/or the driven wheels 620 as a function of torque and angular speed.

Due to conservation of power, and due to the radial coupling of the drive wheel 618 and the driven wheel 620 via gear teeth and/or drive belt, the instantaneous power (P ₁ ) Instantaneous power (P) to the driven wheel 620 ₂ ) Substantially similar (e.g., within 1%). Accordingly, assuming that there is no energy loss (e.g., 100% efficiency) between the drive wheel 618 and the driven wheel 620 due to heat, vibration, bending, friction, belt creep, etc., the transfer of torque and angular velocity between the drive wheel 618 and the driven wheel 620 can be expressed by equation 2 as described above.

The example drive wheel 618 generates a first torque (τ ₁ ) And example driven wheel 620 generates a second torque (τ ₂ ). As described above, equation 3 is used to determine the torque output of the rotating wheel. The force F generated by the drive wheel 618 is substantially similar (e.g., within 1%) to the force F generated by the driven wheel 620 due to newton's third law, with some losses due to heat, vibration, bending, friction, belt creep. Thus, assuming no such loss occurs (e.g., 100% efficiency), equations 2 and 3 may be combined and simplified to equation 4 as described above, and equation 4 may be used to determine the angular velocities of driven wheel 620 and impeller 628. Thus, if the drive wheel 618 has a larger diameter than the driven wheel 620, the impeller 628 will rotate at a greater rate than the rotor shaft 608 because the impeller 628 is axially coupled to the driven wheel 620 via the impeller shaft 624, the magnetic coupling 626, or the like.

In the example shown in fig. 6, the drive wheel 618 has a larger diameter than the driven wheel 620, according to equation 4, so that the second angular velocity is higher than the first angular velocity. Driven wheel 620 is secured (e.g., via one or more bolts) to coupling shaft 622. The example coupling shaft 622 is configured such that it is axially coupled to the impeller shaft 624 via a magnetic coupling 626. The example impeller shaft 624 is also axially connected to an impeller 628 via one or more fasteners (e.g., bolts, rods, interference fits, etc.). Since the coupling shaft 622, the magnetic coupling 626 and the impeller shaft 624 connect the driven wheel 620 to the impeller 628, the second angular velocity of the driven wheel 620 is directly transferred to the impeller 628. In other words, the impeller 628 and the driven wheel 620 are rotatably interlocked and rotate at the same rate.

The example pump 602 of the pump system 600 includes a pump housing 615 to frame and/or otherwise support radial pump bearings 630 and thrust bearings 634. In some examples, the pump housing 615 is additively manufactured to adapt the particular configuration and/or geometry of one or more radial pump bearings 630, thrust bearings 634, and/or impeller shaft 624. In some examples, the pump housing 615 is additively manufactured with the coupling housing 616 and/or the motor housing 612 such that the pump housing 615 is the same part as the coupling housing 616 and/or the motor housing 612. The example pump housing 615 as shown in fig. 6 is manufactured separately from the coupling housing 616 and the motor housing 612 (e.g., additive manufacturing). The example pump housing 615 as shown in fig. 6 is secured to the coupling housing 616 and the motor housing 612 via one or more bolts. In some examples, the pump housing 615 is secured to the coupling housing 616 and the motor housing 612 via one or more bolts, pins, interference fits, and/or adhesives.

The example pump 602 of the pump system 600 includes radial pump bearings 630 to support radial loads generated by the impeller shaft 624. In some examples, radial pump bearing 630 is a rolling element bearing similar to radial motor bearing 610 and/or radial coupling bearing 621. In the example pump system 600 shown in fig. 6, the radial pump bearing 630 is a foil bearing. In some examples, radial pump bearing 630 includes a spring loaded foil liner inside the bearing sleeve. As the impeller shaft 624 begins to rotate, the example spring loaded foil liner supports the weight of the impeller shaft 624. As the second angular velocity of the impeller shaft 624 increases, the air pressure between the impeller shaft 624 and the spring loaded foil liner increases. As the second angular velocity continues to increase, the air pressure also increases to a point where the air pressure pushes the spring loaded foil liner perpendicularly outward from the axis of rotation. The example air gap formed in the radial pump bearing 630 between the impeller shaft 624 and the sleeve of the radial pump bearing 630 then supports the weight of the impeller shaft 624.

The example radial pump bearing 630 does not use fluid lubrication (e.g., oil lubricant) that may contaminate the fluid. However, the example radial pump bearing 630 (e.g., foil bearing) is unable to support the axial loads generated by the driven wheel 620, the coupling shaft 622, and/or the impeller shaft 624. The example pump housing 615 and backplate 642 shown in fig. 6 frame the thrust bearing 634 such that the thrust bearing 634 supports thrust loads generated by the impeller shaft 624. The example thrust shaft 632 is fixed to the impeller shaft 624 and/or otherwise rigidly extends from the impeller shaft 624 perpendicular to the axis of rotation of the impeller shaft 624. As the impeller shaft 624 rotates and transfers axial and/or thrust loads to the thrust shaft 632, the thrust bearing 634 counteracts the axial loads from the thrust shaft 632, while allowing the impeller shaft 624 to rotate with limited (e.g., less than 1%) energy loss. Although two thrust shafts 632 and one thrust bearing 634 are shown in fig. 5, there may be two or more thrust shafts 632 and/or one or more thrust bearings 634 in the pump system 600. In some examples, thrust bearing 634 may be a thrust ball bearing, a cylindrical thrust roller bearing, a tapered roller thrust bearing, a spherical roller thrust bearing, a magnetic bearing, or the like.

The example pump 602 of the pump system 600 shown in fig. 6 includes a magnetic coupling 626 to connect the coupling shaft 622 and the impeller shaft 624. The example magnetic coupling 626 includes an outer hub 638 and an inner hub 640, both of which include permanent magnets of alternating polarity about an axis of rotation. The example inner hub 640 is the male component of the magnetic coupling 626 and fits within the outer hub 638 (e.g., female component). The magnetic force of the permanent magnet causes the coupling shaft 622 to transmit torque directly to the impeller shaft 624 such that the impeller shaft 624 and impeller 628 rotate at the same second angular velocity as the driven wheel 620. The coupling shaft 622 is magnetically coupled to the impeller shaft 624 such that a gap exists between the male and female components. The example barrier canister 636 (e.g., the barrier canister 452) is designed to fit within the gap without physically and/or magnetically interfering with the magnetic coupling 626.

An example barrier canister 636 is secured within the magnetic coupling 626, the coupling housing 616, and/or the pump housing 615 to hermetically seal the driven wheel 620, the coupling shaft 622, and the motor 604 from the fluid. The example barrier canister 636 also hermetically seals the radial motor bearing 610, the drive wheel 618, the driven wheel 620, and/or the example oil of the motor 604 used as a lubricant from contaminating fluids. In some examples, the barrier tank 636 is of the same structure, material, design, etc. as the barrier tank 452 of fig. 4. In some examples, the barrier tank 636 of fig. 6 is also secured to the coupling housing 616 and/or the motor housing 612 in the same manner as the barrier tank 452 of fig. 4, such as via flanges, barrier tank retainer rings, and/or bolts.

In some examples, the barrier tank 636 includes an inner shell layer, an intermediate layer, and an outer layer. In some examples, the inner and outer layers are composed of various combinations of ceramic, polymer, or composite materials, while the intermediate layer is composed of metal electroformed on the inner mandrel. Some further examples of barrier cans 636, including materials, structures, designs, etc., are described in more detail in other portions of this document.

Disclosed herein is a radially coupled pump system 600. Examples disclosed herein include an electric motor 604 having a stator 606, the stator 606 being mounted inside a cylindrical rotor shaft 608, the cylindrical rotor shaft 608 rotating about the exterior of the stator 606. Examples disclosed herein include a drive wheel 618, the drive wheel 618 surrounding and fixed to the rotor 608 such that the rotor 608 directly transfers a first torque output of the rotor 608 to the drive wheel 618. Examples disclosed herein include the drive wheel 618 being radially coupled to the driven wheel 620 via a gearing or belt. Examples disclosed herein further include driven wheel 620 being axially connected to impeller shaft 624 via a magnetic coupling 626. Examples disclosed herein further include the drive wheel 618 having a first diameter and the driven wheel 620 having a second diameter that is less than the first diameter. Accordingly, examples disclosed herein further include the drive wheel 618 rotating at a first angular velocity and the driven wheel 620 rotating at a second angular velocity, wherein the second angular velocity is greater than the first angular velocity. Examples disclosed herein allow motor 604 to be mounted above or below portions of pump 602 such that pump system 600 saves space in an axial direction relative to an axially coupled and aligned pump system (e.g., pump 400 of fig. 4). The example disclosed herein operates the motor 604 more efficiently relative to the example pump 400 of fig. 4, increases the life of the motor 604, increases the power density of the pump system 600, and increases the maximum angular velocity of the impeller 628 because the motor 604 may output less mechanical power than the motor 410 to achieve the same angular velocity as the impeller 406.

Fig. 7 illustrates a cross-sectional view of a radially coupled pump system 700 for a fluid (e.g., a heat exchange fluid, such as a supercritical fluid (e.g., scco 2, etc.)) in a pressurized system (e.g., thermal management system 200 of fig. 3). As shown in fig. 7, a radially coupled pump system 700 ("pump system 700") includes a pump 702 and a motor 704. In some examples, pump system 700 is used to pump the scco 2 through a thermal management system on an aircraft (e.g., aircraft 10 of fig. 1) and/or a gas turbine engine (e.g., gas turbine engine 100 of fig. 2). In some examples, motor 704 of pump system 700 includes stator 706, rotor 708, radial motor bearing 710, motor housing 712, cooling jacket 714, coupling housing 716, coupling shaft 718, coupling bolts 719, magnetic coupling 720, drive wheel 722, drive axle 724, radial drive axle bearing 726, barrier can 728, inner hub 730, and outer hub 732.

The example motor 704 of the pump system 700 shown in fig. 7 includes a stator 706 and a rotor 708. In some examples, the stator 706 includes field magnets (e.g., electromagnets or permanent magnets) that generate a magnetic field based on current (e.g., direct current or alternating current) through the various electromagnets of the stator 706. The example stator 706 generates a first set of magnetic fields that exert a force (e.g., lorentz force) on a second set of magnetic fields generated by the rotor 708. The example rotor 708 generates a second set of magnetic fields via permanent magnets or electromagnets. Since the stator 706 is stationary and fixed in position, this force causes the example rotor 708 to rotate and produce torque.

The example motor 704 of the pump system 700 includes radial motor bearings 710, the radial motor bearings 710 supporting the weight of the rotor shaft 708 and maintaining the rotor 708 in radial and/or axial alignment. The example radial motor bearing 710 supports the radial load (e.g., weight) and thrust load of the rotor 708. In some examples, radial motor bearing 710 is a rolling element bearing such as an angular contact ball bearing, a hybrid ceramic bearing, a tapered roller bearing, a deep groove single ball bearing, a double ball bearing, a spherical bearing, or the like. In some examples, radial motor bearing 710 uses a liquid lubricant (e.g., grease, oil, etc.) to reduce friction and wear in the rotating elements of radial motor bearing 710. In some examples, radial motor bearing 710 uses a solid lubricant (e.g., a silver coating) to reduce friction and wear of rotating elements of radial motor bearing 710. In some examples, radial motor bearing 710 is a foil bearing that uses pressurized air to form a non-contact barrier between the rotor shaft and the sleeve of radial motor bearing 710 at a sufficiently high rotational speed. Although the motor 704 shown in fig. 7 includes two radial motor bearings 710, one or more radial motor bearings 710 may be used in the motor 704.

The example motor 704 of the pump system 700 includes a motor housing 712 to frame and/or otherwise support the stator 706, radial motor bearings 710, and the like. In some examples, the motor housing 712 is additively manufactured (e.g., via Direct Metal Laser Sintering (DMLS), three-dimensional printing, etc.) to accommodate the custom geometry and configuration of the stator 706, radial motor bearing 710, cooling jacket 714, etc.

Because the example stator 706 uses electromagnets to generate eddy currents, the example pump system 700 shown in fig. 7 includes a cooling jacket 714 to dissipate heat generated by the stator 706 during operation. In some examples, the cooling jacket 714 is mechanically secured to the motor housing 712 and includes cooling fins, vents, channels, etc. to transfer heat from the stator 706 to air, water, gas coolant, liquid coolant, etc. The example motor housing 712 shown in fig. 7 is an additive manufactured structure that includes a cooling jacket 714 as an additive manufactured portion of the motor housing 712 such that the cooling jacket 714 and the motor housing 712 are the same additive manufactured portion. The example cooling jacket 714 shown in fig. 7 is fabricated in conjunction with the motor housing 712 to enclose the stator 706 and transfer heat from the stator 706 to air, water, gas coolant, liquid coolant, etc., via cooling fins, vents, channels, etc.

The example motor 704 of the pump system 700 includes a coupling housing 716 to support a drive wheel bearing 726, a barrier can 728, and the like. In the example shown in fig. 7, the coupling housing 716 is manufactured separately from the motor housing 712 and is secured to the motor housing 712 via one or more bolts. In some examples, the coupling housing 716 is manufactured separately from the motor housing 712 (via additive manufacturing or subtractive manufacturing) and is secured to the motor housing 712 via bolts, pins, interference fits, and/or adhesives. In some examples, the coupling housing 716 is additively manufactured as part of the motor housing 712 such that the coupling housing 716 and the motor housing 712 are the same additively manufactured part.

The example motor 704 of the pump system 700 includes a drive wheel 722 coupled to the rotor shaft 708. The example drive wheel 722 of the pump system 700 shown in fig. 7 is connected to the rotor shaft 708 via the coupling shaft 718 and the magnetic coupling 720 such that there is a direct torque transfer from the rotor shaft 708 to the drive wheel 722. For example, if stator 706 generates a first torque to cause rotor 708 to rotate at a first angular velocity, drive wheel 722 also rotates at the first angular velocity. The example drive wheel 722 is radially coupled to the driven wheel 734 to convert the first torque and the first angular velocity to a second torque and a second angular velocity output by the driven wheel 734.

The example motor 704 of the pump system 700 shown in fig. 7 includes a magnetic coupling 720 to connect the coupling shaft 718 and the drive axle 724. The example coupling shaft 718 is rigidly connected to the rotor shaft 708 via coupling bolts 719 that are aligned with the rotational axes of the rotor shaft 708 and the coupling shaft 718. The example magnetic coupling 720 includes an outer hub 732 and an inner hub 730, both of the outer hub 732 and the inner hub 730 including permanent magnets of alternating polarity about an axis of rotation. The example inner hub 730 is the male component of the magnetic coupling 720 and fits within the outer hub 732 (e.g., female component). The magnetic force of the permanent magnets causes the coupling shaft 718 to transfer torque directly to the drive axle 724, causing the drive axle 724 and drive wheel 722 to rotate at the same second angular velocity as the rotor shaft 708. The coupling shaft 718 is magnetically coupled to the drive axle 724 such that a gap exists between the male and female components. The example barrier can 728 (e.g., the barrier can 452) is designed to fit within the gap without physically and/or magnetically interfering with the magnetic coupling 720.

An example barrier can 728 is secured in the magnetic coupling 720 and/or the coupling housing 716 to hermetically seal the motor 504 from the fluid. The example barrier can 728 also hermetically seals the radial motor bearing 710, the rotor shaft 708, and/or the example oil of the motor 704 that acts as a lubricant from contaminating fluids. In some examples, the barrier tank 728 has the same structure, material, design, etc. as the barrier tank 452 of fig. 4. In some examples, the barrier can 728 of fig. 7 is also secured to the coupling housing 716 in the same manner as the barrier can 452 of fig. 4, such as via flanges, barrier can retainer rings, and/or bolts.

In some examples, the barrier can 728 includes an inner shell layer, an intermediate layer, and an outer layer. In some examples, the inner and outer layers are composed of various combinations of ceramic, polymer, or composite materials, while the intermediate layer is composed of metal electroformed on the inner mandrel. Some further examples of barrier cans 728 including materials, structures, designs, etc. are described in more detail in other portions of this document.

The example motor 704 of the pump system 700 includes radial drive axle bearings 726 to support radial loads generated by the drive axle 724. In some examples, radial drive wheel bearing 726 is a rolling element bearing similar to radial motor bearing 710. In the example pump system 700 shown in fig. 7, the radial drive wheel bearings 726 are foil bearings. In some examples, the radial drive axle bearing 726 includes a spring loaded foil liner inside the bearing sleeve. As the drive axle 724 begins to rotate, the example spring loaded foil liner supports the weight of the drive axle 724. As the first angular velocity of the drive axle 724, coupling shaft 718, and rotor shaft 708 increases, the air pressure between the drive axle 724 and the spring loaded foil liner increases. As the first angular velocity continues to increase, the air pressure also increases to a point where the air pressure pushes the spring loaded foil liner outward from the axis of rotation. The example air gap formed in the radial drive axle bearing 726 between the drive axle 724 and the sleeve of the radial drive axle bearing 726 then supports the weight of the drive axle 724.

The example radial drive axle bearing 726 does not use fluid lubrication (e.g., oil lubricant) that may contaminate the fluid. However, the example radial drive axle bearing 726 (e.g., foil bearing) is unable to support the axial load generated by the drive wheel 722 and/or the drive axle 724. In the pump system 700 shown in fig. 7, the magnetic coupling 720 supports an axial load (e.g., a thrust load). In some examples, the drive axle 724 may include one or more thrust shafts that are fixed and/or otherwise extend radially outward from the drive axle 724 perpendicular to the axis of rotation of the drive axle 724. In some examples, coupling housing 716 and/or pump housing 735 frame one or more thrust bearings that support one or more example thrust shafts that may be included with drive axle 724.

The example pump 702 of the pump system 700 shown in fig. 7 includes a driven wheel 734, a pump housing 735, an impeller shaft 736, an impeller 738, a radial pump bearing 740, a thrust shaft 742, and a thrust bearing 744. The drive pulley 722 and the driven pulley 734 of the pump system 700 shown in fig. 7 may be gears (e.g., spur gears, helical gears, double helical gears, etc.) that are radially connected via interlocking gear teeth, or pulleys that are radially connected via a drive belt. In some examples, the teeth of drive wheel 722 generate a force on the teeth of driven wheel 734. In some examples, the drive belt contacting the drive wheel 722 generates a tension force on the outer surface of the driven wheel 734. The example force, the tension, and/or the example first torque generated by drive wheel 722 and the example first angular velocity as drive wheel 722 rotates are based on the mechanical power output of motor 704. As described above, equation 1 represents the instantaneous mechanical power of the drive wheel 722 and/or the driven wheel 734 as a function of torque and angular velocity.

Due to conservation of power, and due to the radial coupling of drive wheel 722 and driven wheel 734 via gear teeth and/or drive belt, the instantaneous power (P ₁ ) Instantaneous power (P) to the driven wheel 734 ₂ ) Substantially similar (e.g., within 1%). Accordingly, assuming that there is no energy loss (e.g., 100% efficiency) between the drive wheel 722 and the driven wheel 734 due to heat, vibration, bending, friction, belt creep, etc., the transfer of torque and angular velocity between the drive wheel 722 and the driven wheel 734 can be expressed by equation 2 as described above.

The example drive wheel 722 generates a first torque (τ ₁ ) And the example driven wheel 734 generates a second torque (τ ₂ ). As described above, equation 3 is used to determine the torque output of the rotating wheel. The force F generated by drive wheel 722 is substantially similar (e.g., within 1%) to the force F generated by driven wheel 734 due to newton's third law, with the force F generated due to heat, vibrationSome losses due to bending, friction, belt creep, etc. Thus, assuming no such loss occurs (e.g., 100% efficiency), equations 2 and 3 may be combined and simplified to equation 4 as described above, and equation 4 may be used to determine the angular speed of driven wheel 734 and impeller 738. Thus, if drive wheel 722 has a larger diameter than driven wheel 734, impeller 738 will rotate at a greater rate than rotor shaft 708 because impeller 738 is axially coupled to driven wheel 734 via impeller shaft 736.

In the example shown in fig. 7, drive wheel 722 has a larger diameter than driven wheel 734, according to equation 4, to make the second angular velocity higher than the first angular velocity. Driven wheel 734 is secured (e.g., via one or more bolts, welds, adhesives, interference fits, etc.) to impeller shaft 736. The example impeller shaft 736 is axially coupled to the impeller 738 via one or more fasteners (e.g., bolts, rods, interference fits, etc.). Since the impeller shaft 736 connects the driven wheel 734 to the impeller 738, the second angular velocity of the driven wheel 734 is directly transferred to the impeller 738. In other words, the impeller 738 and the driven wheel 734 are rotatably interlocked and rotate at the same rate.

The example pump 702 of the pump system 700 includes radial pump bearings 740 to support radial loads generated by the impeller shaft 736. In some examples, radial pump bearing 740 is a rolling element bearing similar to radial motor bearing 710. In the example pump system 700 shown in fig. 7, the radial pump bearing 740 is a foil bearing. In some examples, radial pump bearing 740 includes a spring loaded foil liner inside the bearing sleeve. As impeller shaft 736 begins to rotate, the example spring loaded foil liner supports the weight of impeller shaft 736. As the second angular velocity of the impeller shaft 736 increases, the air pressure between the impeller shaft 736 and the spring loaded foil liner increases. As the second angular velocity continues to increase, the air pressure also increases to a point where the air pressure pushes the spring loaded foil liner outward from the axis of rotation. An example air gap formed in radial pump bearing 740 between impeller shaft 736 and the sleeve of radial pump bearing 740 then supports the weight of impeller shaft 736.

The example radial pump bearing 740 does not use fluid lubrication (e.g., oil lubricant) that may contaminate the fluid. However, the example radial pump bearing 740 (e.g., foil bearing) is unable to support the axial load generated by the driven wheel 734 and/or the impeller shaft 736. The example pump 702 of the pump system 700 includes a thrust shaft 742 to interface with a thrust bearing 744. The example pump housing 735 and coupling housing 716 shown in fig. 7 frame thrust bearings 744 such that thrust bearings 744 support thrust loads generated by thrust shaft 742. The example thrust shaft 742 is secured to the impeller shaft 736 and/or otherwise rigidly extends from the impeller shaft 736 perpendicular to the axis of rotation of the impeller shaft 736. As impeller shaft 736 rotates and transfers axial and/or thrust loads to thrust shaft 742, thrust bearing 744 counteracts axial loads from thrust shaft 742 while allowing impeller shaft 736 to rotate with limited (e.g., less than 1%) energy loss. Although two thrust shafts 742 and one thrust bearing 744 are shown in fig. 7, there may be two or more thrust shafts 742 and/or one or more thrust bearings 744 in pump system 700. In some examples, thrust bearing 744 may be a thrust ball bearing, a cylindrical thrust roller bearing, a tapered roller thrust bearing, a spherical roller thrust bearing, a magnetic bearing, or the like.

Disclosed herein is a radially coupled pump system 700. Examples disclosed herein include motor 704 to drive pump 702 via drive wheel 722, drive wheel 722 being axially connected to motor shaft 708 via magnetic coupling 720. Examples disclosed herein further include a driven wheel 734, the driven wheel 734 being radially coupled to the drive wheel 722 via a gear arrangement or belt. The examples disclosed herein further include a driven wheel 734, the driven wheel 734 being axially connected to the impeller shaft 736. Examples disclosed herein further include the drive wheel 722 having a first diameter and the driven wheel 734 having a second diameter that is less than the first diameter. Accordingly, examples disclosed herein further include the drive wheel 722 rotating at a first angular velocity and the driven wheel 734 rotating at a second angular velocity, the second angular velocity being greater than the first angular velocity. Examples disclosed herein allow motor 704 to be mounted above or below portions of pump 702 such that pump system 700 saves space in an axial direction relative to an axially coupled and aligned pump system (e.g., pump 400 of fig. 4). The examples disclosed herein operate motor 704 more efficiently relative to example pump 400 of fig. 4, increase the life of motor 704, increase the power density of pump system 700, and increase the maximum angular velocity of impeller 738, because motor 704 may output less mechanical power than motor 410 to achieve the same angular velocity as impeller 406.

Fig. 8 is a flow chart illustrating an example process or operation 800, as disclosed herein, a pump system 500 (fig. 5), 600 (fig. 6), 700 (fig. 7) may follow the example process or operation 800 to pressurize a fluid (e.g., a heat exchange fluid, such as a supercritical fluid (e.g., supercritical carbon dioxide (scco) ₂ ) Etc.). Although the operation 800 is described primarily with reference to pumping fluid within a thermal management system transfer bus using the pump systems 500, 600, 700 of fig. 5-7, the operation 800 may be used to pump fluid within any other closed loop transfer bus.

At block 802, the electric motors 504, 604, 704 generate a first torque and a first speed on the rotor shafts 508, 608, 708. For example, current is supplied to the electromagnets of the stators 506, 606, 706 to cause a magnetic field perpendicular to the rotational axis of the rotors 508, 608, 708. The electromagnets of the stators 506, 606, 706 are sequentially charged with a current that changes direction of flow such that the changing polarity of the magnetic field is activated to attract the permanent magnets in the rotors 508, 608, 708. The magnetic force between the electromagnets in the stator 506, 606, 706 and the permanent magnets in the rotor 508, 608, 708 provides a first torque and a first angular velocity to the rotor shaft 508, 608, 708.

At block 804, the process or operation 800 proceeds to block 806 or block 808 depending on the location and/or configuration of the magnetic coupling 526, 626, 720 in the pump system 500, 600, 700. If the rotor shafts 508, 608, 708 and the drive wheels 518, 618, 722 are coupled via the magnetic couplings 526, 626, 720, the process or operation 800 proceeds to block 806, where the rotor 508, 608, 708 directly transfers the first torque and the first angular velocity to the drive wheels 518, 618, 722 via the magnetic couplings 526, 626, 720. If the rotor shafts 508, 608, 708 and the drive wheels 518, 618, 722 are not coupled via the magnetic couplings 526, 626, 720, the process or operation 800 proceeds to block 808, where the rotor 508, 608, 708 directly transfers the first torque and the first angular velocity to the drive wheels 518, 618, 722 via a first mechanical connection (e.g., a bolt, pin, adhesive, interference fit, etc.).

At block 810, the process or operation 800 proceeds to block 812 or block 814 depending on the design, structure, and/or configuration of the drive wheels 518, 618, 722 and the driven wheels 520, 620, 734. If both the drive wheels 518, 618, 722 and the driven wheels 520, 620, 734 are gears that are radially coupled via interlocking gear teeth, the process or operation 800 proceeds to block 812 where, at block 812, the first torque and first angular velocity of the drive wheels 518, 618, 722 are converted to the second torque and second angular velocity of the driven wheels 520, 620, 734 via interlocking gear teeth. One or more gear teeth of the drive wheels 518, 618, 722 exert a force on one or more gear teeth of the driven wheels 520, 620, 734. The force is transferred to driven wheels 520, 620, 734 and a second torque and a second angular velocity are generated.

At block 814, if not both the drive wheels 518, 618, 722 and the driven wheels 520, 620, 734 are gears that are radially coupled via interlocking gear teeth, the first torque and first angular velocity of the drive wheels 518, 618, 722 are converted to the second torque and second angular velocity of the driven wheels 520, 620, 734 via a belt connection between the drive wheels 518, 618, 722 and the driven wheels 520, 620, 734. The drive belt is designed and/or assembled to have non-slip contact with the drive wheels 518, 618, 722 and the driven wheels 520, 620, 734. The drive wheels 518, 618, 722 exert a tensioning force on the drive belt and the tensioning force is transferred to the driven wheels 520, 620, 734 at the areas where the drive belt contacts the driven wheels 520, 620, 734. The transmission of the tensioning force produces a second torque and a second angular velocity of driven wheels 520, 620, 734.

At block 816, the process or operation 800 proceeds to block 818 or block 820 depending on the location and configuration of the magnetic coupling 526, 626, 720 in the pump system 500, 600, 700. If the driven wheel 520, 620, 734 and the impeller shaft 524, 624, 736 are coupled via the magnetic coupling 526, 626, 720, the process or operation 800 proceeds to block 818, where the driven wheel 520, 620, 734 directly transfers the second torque and the second angular velocity to the impeller shaft 524, 624, 736 via the magnetic coupling 526, 626, 720 and/or the coupling shaft 522, 622, 718. If the driven wheel 520, 620, 734 and the impeller shaft 524, 624, 736 are not coupled via the magnetic coupling 526, 626, 720, the process or operation 800 proceeds to block 820, where the driven wheel 520, 620, 734 directly transmits the second torque and the second angular velocity to the impeller shaft 524, 624, 736 via a second mechanical connection (e.g., a bolt, pin, adhesive, interference fit, etc.).

At block 822, the impellers 528, 628, 738 coupled to the impeller shafts 524, 624, 736 generate hydrodynamic energy of the fluid based on the rotational kinetic energy of the impellers 528, 628, 738. Since the impellers 528, 628, 738 are axially coupled and/or connected to the impeller shafts 524, 624, 736, the impellers 528, 628, 738 also rotate at the second angular velocity. The rotational kinetic energy of the impellers 528, 628, 738 is based on the second angular velocity and moment of inertia of the impellers 528, 628, 738. Rotational energy is converted into hydrodynamic energy based on the law of conservation of energy and the design of the impellers 528, 628, 738.

In some examples, the pump system 500, 600, 700 includes means for rotating. For example, the means for rotating may be implemented by motors 504, 604, 704, stators 506, 606, 706, and/or rotor shafts 508, 608, 708 of fig. 5, 6, and/or 7. In some examples, the means for rotating may include an electric motor, such as a DC motor, an AC motor, a brushed DC motor, a brushless DC motor, or the like.

In some examples, the pump system 500, 600, 700 includes a means for acceleration. For example, the means for accelerating may be implemented by the impellers 528, 628, 738 and/or the impeller shafts 524, 624, 736 of fig. 5-8. In some examples, the means for adding may include a motor, an impeller shaft, and/or an impeller.

In some examples, the pump system 500, 600, 700 includes means for switching. For example, the means for shifting may be implemented by the drive wheels 518, 618, 722 and/or the driven wheels 520, 620, 734 of fig. 5-7. In some examples, the means for translating may include a gear in contact via interlocking gear teeth or a pulley in contact with the drive belt.

In some examples, the pump system 500, 600, 700 includes means for connecting. For example, the means for connecting may be implemented by the magnetic couplings 526, 626, 720 of fig. 5-7. In some examples, the means for connecting may include a magnetic coupling, an inner hub, an outer hub, a coupling shaft, and/or a permanent magnet.

In some examples, the pump system 500, 600, 700 includes means for framing. For example, the means for framing may be implemented by the motor housings 512, 612, 712, the coupling housings 516, 616, 716, and/or the pump housings 615, 735 of fig. 5, 6, and/or 7. In some examples, the means for framing may include a housing, shell, support structure, etc. fabricated via additive manufacturing (e.g., binder jetting, directional energy deposition, powder bed infusion, direct metal laser sintering, etc.).

Integrated bearing system for dynamically supporting a shaft in a pump system

Some example fluid pump systems and centrifugal fluid pump systems operate with a motor (e.g., motor 410) axially connected to an impeller (e.g., impeller 406) via an impeller shaft (e.g., impeller shaft 466) as described above with reference to fig. 4. The example rotor shaft 438 shown in fig. 4 is connected to an example impeller shaft 466 via a first magnetic coupling 450 and a second magnetic coupling 460. In some examples, the rotor shaft is directly connected to an impeller in the pump system without a magnetic coupling to connect the rotor shaft and the impeller shaft. In some examples, foil bearings are used to support radial loads generated by the rotor shaft during operation of the pump system. Foil bearings are a form of air bearing that uses a spring loaded foil between the shaft and journal liner to support the shaft at low start-up speeds. Once the shaft rotates at a sufficiently high rate (depending on the configuration of the foil bearing), the working fluid (e.g., air, nitrogen, argon, etc.) is pulled into the foil bearing due to the viscous effects of the working fluid. Thus, the working fluid pressure increases in the foil bearing, pushing the foil outwards from the shaft, and supporting the radial load generated by the shaft, creating a friction-free bearing without liquid lubricant. Since the foil bearing does not use a liquid lubricant, the hermetic seal (e.g., magnetic coupling) may not be used to prevent the lubricant from contaminating the fluid (e.g., a heat exchange fluid, such as a supercritical fluid (e.g., scco 2, etc.)) pressurized by the pump system.

In some examples, foil bearings used to support radial loads generated by the rotor shaft experience wear during start-up and shut-down of the pump system. More specifically, the spring loaded foil supporting the weight of the rotor shaft at lower speeds (start and stop rotational speeds) breaks down over time due to frictional erosion. In examples disclosed herein, an integrated bearing system includes a foil bearing, a rolling element bearing, and a split sprag clutch to support a rotor shaft in a pump system. The example sprag clutch engages the rolling element bearings prior to operation of the pump system and at lower operating speeds of the pump system such that the rolling element bearings support the weight (e.g., total weight and/or majority weight) of the rotor shaft during start and stop speeds of the pump system. In the examples disclosed herein, when the pump system reaches a first operating speed range (e.g., a foil bearing start-up speed (lift off speed) (e.g., a tangential speed of 10 to 50 meters per second (m/s) of the foil bearing)), the sprag clutch disengages the rolling element bearing and the foil bearing supports the weight of the rotor shaft. Thus, examples disclosed herein reduce the radial load supported by the foil bearing during start-up and shut-down of the pump system, reduce wear of the foil bearing due to less frictional erosion, and increase the life (e.g., service life) of the foil bearing.

For the drawings disclosed herein, like numbers refer to like elements throughout. Fig. 9 illustrates a cross-sectional view of a pump system 900 for a fluid (e.g., a heat exchange fluid, such as a supercritical fluid (e.g., scco 2, etc.)) in a pressurized system (e.g., thermal management system 200 of fig. 3). In some examples, pump system a100 is used to pump the scco 2 through a thermal management system on an aircraft (e.g., aircraft 10 of fig. 1) and/or a gas turbine engine (e.g., gas turbine engine 100 of fig. 2). As shown in fig. 9, the pump system 900 includes an impeller 902, a rotor shaft 904, a rotor 905, a stator 906, a thrust bearing 908, a radial shaft 909, a first integrated bearing system 910, a first sprag clutch 912, a first bearing housing 913, a first rolling element bearing 914, a first foil bearing 916, a second integrated bearing system 918, a second sprag clutch 920, a second bearing housing 921, a second rolling element bearing 922, and a second foil bearing 924.

The example pump system 900 shown in fig. 9 includes an impeller 902 to pressurize a fluid (e.g., scco 2) in a system (e.g., the thermal management system 200 of fig. 3). The example impeller 902 is a component of the pump system 900 that is connected to the rotor shaft 904 and rotates at the same rotational speed as the rotor shaft 904. In some examples, the impeller 902 is the same as or similar to impellers used in centrifugal pumps and includes vanes and/or blades to deflect the incoming fluid flow radially outward into the outlet flow line. The example impeller 902 converts mechanical power of an electric motor (e.g., the rotor shaft 904 and the stator 906) into fluid power of a fluid flow.

The example pump system 900 shown in fig. 9 includes a stator 906 to apply torque on a rotor 905 coupled to a rotor shaft 904. Since the example rotor 905 is connected to the rotor shaft 904 (e.g., via bolts, adhesive, interference fit, etc.), the stator 906 causes the rotor shaft 904 to rotate while the stator 906 remains stationary. The example stator 906, the example rotor 905, and the example rotor shaft 904 are included as part of an electric motor familiar to those skilled in the art. In some examples, the stator 906 includes field magnets (e.g., electromagnets or permanent magnets) that generate a magnetic field based on current (e.g., direct current or alternating current) through the various electromagnets of the stator 906. The example stator 906 generates a first set of magnetic fields that apply a force (e.g., lorentz force) to a second set of magnetic fields generated by the rotor 905. The example rotor 905 generates a second set of magnetic fields via permanent magnets or electromagnets. Since the example stator 906 is stationary and fixed in position, this force causes the example rotor 905 to rotate and produce torque. Since the example rotor shaft 904 is connected to the example rotor 905, the rotor shaft 904 generates the same torque and rotates at the same angular speed as the rotor 905.

The example pump system 900 shown in fig. 9 includes thrust bearings 908 to support thrust loads (axial loads) generated by the rotor shaft 904 during operation. The example thrust bearing 908 shown in fig. 9 is a foil bearing that includes a spring loaded foil and journal liner, similar to the foil bearing architecture described above. The example rotor shaft 904 is connected to two or more radial shafts 909, the two or more radial shafts 909 being positioned perpendicular to the axis of rotation of the rotor shaft 904. In some examples, radial shaft 909 is connected to the rotor shaft via bolts, adhesives, interference fits, or the like. The example pump system 900 shown in fig. 9 includes two radial shafts 909, however, more radial shafts 909 may be connected to the rotor shaft 904. In some examples, thrust bearing 908 includes an inner liner that interfaces with radial shaft 909 and spring loaded foil. In some examples, radial shaft 909 is a disk that is connected to rotor shaft 904 and interacts directly with the spring loaded foil of thrust bearing 908.

The example pump system 900 of fig. 9 includes a first integrated bearing system 910 to support radial loads of the rotor shaft 904 during operation of the pump system 900. The example first integrated bearing system 910 includes a first sprag clutch 912, a bearing housing 913, a first rolling element bearing 914, and a first foil bearing 916. The example pump system 900 of fig. 9 also includes a second integrated bearing system 918 to similarly support radial loads of the rotor shaft 904. The second integrated bearing system 918 includes a second sprag clutch 920, a second rolling element bearing 922, and a second foil bearing 924. In some examples, pump system 900 includes an integrated bearing system. In some examples, pump system 900 includes one or more integrated bearing systems. The example first integrated bearing system 910 and the example second integrated bearing system 918 of the example pump system 900 shown in fig. 9 are substantially similar. Accordingly, references and descriptions regarding the first integrated bearing system 910 ("bearing system 910"), the first sprag clutch 912 ("sprag clutch 912"), the first bearing housing 913 ("bearing housing 913"), the first rolling element bearing 914 ("rolling element bearing 914") and the first foil bearing 916 ("foil bearing 916") may also apply to the second integrated bearing system 918, the second sprag clutch 920, the second bearing housing 921, the second rolling element bearing 922 and the second foil bearing 924, respectively.

The example pump system 900 shown in fig. 9 includes a sprag clutch 912 to engage and disengage the rolling element bearing 914 and foil bearing 916 from each other during operation of the pump system 900. The example sprag clutch 912 is a split sprag clutch that is similar to a rolling element bearing, but includes non-rotationally asymmetric sprag elements instead of rotationally symmetric cylinders, spheres, and the like. The example sprag clutch 912 includes an inner race and an outer race with sprag elements mounted in place between the inner race and the outer race. The example sprag clutch 912 also includes spring bands to create a preloaded spring force on the sprag elements to engage the sprag clutch with the inner and outer races during non-operation. Due to the asymmetric splayed geometry of the sprag elements, when the sprag elements rotate and wedge between the outer and inner races, the friction forces that occur between the components of sprag clutch 912 cause the inner race to rotate at the same angular velocity as the outer race. When the example sprag clutch 912, inner race, and outer race rotate in the first operating speed range, the sprag elements of the sprag clutch 912 remain engaged with the outer race and inner race due to the preloaded spring force and the resulting spring torque. When the example sprag clutch 912, inner race, and outer race rotate in the second operating speed range, the sprag elements of the sprag clutch 912 become disengaged from the outer race and inner race due to centrifugal forces and centrifugal moments generated thereby, which counteract and exceed the spring moments. Further description of an example sprag clutch 912 and its operation is provided below.

The example pump system 900 illustrated in fig. 9 includes rolling element bearings 914 to support the radial load of the rotor shaft 904 in the first operating speed range. Some examples of the first operating speed range include a first tangential speed range of the rotor shaft 904 and/or foil bearing 916 from 0m/s to 50m/s, a first fluid flow rate range from 0m/s to 10m/s exiting the pump system 900, and so forth. The example rolling element bearing 914 includes an inner race, an outer race, and rolling elements (e.g., balls, spheres, cylinders, etc.). The inner and outer races of the example rolling element bearing 914 are free to rotate in either direction. In some examples, the rolling element bearings 914 include a liquid lubricant (e.g., oil, grease, etc.) to reduce friction within the rolling element bearings 914 and increase the life of the rolling element bearings 914. If the example pump system 900 uses a liquid lubricant for the rolling element bearings 914, an example oil separator may be included in the pump system 900 to help ensure that the fluid is not contaminated. Some examples of oil separators that may be used in the examples disclosed herein are described in further detail below. In some examples, the rolling element bearing 914 includes an inorganic grease (e.g., a silicon grease, bentonite, polyurea, etc.) as a lubricant. The example rolling element bearing 914 shown in fig. 9 uses a solid lubricant (e.g., silver coating, graphite, molybdenum disulfide, etc.) to reduce friction in the rolling element bearing 914 and increase the life of the rolling element bearing 914 while eliminating the risk of contamination of the fluid with liquid lubricant. The rolling element bearing 914 may be one of a variety of rolling element bearings familiar to those skilled in the art, such as a cylindrical rolling element bearing, an angular contact ball bearing, a hybrid ceramic bearing, a tapered rolling element bearing, a deep groove single ball bearing, a double ball bearing, a spherical ball bearing, or any combination thereof. In some examples, the rolling element bearing 914 is hermetically sealed away from the example fluid via one or more hermetic seals (e.g., piston seals, epoxy seals, ceramic-metal seals, etc.). Depending on the type of rolling element bearing, the type of lubricant, and/or the effectiveness of the hermetic seal, example rolling element bearing 914 may have a life of 1000 hours or more. In some examples, the rolling element bearings 914 are externally cooled via conductive heat exchange from the rolling element bearings 914 to the fuel, oil, air, and/or the heat transfer bus 202 of fig. 2. Additionally or alternatively, an evaporative cooling system may be used to cool the example rolling element bearing 914.

The example pump system 900 illustrated in fig. 9 includes a foil bearing 916 to support radial loading of the rotor shaft 904 at the second operating speed range. Some examples of the second operating speed range include a second tangential speed range of the rotor shaft 904 and/or foil bearing 916 from 50m/s to 200m/s, a second fluid flow rate range from 10m/s to 100m/s exiting the pump system 900, and so forth. The example foil bearing 916 includes an inner liner, a spring loaded foil, and a journal liner as described above. The inner liner and journal liner of the example foil bearing 916 are free to rotate in either direction. The example foil bearing 916, the example rolling element bearing 914, the example sprag clutch 912, and, in general, the example integrated bearing system 910 are described in more detail below.

The example pump system 900 shown in fig. 9 includes a bearing housing 913 to support a rolling element bearing 914 and a foil bearing 916. In some examples, bearing housing 913 is an additive manufacturing part designed to fit the dimensions of rolling element bearing 914 and foil bearing 916. In some examples, the bearing housing 913 is manufactured via subtractive manufacturing to fit the dimensions of the rolling element bearing 914 and the foil bearing 916. In some examples, the bearing housing 913 securely supports the rolling element bearing 914 and the foil bearing 916 via bolts, pins, adhesive, and/or interference fits.

FIG. 10 illustrates an enlarged view 1000 of an example integrated bearing system 910 of a pump system 900 for supporting radial loads generated by a rotor shaft 904 during operation of the pump system 900. As shown in fig. 10, the enlarged view 1000 includes a rotor shaft 904, an integrated bearing system 910, a sprag clutch 912, a bearing housing 913, a rolling element bearing 914, a foil bearing 916, a sprag element 1002, a first inner race 1004, a first outer race 1006, a second inner race 1008, and a second outer race 1010. As previously described, the example components of the integrated bearing system 910 shown in fig. 10 may be included in the example second integrated bearing system 918 shown in fig. 9. The example enlarged view 1000 of fig. 10 shows the rotor shaft 904, the integrated bearing system 910, the sprag clutch 912, the bearing housing 913, the rolling element bearing 914 and the foil bearing 916 as previously described with reference to fig. 9.

The example integrated bearing system 910 as shown in fig. 10 includes a sprag element 1002 to engage the first inner race 1004 and the first outer race 1006 such that the first inner race 1004 and the first outer race 1006 rotate simultaneously and have the same torque output. Although two diagonal brace members 1002 are shown in fig. 10, an example integrated bearing system 910 may include two or more diagonal brace members 1002. As previously described, the example sprag element 1002 is asymmetrically shaped such that when the sprag element 1002 rotates in a first direction about the rotational axis, the sprag element wedges between the first inner race 1004 and the first outer race 1006 and creates frictional forces between the components. Friction forces generated by the example sprag element 1002 occur between the sprag element 1002 and the first inner race 1004 and between the sprag element 1002 and the first outer race 1006. The friction generated by the sprag elements 1002 causes the first inner race 1004 and the first outer race 1006 to rotate at the same angular velocity. As previously described, the asymmetric shape of the diagonal brace member 1002 also allows the first inner race 1004 and the first outer race 1006 to freely rotate in either direction when the diagonal brace member 1002 rotates about the rotational axis in a second direction opposite the first direction. The diagonal bracing element 1002 and its operation are described in more detail below.

The example integrated bearing system 910 as shown in fig. 10 includes a first inner race 1004 to engage the sprag element 1002 and the rolling element bearing 914 at a first operating speed range (e.g., tangential speed range of the rotor shaft 904 and/or foil bearing 916 from 0m/s to 50m/s, fluid flow rate range from 0m/s to 10m/s exiting the pump system 900, etc.). The example first inner race 1004 shown in fig. 10 is a hollow shaft that surrounds the rotor shaft 904 and is connected to the second inner race 1008 of the rolling element bearing 914 via bolts, adhesives, interference fits, or the like. In some examples, the first inner race 1004 is manufactured (e.g., subtractive processing or additive manufacturing) as the same part as the second inner race 1008. The example first inner race 1004 is longer than the second inner race 1008 and the second outer race 1010 such that the first inner race 1004 interfaces with the second inner race 1008 and the diagonal brace element 1002.

The example integrated bearing system 910 as shown in fig. 10 includes a first outer race 1006 to engage the sprag element 1002 and foil bearing 916 at a second operating speed range (e.g., a tangential speed range of the rotor shaft 904 and/or foil bearing 916 from 50m/s to 200m/s, a fluid flow rate range of the fluid exiting the pump system 900 from 10m/s to 100m/s, etc.). The example first outer race 1006 shown in fig. 10 is a shaft that is connected to the rotor shaft 904 via bolts, adhesives, interference fits, or the like. In some examples, the first outer race 1006 is manufactured (e.g., subtractive processing or additive manufacturing) as the same part as the rotor shaft 904. The example first outer race 1006 is designed such that the first outer race 1006 interfaces with the inner lining of the sprag element 1002 and the example foil bearing 916.

Fig. 11 illustrates an example split sprag clutch 1100 (e.g., sprag clutch 912 of fig. 9 and/or 10) for engaging and/or disengaging an example rolling element bearing (e.g., rolling element bearing 914 of fig. 9 and/or 10) and/or an example foil bearing (e.g., foil bearing 916 of fig. 9 and/or 10) of an example integrated bearing system 910. The example sprag clutch 1100 shown in fig. 11 is shown from an equidistant viewpoint 1102 and from a frontal viewpoint 1104. The example sprag clutch 1100 shown in fig. 11 includes a sprag element 1106 (e.g., sprag element 1002 of fig. 10), an inner ring 1108, and an outer ring 1110. Although twenty-six sprag elements 1106 are shown from the front perspective 1104 of the example sprag clutch 1100, more or less than twenty-six sprag elements may be included in the example sprag clutch 1100 of fig. 11 and/or the example sprag clutch 912 of fig. 9 and/or 10.

The example sprag clutch 1100 shown in fig. 11 includes an inner ring 1108 and an outer ring 1110. The example inner ring 1108 is annular and includes a slot shaped to fit the bottom portion of the diagonal brace element 1106. The example outer ring 1110 is also annular and includes a slot shaped to fit the upper portion of the diagonal brace element 1106. The slots included in the example inner ring 1108 and the example outer ring 1110 are designed such that the asymmetric splayed shape of the diagonal bracing element 1106 hooks into the slots. The example sprag element 1106, inner ring 1108, and outer ring 1110 are also designed such that the top and bottom surfaces of the sprag element 1106 protrude outwardly from the outer ring 1110 and inwardly from the inner ring 1108. In some examples, inner ring 1108 and/or outer ring 1110 are coupled to diagonal brace element 1106 via a rod, pin, screw, or the like to maintain the position of diagonal brace element 1106 between an inner ring (e.g., first inner ring 1004) and an outer ring (e.g., first outer ring 1006). In some examples, the inner ring 1108 and/or the outer ring 1110 maintain the position of the diagonal brace element 1106 without fasteners (e.g., bolts, pins, bars, etc.). In some examples, the sprag elements 1106, inner ring 1108, and/or outer ring 1110 are manufactured separately and assembled together to form the sprag clutch 1100. In some examples, the sprag elements 1106, inner ring 1108, and/or outer ring 1110 are manufactured separately as parts to be assembled or as manufacturing components via additive manufacturing (such as direct metal laser sintering). In some examples, the sprag clutch 1100 includes a spring band to exert a preloaded spring force on the sprag element 1106 such that the sprag element 1106 engages the inner ring 1108 and the outer ring 1110 prior to operation and while the example pump system 900 operates within the first operating speed range.

Fig. 12A illustrates an example engaged state 1200A of an example sprag element 1202 (e.g., one of sprag elements 1002 and/or 1106). The example engaged state 1200A shown in fig. 12 shows the diagonal brace member 1202 having a diagonal brace rotation axis 1204, the diagonal brace member 1202 rotating about the diagonal brace rotation axis 1204. In some examples, the diagonal strut axis of rotation 1204 is also the location of the Center of Gravity (CG) of the diagonal strut element 1202. The example sprag element 1202 engages with the inner race 1206 (e.g., inner race 1004) and the outer race 1208 (e.g., outer race 1006) prior to operation of the pump system 900 due to the preloaded spring force acting on the sprag element 1202. In some examples, a spring band is included in a sprag clutch (e.g., sprag clutch 1100) to exert a preloaded spring force on the left side of sprag element 1202 above sprag rotational axis 1204 relative to the orientation shown in fig. 12A. The preloaded spring force acting on the sprag element 1202 creates a spring moment 1210 on the sprag element 1202. The example spring moment 1210 causes the sprag elements 1202 to wedge and/or become trapped between the inner and outer races 1206, 1208 prior to operation of the pump system 900. When the pump system 900 begins to operate, the outer race 1208 rotates in a counterclockwise direction (relative to the orientation shown in fig. 12A) and friction is generated between the sprag element 1202, the outer race 1208, and the inner race 1206 such that the inner race 1206 rotates counterclockwise at the same rate as the outer race 1208. The example spring strap is designed to generate a spring moment 1210 that is large enough to counteract a friction moment acting on the sprag element 1202 in a counter-clockwise direction that is opposite the spring moment 1210. At this point in the operation of the example pump system 900, the point of contact between the sprag element 1202 and the outer race 1208 is to the right of the sprag rotational axis 1204 and CG of the sprag element 1202. The example contact point is also the location where friction and resulting friction torque act on the sprag element 1202. During operation of the example pump system 900 in the first operating speed range, centrifugal force acts on the diagonal brace member 1202 at the diagonal brace rotation axis 1204 and/or CG of the diagonal brace member 1202. Since the diagonal strut rotation axis 1204 and/or CG of diagonal strut element 1202 is to the left of the contact point in the first operating speed range, centrifugal force produces a first centrifugal moment opposite the friction moment acting in the same direction as the spring moment. Thus, when the example shaft (e.g., rotor shaft 904) drives rotation of outer race 1208 via a mechanical connection (e.g., bolt, adhesive, interference fit, etc.) at a first operating speed range, sprag elements 1202 remain engaged with outer race 1208 and inner race 1206, which causes inner race 1206 to rotate at the same speed as outer race 1206. Due to the design, shape, structure, material, etc. of the example spring band, the example sprag element 1202 remains engaged with the inner race 1206 and the outer race 1208 as long as the outer race 1208 continues to rotate at angular speeds within a first operating speed range (e.g., less than the foil bearing start-up speed (e.g., 10m/s to 50m/s of the rotor shaft 904 and/or the foil bearing 916 tangential speed)).

Fig. 12B illustrates an example detached state 1200B of an example diagonal brace element 1202 (e.g., one of diagonal brace element 1002 and/or diagonal brace element 1106). The example detached state 1200B shown in fig. 12B shows the same diagonal brace element 1202 having the same diagonal brace rotation axis 1204 and/or CG about which the diagonal brace element 1202 rotates. The example split state 1200B shown in fig. 12B includes the same inner race 1206 and the same outer race 1208 as in fig. 12A. In the disengaged state 1200B shown in fig. 12B, the outer race 1208 (e.g., outer race 1006) is connected to an example shaft (e.g., rotor shaft 904) and rotates at a rate within a second operating speed range (e.g., greater than foil bearing start-up speed (e.g., tangential speed of 10m/s to 50 m/s)). Once the outer race 1208 and shaft (e.g., rotor shaft 904) rotate at a rate within the second operating speed range, the sprag element 1202 separates from the outer race 1208 and inner race 1206 and rotates in a counter-clockwise direction. As the example pump system 900 increases the operating speed closer to the lower end of the second operating speed range, the friction forces and friction moments acting on the sprag element 1202 increase. The friction moment acting on the sprag element 1202 counteracts the spring moment 1210. Once the operating speed of the pump system 900 reaches the lower limit of the second operating speed range, the friction torque is able to sufficiently cancel the spring torque 1210 such that the diagonal strut rotation axis 1204 and/or CG of the diagonal strut element 1202 moves to the right of the point of contact between the diagonal strut element and the outer race 1208. Once the example contact point shifts to the left of the diagonal brace rotation axis 1204 and/or CG of the diagonal brace element 1202, the first centrifugal torque switches direction and becomes a second centrifugal torque 1212, the second centrifugal torque 1212 supplements the friction torque and opposes the spring torque 1210. Once the sum of the friction torque and the second centrifugal torque 1212 exceeds the spring torque 1210, the sprag elements 1202 disengage from the inner race 1206 and the outer race 1208. Thus, in response to the example shaft (e.g., rotor shaft 904) driving the outer race 1208 to rotate via a mechanical connection (e.g., bolt, adhesive, interference fit, etc.) at the second operating speed range, the sprag element 1202 separates from the outer race 1208 and the inner race 1206, which frees the inner race 1206 from the outer race 1208 to rotate freely.

Fig. 13 illustrates example load paths that the example integrated bearing system 1300 (e.g., the integrated bearing system 910 of fig. 9 and 10) and the integrated bearing system 1300 supports at different points during operation of the example pump system (e.g., the pump system 900 of fig. 9). The example integrated bearing system 1300 includes a shaft 1302 (e.g., the rotor shaft 904 of fig. 9 and/or 10), a bearing housing 1304 (e.g., the bearing housing 913 of fig. 9 and/or 10), a sprag clutch 1306 (e.g., the sprag clutch 912 of fig. 9 and/or 10), an inner race 1308 (e.g., the inner race 1004 of fig. 10 and/or the inner race 1206 of fig. 12A and/or 12B), an outer race 1310 (e.g., the outer race 1006 of fig. 10 and/or the outer race 1208 of fig. 12A and/or 12B), a rolling element bearing 1312 (e.g., the rolling element bearing 914 of fig. 9 and/or 10), a foil bearing 1314 (e.g., the foil bearing 916 of fig. 9 and/or 10), a first load path 1316, and a second load path 1318. The example first load path 1316 and the example second load path 1318 are representations of forces acting on the example inner race 1308 and the example outer race 1310, respectively, rather than physical objects.

As previously described and shown in fig. 9 and/or 10, the example outer race 1310 is coupled to the example shaft 1302 via mechanical fasteners (e.g., bolts, screws, pins, adhesives, interference fits, etc.). Also as previously described, the example bearing housing 1304 securely supports the example rolling element bearing 1312 and the example foil bearing 1314 in place during operation via mechanical fasteners (e.g., bolts, screws, pins, adhesives, interference fits, etc.). The example sprag clutch 1306 engages the example outer race 1310 and the example inner race 1308 when the example shaft 1302 rotates at a first angular velocity that is associated with a first tangential velocity that does not satisfy the foil bearing start-up speed (e.g., a tangential velocity of 10m/s to 50 m/s). In response to the example sprag clutch 1306 engaging the inner race 1308 and the outer race 1310 in the first operating speed range, the shaft 1302 generates an example first load path 1316 that acts on the inner race 1308 and the rolling element bearings 1312. Thus, in a first operating speed range, the example rolling element bearing 1312 supports the weight of the shaft 1302.

As previously described and shown in fig. 12A and 12B, the example sprag clutch 1306 is disengaged from the inner race 1308 and the outer race 1310 at a second angular velocity associated with a second tangential velocity that meets foil bearing start-up speeds (e.g., tangential velocities of 10m/s to 50 m/s). In response to sprag clutch 1306 disengaging inner race 1308 and outer race 1310 at a second tangential velocity, shaft 1302 generates an example second load path 1318 that acts on inner and outer races 1310 and foil bearings 1314. Thus, in the second operating speed range, the example foil bearing 1314 supports the weight of the shaft 1302. In some examples, first load path 1316 and second load path 1318 have the same force value that is sufficiently similar to the weight of shaft 1302.

FIG. 14 is a flow chart illustrating an example process or operation 1400, as disclosed herein, that an integrated bearing system 910 may follow to dynamically support a rotor shaft 904 in a pump system 900. Although operation 1400 is described primarily with reference to dynamically supporting rotor shaft 904 in pump system 900 of fig. 9, operation 1400 may be used to support another rotating shaft in another pump system using integrated bearing system 910. Although operation 1400 is described primarily with reference to dynamically supporting rotor shaft 904 with integrated bearing system 910, another integrated bearing system (e.g., integrated bearing system 918) may use operation 1400 to dynamically support rotor shaft 904 or another rotor shaft.

At block 1402, the pump system 900 begins pressurizing fluid (e.g., heat exchange fluid, supercritical carbon dioxide (scco 2), etc.) flowing through the thermal management system and increasing the flow rate of the fluid exiting the pump system 900. For example, current is supplied to a stator 906 in a motor of the pump system 900, which causes electromagnets in the stator 906 to generate one or more magnetic fields that alternate polarity over time based on the direction of the current flowing through the stator 906. The magnetic field generated is perpendicular to the axis of rotation of the rotor 905 in the motor. The rotor 905 is attached to the rotor shaft 904 and includes permanent magnets that are attracted and/or repelled by the alternating polarity of the electromagnets in the stator 906. As the rotor shaft 904 rotates at an increased angular velocity, the impeller 902 coupled to the rotor shaft 904 also rotates at an increased angular velocity. The impeller 902 includes vanes or blades that cause an increase in fluid pressure and flow rate.

At block 1404, the integrated bearing system 910 of the pump system 900 is engaged with the inner race 1004 attached to the rolling element bearing 914 and the outer race 1006 attached to the rotor shaft 904. For example, the sprag clutch 912 of the integrated bearing system 910 includes a sprag element 1002 (e.g., sprag element 1106 of fig. 11), the sprag element 1002 engaging the inner race 1004 and the outer race 1006 due to a preloaded spring force acting on the sprag element 1002. When sprag element 1002 wedges between outer race 1006 and inner race 1004, a reaction force and friction force are generated, which causes inner race 1004 to rotate at the same rate as outer race 1006.

At block 1406, an integrated bearing system 910 of the pump system 900 supports the rotor shaft 904 via the inner race 1004. For example, the outer race 1006 rotates at the same rate as the rotor shaft 904, the sprag clutch 912 engages with the outer race 1006 and the inner race 1004, the inner race 1004 rotates at the same rate as the outer race 1006 and the rotor shaft 904, and the rolling element bearings 914 support the radial load of the rotor shaft 904 via the inner race 1004.

At block 1408, the pump system 900 increases the operating speed of the motor. For example, current is supplied to the stator 906 at a greater rate such that electromagnets in the stator 906 alternate polarity at a greater rate. As the electromagnets of the stator 906 alternate at a greater rate, the angular velocity of the rotor 905 increases at the same rate. As the angular velocity of the rotor 905 and the connected rotor shaft 904 increases, the tangential velocity of the rotor shaft 904 and outer race 1006 also increases.

At block 1410, if the tangential speed of the rotor shaft A104 and/or the outer race 1006 meets the foil bearing start-up speed (e.g., 10m/s to 50 m/s), then operation 1400 proceeds to block 1412. If the tangential speed of the rotor shaft A104 and/or the outer race 1006 does not meet the foil bearing start-up speed, operation 1400 returns to block 1406 where the rolling element bearings 914 continue to support the weight of the rotor shaft 904 via the inner race 1004.

At block 1412, the integrated bearing system 910 is separated from the inner race 1004 and the outer race 1006. For example, once the tangential velocity of rotor shaft a104 and/or outer race 1006 is high enough to meet the foil bearing start-up speed, centrifugal and frictional forces acting on the sprag elements 1002 of sprag clutch 912 counteract and exceed the spring torque forces, causing sprag elements 1002 to counter-rotate and disengage from inner race 1004 and outer race 1006.

At block 1414, the integrated bearing system 910 supports the radial load generated by the rotor shaft a104 via the outer race 1006. For example, once the sprag element 1002 is separated from the outer race 1006 and the inner race 1004, the foil bearing 916 supports the total weight and/or a majority of the weight of the rotor shaft a104 via the outer race 1006, the outer race 1006 being connected to the rotor shaft 904 and interacting with the foil bearing 916. As long as the foil bearing start-up speed is met, foil bearing 916 continues to support the total radial load and/or most of the radial load of rotor shaft A104.

At block 1416, if the tangential speed of the rotor shaft a104 and/or foil bearing 916 continues to meet the foil bearing start speed, operation 1400 returns to block 1414 where, at block 1414, the integrated bearing system 910 continues to support the radial load of the rotor shaft 904 via the outer race 1006. If the operating speed of the pump system 900 slows such that the tangential speed of the rotor shaft 904 and/or foil bearing 916 does not meet the foil bearing start-up speed, operation 1400 proceeds to block 1418.

At block 1418, the integrated bearing system 910 of the pump system 900 is engaged with the inner race 1004 attached to the rolling element bearings 914 and the outer race 1006 attached to the rotor shaft 904. For example, the spring moment forces acting on the sprag elements exceed the opposing friction and centrifugal forces, and the sprag clutch 912 of the integrated bearing system 910 engages with the inner race 1004 and the outer race 1006. At block 1420, integrated bearing system 910 supports a radial load of rotor shaft 904 via inner race 1004. For example, the sprag clutch 912 of the integrated bearing system 910 is engaged with the inner race 1004 attached to the rolling element bearings 914, and the rolling element bearings 912 support the total radial load and/or the majority of the radial load of the rotor shaft 904 via the inner race 1004. Operation 1400 continues at block 1420 until the pump system 900 ceases to operate, at which point operation 1400 of fig. 14 ends.

In some examples, the pump system 900 includes a means for increasing kinetic energy. For example, the means for adding may be implemented by the impeller 902, rotor shaft 904, rotor 905, and/or stator 906 of fig. 9. In some examples, the means for adding may include a motor, an impeller shaft, and an impeller.

In some examples, the pump system 900 includes a means for providing torque. For example, the means for providing may be implemented by the stator 906 and/or the rotor 905 of fig. 9. In some examples, the means for providing may comprise an electric motor.

In some examples, the pump system 900 includes a means for a first support. For example, the means for first supporting may be implemented by the first integrated bearing system 910 of fig. 9 and/or 10, the second integrated bearing system 918 of fig. 9, the first rolling element bearing 914 of fig. 9 and/or 10, the second rolling element bearing 922 of fig. 9, the integrated bearing system 1300 of fig. 13, and/or the rolling element bearing 1312 of fig. 13. In some examples, the means for first supporting may include an angular contact ball bearing, a hybrid ceramic bearing, a tapered roller bearing, a deep groove single ball bearing, a double ball bearing, and/or a spherical bearing.

In some examples, the pump system 900 includes a means for a second support. For example, the means for second supporting may be implemented by the first integrated bearing system 910 of fig. 9 and/or 10, the second integrated bearing system 918 of fig. 9, the first foil bearing 916 of fig. 9 and/or 10, the second foil bearing 924 of fig. 9, the integrated bearing system 1300 of fig. 13, and/or the foil bearing 1314 of fig. 13. In some examples, the means for second supporting may comprise an air foil bearing and/or a fluid static foil bearing.

In some examples, the pump system 900 includes means for engaging. For example, the means for engaging may be implemented by the first integrated bearing system 910 of fig. 9 and/or 10, the second integrated bearing system 918 of fig. 9, the first sprag clutch 912 of fig. 9 and/or 10, the second sprag clutch 920 of fig. 10, the sprag element 1002 of fig. 10, the sprag clutch 1100 of fig. 11, the sprag element 1106 of fig. 11, the sprag element 1202 of fig. 12A-12B, and/or the sprag clutch F506 of fig. 13. In some examples, the means for engaging may include a clutch and/or one or more asymmetrically shaped rotating elements.

In some examples, the pump system 900 includes a means for separating. For example, the means for separating may be implemented by an oil separator. Further description of an example oil separator that may implement the apparatus for separation is discussed in more detail below.

Example integrated bearing systems for dynamically supporting a shaft in a pump system are disclosed herein. Example integrated bearing systems disclosed herein include a sprag clutch, an inner race attached to a rolling element bearing, and an outer race attached to a foil bearing and a rotor shaft. The example integrated bearing system disclosed herein includes a sprag clutch to engage with the inner and outer races in a first operating speed range (e.g., tangential speed range from 0m/s to 10m/s and/or 50 m/s). Thus, the example rolling element bearing supports radial loads generated when the example rotor shaft operates within the first operating speed range. The example integrated bearing system disclosed herein also includes a sprag clutch to disengage from the inner and outer races at a second operating speed range (e.g., tangential speed range from 10m/s and/or 50m/s to 200 m/s) due to centrifugal forces acting on the sprag elements of the sprag clutch. Thus, the example foil bearing supports radial loads generated when the example rotor shaft operates within the second operating speed range. The example integrated bearing systems disclosed herein reduce wear of foil bearings in example pump systems (relative to example pump systems without integrated bearing systems) because rolling element bearings support a majority and/or total radial load of the rotor shaft during start and stop speeds of the pump system. The example integrated bearing systems disclosed herein allow foil bearings to operate for longer periods of time without damage and/or maintenance (relative to foil bearings in pump systems without example integrated bearing systems) because example foil bearings utilize air pressure in the foil bearings (without spring loaded foils within the foil bearings) to support a majority and/or the total radial load of the rotor shaft while the foil bearings operate at a second operating speed range.

Layered barrier tank for magnetic coupling and method of producing the same

In some known pumps, to reduce the effect of a barrier can (e.g., barrier can 452 of fig. 4) on the magnetic field generated by the magnetic coupling (e.g., first magnetic coupling 450 and second magnetic coupling 460 of fig. 4), the barrier can uses a non-metallic material. For example, the barrier can may comprise plastic. However, plastic barrier cans include a large thickness to provide adequate structural strength, and are still often not strong enough to withstand high pressures (e.g., pressures in excess of 1,000 pounds Per Square Inch Absolute (PSIA)). Additionally, non-metallic materials may deform at higher temperatures. Thus, the use of non-metallic materials for the barrier tank limits the potential operating pressure and/or temperature of the associated pump. Thus, the non-metallic barrier tank limits the rate at which fluid can be driven through the heat transfer bus 202 and, in turn, limits the rate at which thermal energy can be transferred between the fluid and the working fluid.

In some pumps, the barrier tank is formed of titanium in order to enable the barrier tank to withstand increased pressures (e.g., pressures in excess of 1,000PSIA). However, titanium barrier cans may cause eddy current losses between the rotating magnetic fields generated by the magnetic coupling. Further, such eddy current losses increase when the titanium barrier tank comprises a greater thickness to withstand higher pressures. Thus, the titanium barrier can may limit the rate at which the magnetic coupling may rotate while maintaining the magnetic coupling. Thus, the titanium barrier can may affect the torque transferred between the motor shaft and the impeller shaft. Furthermore, to overcome eddy current losses, the titanium barrier may require a larger magnet for the magnetic coupling, which increases the size and/or cost of the pump, a larger motor to drive rotation of the magnetic coupling, and/or a cooling arrangement to release heat generated by the magnetic coupling during rotation.

Fig. 15 illustrates a first example shield 1500 (e.g., a barrier tank), the first example shield 1500 may be used with the heat transfer bus pump 400 (e.g., the barrier tank 452 of fig. 4), the pump system 500 of fig. 5 (e.g., the barrier tank 536 of fig. 5), the pump system 600 of fig. 6 (e.g., the barrier tank 636 of fig. 6), the pump system 700 of fig. 7, and/or any other pump system disclosed herein that uses a barrier tank or shield to contain a fluid flow. In the example shown in fig. 15, the shroud 1500 includes an inner shell 1502, an outer shell 1504, and a core shell 1506 (e.g., a metal core shell, a metal core layer, etc.), the core shell 1506 being positioned between the inner shell 1502 and the outer shell 1504. The shroud 1500 defines a cavity 1508. Thus, when the shield 1500 is implemented in the heat transfer bus pump 400, one magnetic coupling (e.g., the second magnetic coupling 460 of fig. 4) may be positioned in the cavity 1508, and another magnetic coupling (e.g., the first magnetic coupling 450 of fig. 4) may be positioned around the shield 1500. Thus, the inner shell layer 1502 may be in contact with a first fluid (e.g., a heat exchange fluid, such as a supercritical fluid (e.g., scco 2, etc.)) and the outer shell layer 1504 may be in contact with a second fluid (e.g., air, hydrogen, etc.).

In the example shown in fig. 15, the inner surface 1510 of the core shell layer 1506 is in full contact with the inner shell layer 1502. Similarly, the outer surface 1512 of the core shell layer 1506 is in full contact with the outer shell layer 1504. In particular, the inner shell layer 1502 and the outer shell layer 1504 provide an insulating layer that surrounds the core shell layer 1506. As a result, the continuous surface contact that the core-shell layer 1506 has with the inner shell layer 1502 and the outer shell layer 1504 may help the core-shell layer 1506 dissipate heat generated by the core-shell layer 1506 encountering a rotating magnetic field. Specifically, the inner shell layer 1502 may transfer thermal energy between the first fluid and the core shell layer 1506. Further, the outer shell 1504 may transfer thermal energy between the second fluid and the core shell 1506. The heat transfer bus pump 400 may recirculate the first fluid to increase the rate at which thermal energy is transferred between the core-shell layer 1506 and the first fluid through the inner shell layer 1502. Further, the vent 461 (fig. 4) may enable the second fluid to circulate in the coupling housing 424 (fig. 4). In some examples, the fan drives the second fluid into and/or out of the coupling housing to increase the rate at which thermal energy is transferred between the core-shell layer 1506 and the second fluid through the outer shell layer 1504. In some other examples, the coupling housing 424 and/or the motor housing 412 (fig. 4) are filled with a second fluid, which enables the second fluid to circulate and cool the shroud 1500 when the coupling housing 424 does not include the vent 461.

In fig. 15, the shroud 1500 may include a thickness between 0.090 inches (in) and 0.125 in. In some examples, inner shell layer 1502 includes a first thickness (e.g., between 0.005in and 0.040 in), outer shell layer 1504 includes a first thickness or a second thickness (e.g., between 0.005in and 0.040 in), and core shell layer 1506 includes a third thickness (e.g., between 0.005in and 0.090 in). In some examples, the third thickness is greater than the first thickness and the second thickness. However, the third thickness may alternatively be less than the first thickness and/or the second thickness, or approximately equal to the first thickness and/or the second thickness. The thickness of the shroud 1500, and more specifically, the thickness of the inner shell layer 1502, the outer shell layer 1504, and the core shell layer 1506, may be based on the pressures encountered during operation of an associated pump (e.g., the heat transfer bus pump 400). For example, the shroud 1500 may include a first thickness (e.g., 0.125 in) when the pump 400 is operated at a first maximum pressure, and the shroud 1500 may include a second thickness (e.g., 0.090 in) when the pump 400 is operated at a second maximum pressure that is less than the first maximum pressure.

In the example shown in fig. 15, the inner shell layer 1502, the outer shell layer 1504, and the core shell layer 1506 each include a uniform thickness. In some examples, the inner shell layer 1502, the outer shell layer 1504, and/or the core shell layer 1506 each include a non-uniform thickness, as discussed in further detail below.

The inner shell layer 1502 and the outer shell layer 1504 include non-metallic materials, such as ceramic materials, polymeric materials, and/orA composite material. In some examples, the ceramic material is alumina (I) (Al ₂ O), aluminum (II) (AlO) (e.g., aluminum monoxide), aluminum (III) (Al ₂ O ₃ ) (e.g., alumina, aluminum oxide), zirconia (e.g., zirconia toughened alumina), and/or silicon carbide. In some examples, the polymer material and/or composite material includes a carbon fiber composite material and/or polyimide (e.g., T650-35, PMR-15, MVK-14 standard modulus, etc.). The carbon fiber composite material may include short carbon fibers, long carbon fibers, and/or annular carbon fibers (endless carbon fibers). Thus, the inner shell layer 1502 defines a first non-metallic layer of the shroud 1500 and the outer shell layer 1504 defines a second non-metallic layer of the shroud 1500. In some examples, both the inner shell layer 1502 and the outer shell layer 1504 include a ceramic material. In some examples, both the inner shell layer 1502 and the outer shell layer 1504 include a polymer. In some examples, both inner shell layer 1502 and outer shell layer 1504 comprise a composite material. In some examples, inner shell layer 1502 includes a first material, such as a ceramic material, and outer shell layer 1504 includes a second material, such as a polymer or composite material, that is different from the first material. Further, the core shell layer 1506 includes nickel and/or cobalt. Additionally or alternatively, the core shell layer 1506 may include a different metal.

In fig. 15, the shroud 1500 includes a flange portion 1514. In fig. 4, the inner shell layer 1502, outer shell layer 1504, and core shell layer 1506 extend circumferentially outward to form a flange portion 1514. Thus, the O-ring 459 of fig. 4 may be positioned around the flange portion 1514. Further, the flange portion 1514 may be pressed against the rear end of the front bearing housing 428 of fig. 4 via the barrier can retainer 454 and bolts 458 of fig. 4. When the inner shell layer 1502 and the outer shell layer 1504 surround the core shell layer 1506, the O-ring 459 presses against the outer shell layer 1504 to enable the shroud 1500 to hermetically close the rear end of the front bearing housing 428.

The inner shell layer 1502 may be formed via molding and/or slurry-based processing techniques, such as additive manufacturing (e.g., thermal spraying, cold spraying, etc.) and/or sintering. In some examples, when the inner shell layer 1502 is formed via thermal and/or cold spraying, there is an initial mandrel on which the inner shell layer 1502 is sprayed and then separated therefrom. In some examples, when the inner shell layer 1502 is formed via thermal and/or cold spraying, an initial portion (e.g., an inner portion or an outer portion) of the inner shell layer 1502 may be formed via another manufacturing technique (such as a slurry-based process) and the remaining portion of the inner shell layer 1502 may be sprayed onto the initial portion. Further, the initial portion of the inner shell layer 1502 may be machined to a thickness prior to thermal and/or cold spraying. In some examples, the inner shell layer 1502 may be formed via other manufacturing techniques such as casting (e.g., slip casting, cast casting, etc.) and/or pressing.

Further, the core shell layer 1506 is electroformed (e.g., electrodeposited) on the outer surface 1516 of the inner shell layer 1502. That is, the inner shell layer 1502 serves as a mandrel upon which the core shell layer 1506 is formed. Advantageously, electroforming the core shell layer 1506 enables a reduction in the thickness of the core shell layer 1506 compared to that which can be provided by conventional manufacturing techniques for forming metals.

Further, the outer shell layer 1504 may be formed over the core shell layer 1506 via thermal or cold spray. Thus, the electroformed layer of the core shell layer 1506 may serve as a bond coat for the outer shell layer 1504. In some examples, the inner shell layer 1502 may be formed via other manufacturing techniques, such as composite lay-up processing (e.g., composite lay-up), molding (e.g., injection molding), slip casting, pressing, and/or tape casting.

For example, the inner shell layer 1502 may be molded, the core shell layer 1506 electroformed over the inner shell layer 1502, and the outer shell layer 1504 thermally sprayed over the core shell layer 1506. In some examples, the core shell layer 1506 is electroformed on the inner surface of the outer shell layer 1504, rather than the outer surface of the inner shell layer 1502. Further, the inner shell layer 1502 may be thermally sprayed or cold sprayed onto the core shell layer 1506. Further, the shield 1500 may be finished via machining or grinding to maintain the thickness of the shield 1500 within a certain tolerance and to define a uniform profile along the inner surface of the inner shell layer 1502 and/or the outer surface of the outer shell layer 1504.

Advantageously, the core-shell layer 1506 enables the first example shroud 1500 to withstand increased pressures without fracturing and, in turn, enables the heat transfer bus pump 400 to drive fluid at higher pressures. Specifically, the first example shroud 1500 enables the speed of the motor 410 to be increased to increase the output (e.g., volumetric flow rate) produced by the impeller 406. As a result, the heat transfer bus pump 400 may provide more fluid to the region of the aircraft 10 of fig. 1 and/or the gas turbine engine 100 of fig. 2 in a shorter time to enable heat transfer between the fluid and the working fluid in the aircraft 10 and/or the gas turbine engine 100 of fig. 1 to occur at a faster rate. Further, the geometry of the inner shell layer 1502, outer shell layer 1504, and/or core shell layer 1506 may be non-cylindrical to increase the stiffness of the first shroud 1500 and, in turn, the pressure that the shroud 1500 can withstand.

In addition, electroforming the core shell layer 1506 enables the core shell layer 1506 to be formed with reduced thicknesses that are not producible by conventional manufacturing techniques. As a result, when the first shroud 1500 is implemented in the heat transfer bus pump 400, the core shell layer 1506 causes reduced eddy current losses as compared to known barrier cans comprising metal. Thus, the reduced eddy current loss enables the sizes of the motor 410, the first magnetic coupling 450, and the second magnetic coupling 460 to be reduced. In addition, the reduced eddy current loss reduces thermal energy generated by the core-shell layer 1506 due to the rotating magnetic field generated by the first and second magnetic couplings 450 and 460 of fig. 4. Thus, electroformed core shell 1506 prevents the need for a cooling sleeve around coupling housing 424. Additionally, the core shell 1506 increases the temperature range that the shroud 1500 can withstand.

Similarly, thermal spraying enables the inner shell layer 1502 and/or the outer shell layer 1504 to be formed with a reduced thickness. Thus, the overall thickness of the first shield 1500 is minimized or otherwise reduced, which enables the gap between the first and second magnetic couplings 450, 460 to be minimized or otherwise reduced. Accordingly, smaller magnets and/or smaller motors may be utilized to more efficiently transfer torque between the motor shaft 438 and the impeller shaft 466 to reduce the size and/or cost of the heat transfer bus pump 400. Additionally, the reduced thickness of inner shell layer 1502 and/or outer shell layer 1504 and/or the continuous surface contact of core shell layer 1506 with inner shell layer 1502 and outer shell layer 1504 enables inner shell layer 1502 and/or outer shell layer 1504 to more efficiently transfer thermal energy between the encountered fluid and core shell layer 1506. Thus, the inner shell layer 1502 and/or the outer shell layer 1504 may help the core shell layer 1506 to dissipate heat. Further, the reduced eddy current losses caused by the shroud 1500 and the reduced thickness of the shroud 1500 may enable increased separation between the shroud 1500 and the magnetic couplings 450, 460 such that fluid may flow between the shroud 1500 and the magnetic coupling 450 at an increased flow rate to increase the rate at which thermal energy is transferred between the shroud 1500 and the fluid.

Further, reducing the thickness of the first shield 1500 and reducing eddy current losses caused by the shield 1500 enables rotation of the first and second magnetic couplings 450, 460 to remain interlocked at higher rotational speeds. Thus, the first shroud 1500 enables the heat transfer bus pump 400 to drive fluid at an increased flow rate and/or an increased pressure.

FIG. 16 illustrates another example inner shell layer 1600 that may be used in the first example shroud 1500 of FIG. 15 (e.g., the inner shell layer 1502 of FIG. 15). In fig. 16, inner shell layer 1600 includes base portion 1602 and ribs 1604 (e.g., ridges) radially protruding from base portion 1602. Specifically, rib 1604 extends away from a cavity 1606 (e.g., cavity 1508) defined by base portion 1602. Thus, a first portion of inner shell layer 1600 includes a first thickness defined by base portion 1602 and a second portion of inner shell layer 1600 includes a second thickness defined by base portion 1602 and rib 1604. In some examples, the second thickness is between 0.75 inches and 1.0 inches. Advantageously, the ribs 1604 enable the shroud 1500 of fig. 15 to provide increased structural rigidity and thus increase the maximum pressure that the shroud 1500 can withstand.

In the example shown in fig. 16, ribs 1604 are spaced apart along the perimeter of base portion 1602. Further, circumferentially spaced ribs 1604 extend along base portion 1602 in an axial direction a defined by inner shell layer 1600. In the example shown in fig. 16, the rib 1604 extends in a straight line in the axial direction a. However, it should be appreciated that the ribs 1604 may extend in any shape along the base to increase the rigidity of the shroud 1500 of fig. 15. For example, ribs 1604 may extend from base portion 1602 in a straight line that is not defined by an axial direction (e.g., where the circumferential position of a first end of a ridge is different from the circumferential position of a second end of the ridge). In some examples, rib 1604 extends helically along base portion 1602 in axial direction a. In some examples, ribs 1604 extend along base portion 1602 in a circumferential direction C defined by inner shell layer 1600. In some examples, rib 1604 includes a wave-shape such that the position of rib 1604 varies in circumferential direction C as rib 1604 extends along base portion 1602 in axial direction a.

In addition, the core shell layer 1506 of FIG. 15 may be electroformed onto the inner shell layer 1600. Thus, the core shell layer 1506 of fig. 15 is laminated to the base portion 1602 and ribs 1604 of the inner shell layer 1600. As a result, the core shell layer 1506 of fig. 15 may include a first portion secured to the base portion 1602 and a second portion secured to the rib 1604. Thus, a first portion of the core shell layer 1506 of fig. 15 may include a first inner diameter and a first outer diameter, and a second portion of the core shell layer 1506 may include a second inner diameter and a second outer diameter that are greater than the first inner diameter and the first outer diameter. Further, the geometry of the core shell layer 1506 may further increase the structural rigidity of the shroud 1500.

Fig. 17A-C illustrate steps of an example manufacturing process for forming the first shroud 1500. In particular, FIGS. 17A-C illustrate steps of a manufacturing process where the first shroud 1500 includes the first inner shell layer 1502 of FIG. 15 and the second inner shell layer 1600 of FIG. 16. In fig. 17A, inner shell layers 1502, 1600 are formed. For example, the inner shell layers 1502, 1600 may be formed via molding, thermal spraying, and/or cold spraying. In fig. 17B, the core shell layer 1506 is electroformed onto the inner shell layers 1502, 1600. In fig. 17C, the outer shell 1504 is thermally or cold sprayed over the core shell 1506.

Fig. 18 is a flow chart illustrating an example method 1800 of manufacturing a barrier can, such as the shroud 1500 of fig. 15 and/or 17C. In some examples, at least a portion of the example method 1800 represents example machine readable instructions that may be executed and/or instantiated by processor circuitry in communication with a manufacturing device to manufacture the shroud 1500. Additionally or alternatively, the method 1800 of fig. 18 may use an Application Specific Integrated Circuit (ASIC) and/or a Field Programmable Gate Array (FPGA) that is structured such that operations corresponding to the method 1800 are performed by a manufacturing device.

The example method 1800 of fig. 18 begins at block 1802, and at block 1802, the inner shell layers 1502, 1600 are formed. For example, the inner shell layers 1502, 1600 may be formed via molding and/or slurry-based manufacturing techniques, such as additive manufacturing (e.g., thermal spray or cold spray) and/or sintering.

At block 1804, a core shell layer 1506 is formed over the inner shell layers 1502, 1600. For example, the core shell layer 1506 may be electroformed on the outer surface of the inner shell layers 1502, 1600. Thus, the inner shell layers 1502, 1600 act as mandrels for electroforming the core shell layer 1506. As a result, the inner surface of the core shell layer 1506 is in full contact with the inner shell layers 1502, 1600.

At block 1806, an outer shell layer 1504 is formed over the core shell layer 1506. For example, the outer shell layer 1504 may be thermally and/or cold sprayed over the core shell layer 1506. In some examples, the outer shell layer 1504 is thermally and/or cold sprayed over a portion (e.g., an edge) of the inner shell layer 1502 such that the outer shell layer 1504 and the inner shell layer 1502 encapsulate the core shell layer 1506. As a result, the outer surface of the core shell layer 1506 is in full contact with the outer shell layer 1504.

In some examples, the shield 1500 includes a first means for insulation. For example, the first means for insulating may be implemented by the inner shell layer 1502 of FIGS. 15 and 17A-C or the inner shell layer 1600 of FIGS. 16 and 17A-C. In some examples, the first means for insulating may comprise a ceramic, a polymer, or a composite material. For example, the first means for insulating may comprise alumina (I) (Al ₂ O), aluminum (II) (AlO) (e.g., aluminum monoxide), aluminum (III) (Al ₂ O ₃ ) (e.g., alumina, aluminum oxide), zirconia (e.g., zirconia toughened alumina), and/or silicon carbide.

In some examples, the shield 1500 includes a second means for insulation. For example, the second means for insulating may be implemented by the outer casing layer 1504 of FIGS. 15 and 17A-C. In some examples, the second means for insulating may comprise a ceramic, a polymer, or a composite material. For example, by The first means for insulating may comprise alumina (I) (Al ₂ O), aluminum (II) (AlO) (e.g., aluminum monoxide), aluminum (III) (Al ₂ O ₃ ) (e.g., alumina, aluminum oxide), zirconia (e.g., zirconia toughened alumina), and/or silicon carbide.

In some examples, shield 1500 includes means for supporting a first means for insulation and a second means for insulation. The means for supporting may fill an area defined between the first means for insulating and the second means for insulating. For example, the means for supporting may be implemented by the core-shell layer 1506. In some examples, the means for supporting comprises nickel, cobalt, and/or one or more other metals.

In some examples, the shroud 1500 includes means for stiffening. For example, the means for reinforcing may be implemented by ribs 1604 in the inner shell layer 1600 of FIGS. 16 and 17A-17C and/or a core shell layer 1506 positioned around the ribs 1604.

Example layered magnetic coupling shields or barrier cans are disclosed herein. An example layered magnetic coupling shield or barrier can may include an inner shell layer, an outer shell layer, and a metal core shell layer between the inner shell layer and the outer shell layer. An inner or outer shell layer may be used as the mandrel, with a metal core shell layer formed on the mandrel. Electroforming the metal core shell enables the metal core shell to be reduced in thickness (e.g., as little as 2 mils) compared to other manufacturing techniques. Further, the metal core encasement may cause less eddy current losses between magnetic couplings positioned within and around the layered shield or barrier can while providing structural support that can withstand higher pressures (e.g., pressures greater than 6,400PSI). In addition, the inner and outer shells may insulate the metal core shell from the fluid to prevent the metal core shell from oxidation and/or from certain extreme temperatures. Further, the inner and/or outer shells may be formed via thermal and/or cold spray to further reduce the thickness of the barrier can, thereby enabling the barrier can or shroud to induce less eddy current losses and/or enabling the size of the magnetic coupling to be reduced.

High-voltage magnetic coupling shield and production method thereof

Fig. 19 illustrates another example shield 1900 (e.g., a barrier tank), another example shield 1900 may be used with the heat transfer bus pump 400 (e.g., the barrier tank 452 of fig. 4), the pump system 500 of fig. 5 (e.g., the barrier tank 536 of fig. 5), the pump system 600 of fig. 6 (e.g., the barrier tank 636 of fig. 6), the pump system 700 of fig. 7 (e.g., the barrier tank 728 of fig. 7), and/or any other pump system disclosed herein that uses a barrier tank or shield to contain a fluid flow. In the example shown in fig. 19, the shroud 1900 includes an outer shell 1902 (e.g., an outer layer) and an inner shell 1904 (e.g., a liner) secured to the outer shell 1902.

In fig. 19, the thickness of the housing layer 1902 is between 25 mils and 150 mils. The housing layer 1902 comprises a composite material to provide structural strength and withstand the pressures encountered by the shroud 1900. The composite material may include carbon fibers, graphite fibers, and/or epoxy. The epoxy may bond the fibers in a certain location and/or orientation to increase the structural strength of the outer shell layer 1902. Further, the housing layer 1902 may provide structural strength of the metallic material with reduced weight. In addition, the use of a composite material in the housing layer 1902 as opposed to metal improves (e.g., reduces) eddy current losses encountered between the first magnetic coupling 450 and the second magnetic coupling 460. Advantageously, the reduced eddy current losses resulting from the use of the housing layer 1902 increases the maximum speed at which the magnetic couplings 450, 460 can operate while maintaining rotational interlock, and improves the efficiency of torque transfer between the first magnetic couplings 450. Further, the reduced eddy current losses enable the size of the first magnetic coupling 450, the second magnetic coupling 460, and/or the motor 410 of fig. 4 to be reduced. Additionally, the reduced eddy current loss prevents the need for a cooling jacket around the coupling housing 424 because the thermal energy generated by the rotation of the first and second magnetic couplings 450, 460 is reduced.

In fig. 19, the carbon fibers and/or graphite fibers are positioned in more than one orientation, as discussed in further detail below. For example, the fibers may be positioned in a first orientation, a second orientation, a third orientation, and a fourth orientation, the second orientation being different from the first orientation, the third orientation being different from the first orientation and the second orientation, the fourth orientation being different from the first orientation, the second orientation, and the third orientation. In some examples, the first orientation is in an axial direction a defined by the shroud 1900 and the second orientation is in a circumferential direction C defined by the shroud 1900. Thus, the first orientation is substantially orthogonal to the second orientation. The third orientation may be approximately 45 ° from the first orientation and the second orientation in the first direction. The fourth orientation may be approximately 45 ° from the first orientation and the second orientation in a second direction that is substantially orthogonal to the first direction. Thus, the third orientation is substantially orthogonal to the fourth orientation.

In the example shown in fig. 19, the composite material forming the housing layer 1902 is porous. Accordingly, the inner shell layer 1904 covers the inner surface of the outer shell layer 1902 to prevent fluid from escaping through the pores of the outer shell layer 1902 and, in turn, to enable the shroud 1900 to hermetically seal the front bearing housing 428 and prevent the fluid from being contaminated. The thickness of the inner shell layer 1904 may be as small as 2 mils. The inner shell layer 1904 includes a thermoplastic composite and/or a metallic material. In some examples, inner shell layer 1904 includes Advantageously, when the inner shell layer 1904 is only 5 mils thick, it is +.>The associated temperature and structural strength properties enable the shroud 1900 to have 6,400PSIA. Additionally, give +.>Excluding metallic material, ">Such that the inner shell layer 1904 can minimize or otherwise reduce eddy current losses caused by the shroud 1900. In some examples, inner shell layer 1904 includes a layer other than +.>Other thermoplastic composites, such as Polyetheretherketone (PEEK). In some examples, the inner shell 1904 includes a nickel-based alloy to maximize or otherwise increase the pressure that the shroud 1900 can withstand. For example, the inner shell layer 1904 may include a nickel-chromium-based alloy, such as a nickel-chromium-molybdenum alloy (e.g., INCO 718).

In fig. 19, the housing layer 1902 is formed via a composite lay-up process. For example, the composite lay-up process may include laying up composite layers layer by layer such that a first composite layer of the housing layer 1902 is formed on a second composite layer, a second composite layer is formed on a third composite layer, and so on. Thus, the composite layer comprises carbon fibers and/or graphite fibers in an epoxy resin. Carbon and/or graphite fibers are layered with the epoxy in certain locations and/or orientations, and in turn thermosetting may be used to enable the epoxy to bond the fibers in place. Specifically, the fibers are layered on top of each other in a first orientation, a second orientation, a third orientation, and a fourth orientation. For example, a first set of fibers may be set in a first orientation, a second set of fibers may be set on top of the first set of fibers in a second orientation (e.g., around a circumference defined by the first set of fibers), a third set of fibers may be set on top of the second set of fibers in a third orientation, and a fourth set of fibers may be set on top of the third set of fibers in a fourth orientation. Further, the layers of the first, second, third and fourth sets of fibers may be stacked such that the fibers define a thickness. For example, the thickness may be based on the pressure at which an associated pump (e.g., heat transfer bus pump 400 of fig. 4) is to operate. Additionally, groups of fibers may be stacked in another arrangement or in multiple arrangements. For example, the housing layer 1902 may include a third set of fibers stacked on the first set of fibers, a second set of fibers stacked on the third set of fibers, and a fourth set of fibers stacked on the second set of fibers. Further, the multiple groups of fibers of the first group may be stacked in a different arrangement than the multiple groups of fibers of the second group positioned around the first group. Additionally, the inner shell layer 1904 may include staple fibers for structural reinforcement.

Thus, the housing layer 1902 may be formed via a composite lay-up process such that the housing layer 1902 includes a first thickness. In some examples, the inner surface 1905 of the outer shell layer 1902 may be machined downward such that the outer shell layer 1902 has a second thickness that provides room for the inner shell layer 1904 while maintaining the shroud 1900 within a range of thicknesses. In some examples, the thickness of the housing layer 1902 may be as high as 0.125in.

In FIG. 19, when the inner shell layer 1904 is to include a nickel-based alloy, the inner shell layer 1904 is formed on the inner surface 1905 of the outer shell layer 1902 via electroforming. For example, when inner shell 1904 is to includeOr another thermoplastic composite material (e.g., PEEK), inner shell layer 1904 may be formed by +.>Or machined rods of PEEK. Further, the outer shell 1902 may be laminated on the outer surface 1907 of the inner shell 1904. In some examples, the flange portion 1906 of the shroud 1900 is formed entirely via the housing layer 1902.

Fig. 20A-D illustrate an example orientation of fibers of the housing layer 1902 of fig. 19. In fig. 20A-D, the composite layers may be laid down layer-by-layer in a direction 2001, the direction 2001 being perpendicular to the inner composite layers of the inner shell layer 1904 and/or the outer shell layer 1902 of fig. 19.

Fig. 20A illustrates example first fibers (e.g., a first set of fibers) of the housing layer 1902 positioned in a first orientation 2002, the first orientation 2002 extending along a circumferential direction C defined by the shroud 1900 of fig. 19. Thus, the fibers in the first fibers circumferentially surround the cavity defined by the shroud 1900 of fig. 19. Further, the fibers in the first fibers are spaced apart along an axial direction a defined by the shroud 1900 of fig. 19.

Fig. 20B illustrates example second fibers (e.g., a second set of fibers) of the housing layer 1902 positioned on a second orientation 2004, the second orientation 2004 extending along an axial direction a defined by the shroud 1900 of fig. 19. Thus, the second fibers extend in the axial direction a and encircle the aft end of the cavity defined by the shroud 1900 of fig. 19. In other words, the second fiber surrounds the cavity in a U-shape. Thus, the second orientation 2004 is substantially orthogonal to the first orientation 2002. Further, the fibers in the second fibers are spaced apart along a circumferential direction C defined by the shroud 1900. Accordingly, the respective ends of the fibers in the second fiber are positioned directly opposite each other (e.g., 180 ° from each other) across the cavity of the shroud 1900.

Fig. 20C illustrates example third fibers (e.g., a third set of fibers) of the housing layer 1902 positioned on a third orientation 2006, the third orientation 2006 extending approximately 45 ° in the first direction between the first orientation 2002 and the second orientation 2004. Thus, the third fibers extend in both the axial direction a and the circumferential direction C defined by the shroud 1900 of fig. 19. In other words, the third fibers surround the cavity defined by the shroud 1900 of fig. 19 in a rectangular shape. Further, the fibers in the third fibers are spaced apart along an axial direction a defined by the shroud 1900 of fig. 19.

Fig. 20D shows example fourth fibers (e.g., fourth set of fibers) of the housing layer 1902 positioned in a fourth orientation 2008, the fourth orientation 2008 extending approximately 45 ° in a second direction between the first orientation and the second orientation. In particular, fourth orientation 2008 is substantially orthogonal to third orientation 2006. That is, the fourth orientation 2008 extends in both the axial direction a and the circumferential direction C defined by the shroud 1900 of fig. 19. Thus, the fourth fibers surround the cavity defined by the shroud 1900 of fig. 19 in a rectangular shape. Further, the fibers in the fourth fibers are spaced apart along an axial direction a defined by the shroud 1900 of fig. 19.

Fig. 21 shows an example overlay of carbon fibers and/or graphite fibers positioned in a portion 1908 of the housing layer 1902 as identified in fig. 19 in a first orientation 2002, a second orientation 2004, a third orientation 2006, and a fourth orientation 2008. In fig. 21, the housing layer 1902 includes a first fiber 2102 in a first orientation 2002, a second fiber 2104 in a second orientation 2004, a third fiber 2106 in a third orientation 2006, and a fourth fiber 2108 in a fourth orientation 2008. Specifically, the first fibers 2102 extend in the circumferential direction C around the cavity defined by the shroud 1900 of fig. 19. Further, the second fibers 2104 extend substantially orthogonal to the first fibers 2102 in an axial direction a defined by the shroud 1900 of fig. 19. The third fibers 2106 extend approximately 45 ° between the first fibers 2102 and the second fibers 2104. In addition, the fourth fibers 2108 extend substantially orthogonal to the third fibers 2106.

Fig. 22A is a flow chart illustrating a first example method 2200 of manufacturing a barrier can, such as shroud 1900 of fig. 19. In some examples, at least a portion of the example method 2200 represents example machine readable instructions that may be executed and/or instantiated by processor circuitry in communication with the manufacturing device to manufacture the shroud 1900. Additionally or alternatively, method 2200 of fig. 22A may use Application Specific Integrated Circuits (ASICs) and/or Field Programmable Gate Arrays (FPGAs) that are structured such that manufacturing operations corresponding to method 2200 are performed by the manufacturing apparatus.

The example method 2200 of fig. 22A begins at block 2202, where an outer shell layer 1902 (fig. 19-21) is formed at block 2202. For example, the housing layer 1902 may be formed via a composite lay-up process and/or a thermoset process. Specifically, in the epoxy, the first fibers 2102 (fig. 21) are positioned in a first orientation 2002 (fig. 20A and 21), the second fibers 2104 (fig. 21) are positioned in a second orientation 2004 (fig. 20B and 21), the second orientation 2004 is substantially orthogonal to the first orientation 2002, the third fibers 2106 (fig. 21) are positioned in a third orientation 2006 (fig. 20C and 21), and the fourth fibers 2108 (fig. 21) are positioned in a fourth orientation 2008 (fig. 20D and 21). Further, the first fibers 2102, the second fibers 2104, the third fibers 2106, and the fourth fibers 2108 may alternate in respective layers. In turn, these layers define the thickness of the housing layer 1902. In some examples, the respective layers of fibers 2102, 2104, 2106, 2108 may be thermoset such that the epoxy holds the fibers 2102, 2104, 2106, 2108 in the respective orientations 2002, 2004, 2006, 2008.

At block 2204, an inner surface of the outer shell layer 1902 is machined. For example, the inner surface of the housing layer 1902 may be ground or machined such that the thickness of the housing layer 1902 is reduced. Thus, machining the outer shell layer 1902 to a reduced thickness may provide space for the inner shell layer 1904 (FIG. 19) such that the second magnetic coupling 460 does not contact the inner shell layer 1904.

At block 2206, an inner shell layer 1904 is formed over an inner surface of outer shell layer 1902. For example, when the inner shell layer 1904 comprises a metallic material, the inner shell layer 1904 may be formed on the inner surface of the outer shell layer 1902 via electroforming. Further, when inner shell layer 1904 comprises a thermoplastic composite material (such asAnd/or PEEK), an inner shell layer 1904 may be formed on the inner surface of outer shell layer 1902 via additive manufacturing. Thus, forming the inner shell layer 1904 via additive manufacturing or electroforming enables the inner shell layer 1904 to be formed with a reduced thickness, which provides space for the second magnetic coupling 460 in the cavity defined by the shroud 1900 (fig. 19) while sealing the inner surface of the outer shell layer 1902.

Fig. 22B is a flow chart illustrating a second example method 2250 of manufacturing a barrier can, such as the shroud 1900 of fig. 19. In some examples, at least a portion of the example method 2250 represents example machine readable instructions that may be executed and/or instantiated by processor circuitry in communication with the manufacturing device to manufacture the shroud 1900. Additionally or alternatively, the method 2250 of fig. 22B may use an Application Specific Integrated Circuit (ASIC) and/or a Field Programmable Gate Array (FPGA) that is structured such that manufacturing operations corresponding to the method 2250 are performed by a manufacturing device.

The example method 2250 of fig. 22B begins at block 2252, where, at block 2252, the inner shell layer 1904 (fig. 19) is formed. For example, inner shell layer 1904 may be formed fromOr another thermoplastic composite material (e.g., PEEK) is machined. In some examples, when the inner shell layer 1904 comprises a metallic material, the inner shell layer 1904 is electroformed on the mandrel and then separated from the mandrel.

At block 2254, the outer shell 1902 (fig. 19-21) is laminated over the inner shell 1904. For example, the housing layer 1902 may be formed via a composite lay-up process. In particular, a first layer of the outer shell layer 1902, including at least one set of fibers 2102, 2104, 2106, 2108, may be laminated to an outer surface 1907 (fig. 19) of the inner shell layer 1904. Further, a second layer of the housing layer 1902 including at least one set of fibers 2102, 2104, 2106, 2108 may be laminated to the first layer. In some examples, the first layer is thermoset prior to applying the second layer. Thus, the housing layer 1902 forms multiple layers on the inner housing layer 1904.

Example layered magnetic coupling shields or barrier cans are disclosed herein. An example layered magnetic coupling shield or barrier can may include an outer shell layer to provide structural support that can withstand higher pressures (e.g., pressures of at least 6,400PSI). Further, an example layered magnetic coupling shield or barrier can may include an inner shell layer formed on an inner surface of the outer shell layer to prevent leakage of fluid through pores of the outer shell layer. Advantageously, when in use Or another thermoplastic (e.g., PEEK) to form the inner shell layer 1904, no eddy current losses occur. Further, when the inner shell layer comprises a metallic material, the ratio of eddy current losses (in kilowatts (kW)) to the inner shell layer thickness (in mils (e.g., thousandths of an inch)) may be less than 0.06. As a result, the example layered magnetic coupling shields and/or barrier cans enable the magnetic coupling to maintain magnetic engagement and, in turn, be rotationally interlocked at a higher angular velocity. Thus, the example layered magnetic coupling shroud or barrier tank may enable impellers in an associated pump to be driven at higher angular velocities to increase the pressure and/or flow rate of a fluid (e.g., a heat exchange fluid, such as a supercritical fluid (e.g., scco 2, etc.)) to enable the fluid to transfer more thermal energy to and/or from a working fluid in an associated aircraft and/or engine.

Oil lubrication supercritical fluid pump with oil separator

As described above, in order to transfer thermal energy between a fluid (e.g., a heat exchange fluid, such as a supercritical fluid (e.g., scco 2, etc.) and a working fluid without adversely affecting components of aircraft 10 and/or gas turbine engine 100, the fluid should not be contaminated with foreign substances in the area where the fluid is to transfer thermal energy. That is, the fluid should not be contaminated with oil, water (e.g., steam), and/or ambient air while passing through the heat source heat exchanger 206 and the heat sink heat exchanger 208 of fig. 2.

As discussed above, the rolling element bearings 440, 448 supporting the shaft 438 of the motor 410 require oil lubrication that is not fluid. Further, the barrier canister 452 of fig. 4 separates the fluid from the motor housing 412 to prevent contamination of the fluid by oil lubrication of the rolling element bearings 440, 448 in the pump 400. However, the use of separate housings, such as motor housing 412, rear bearing housing 418, intermediate bearing housing 420, and coupling housing 424, increases the size, weight, and/or cost of pump 400. Furthermore, driving the rotation of the impeller 406 via the magnetic couplings 450, 460 may cause eddy current losses that limit the rotational speed at which the magnetic couplings 450, 460 may drive the impeller 406.

Disclosed herein are example oil separators that enable a fluid to be mixed with oil and then separated from the oil. Thus, the example oil separator enables fluid to flow through a housing that includes oil lubricated bearings to mount a motor shaft (e.g., shaft 438 of fig. 4). As a result, the oil separator enables the size, weight, and/or cost of the pump 204 of fig. 3 to be reduced. Additionally, the oil separator may allow for a reduction in the number of components in the pump 204. For example, by enabling the fluid to mix with the oil, the oil separator eliminates the need for a barrier tank (e.g., barrier tank 452 of fig. 4), a magnetic coupling (e.g., magnetic couplings 450, 460 of fig. 4), and/or a different housing that keeps the oil lubricated portion separate from the fluid. Further, the example oil separator enables the pump 204 to drive the impeller without a magnetic coupling, which increases the rotational speed at which the impeller can operate, thereby increasing the maximum pressure and/or flow rate at which the pump 204 can drive fluid through the heat transfer bus 202.

Specifically, an example pump system that pressurizes a fluid (e.g., a heat exchange fluid, such as a supercritical fluid (e.g., scco 2, etc.) within a closed loop transfer bus (e.g., heat transfer bus 202) includes a pump housing and a conduit fluidly coupled to the pump housing. During operation of the example pump system, a first portion of the conduit includes a mixture of oil and supercritical fluid (e.g., supercritical carbon dioxide), and a second portion of the conduit includes the supercritical fluid itself. Thus, a separator (e.g., an oil separator) is positioned in a third portion of the conduit between the first portion of the conduit and the second portion of the conduit such that the separator can separate oil in the mixture from the supercritical fluid. Thus, the separator enables the supercritical fluid to flow within the pump housing and mix with oil from the lubricated bearings, e.g., the lubricated bearings mount and/or support the shaft of the motor driving the impeller.

In some examples, the pump system includes more than one separator. Example separators may be static (e.g., stationary) or dynamic (e.g., movable, rotatable, etc.). In some examples, the dynamic or rotatable separator includes a rotatable shaft and vanes or ridges extending radially outward from the rotatable shaft. In some examples, the rotatable separator comprises a rotatable cone. In some such examples, the cone shell includes an open axial end and a slot facing the surrounding conduit. In some examples, the cone is positioned around the rotatable shaft. In some such examples, the rotatable shaft may rotate in a first direction and the cone shell may be stationary or rotate in a second direction opposite the first direction.

Thus, when the vanes and/or cone shell rotate, the oil in the mixture is subjected to more centrifugal force than the particles of supercritical fluid because of the higher density of the oil compared to supercritical fluid. Further, the greater centrifugal forces encountered by the oil cause the oil particles to adhere to the inner surface of the shell, adhere to surrounding tubing, be driven through apertures in the shell, and/or be driven through an oil recirculation flow path that directs the oil back to the pump 204 or a reservoir supply (e.g., a tank). Furthermore, the reduced centrifugal force encountered by the supercritical fluid particles as the oil is driven radially outward enables the supercritical fluid to flow in the intermediate portion of the conduit and/or through the cone shell.

In some examples, the static or stationary separator includes an oil absorbing material. For example, the oil absorbing material may include a polymer (e.g., polyurethane, polypropylene, polyethylene, cross-linked polymer, etc.) and/or a powder (e.g., talc, aluminum starch, rice starch, silica, etc.). In some examples, the stationary separator includes a baffle that eliminates or otherwise reduces any linear flow path of the supercritical fluid through the third portion of the conduit. Specifically, the baffle comprises an oil absorbing material. As a result, the baffles cause the oil particles mixed with the supercritical fluid to contact the stationary separator and, in turn, be absorbed by the oil absorbing material. Thus, the stationary separator acts as a filter that collects oil and allows supercritical fluid to pass therethrough. Further, the pressure of the higher density oil and fluid flowing through the stationary separator may cause the oil to fall through the apertures (e.g., aperture channels) in the baffle, causing oil particles to enter the oil recirculation flow path.

The baffles may be formed in various shapes with different thicknesses and/or porosities to enable the pressure drop encountered by the supercritical fluid in the third portion of the conduit to be controlled. In some examples, the structure of the baffle may be formed from sheet metal and/or via additive manufacturing. The example stationary separator may be disposed horizontally or vertically in the third portion of the conduit.

In some examples, the static oil separator includes a first conduit (e.g., a main conduit) fluidly coupled to a second conduit (e.g., an oil collection conduit), the second conduit being positioned below the first conduit. In some examples, the second conduit is fluidly coupled to the first conduit at a plurality of different locations. Because of the higher density of the oil compared to supercritical fluids, the oil can fall from the first conduit and into the second conduit. Further, the first conduit may include a baffle that causes the mixture of supercritical fluid and oil to flow at a downward velocity as the mixture encounters a point where the first conduit is fluidly coupled to the second conduit. Further, the downward velocity and higher density of the oil may cause oil particles to fall out of the first conduit and into the second conduit. Further, the baffles formed by the first conduit may cause the mixture to flow upward toward the connecting ends between the conduits such that the first conduit changes the fluid in the mixture from a downward velocity to an upward velocity. Therefore, since the density of the supercritical fluid is low, it is easier for the supercritical fluid to change from the downward velocity to the upward velocity. As a result, the composition of the oil in the first conduit decreases at each connection point fluidly coupling the first conduit to the second conduit. Further, the oil may be completely separated from the supercritical fluid in the first conduit at or before the final junction between the conduits. Further, the second conduit may form or be fluidly coupled to an oil recirculation flow path.

Fig. 23 illustrates an example pump system 2300, the example pump system 2300 including a first example separator 2302 (e.g., a first stationary separator, a cartridge filter, etc.) to separate a supercritical fluid (e.g., supercritical carbon dioxide) from oil in a conduit 2304 (e.g., a discharge conduit), the supercritical fluid being driven through the conduit 2304 (e.g., within the heat transfer bus 202 prior to entering the heat transfer bus 202 of fig. 2 or prior to the heat exchangers 206, 208). In the example shown in fig. 23, the pump system 2300 includes a pump housing 2306. Specifically, pump housing 2306 is formed from motor housing 2308, back plate 2310, and compressor collector 2312 that are coupled together via bolts 2314. The pump housing 2306 further includes a cover 2316, the cover 2316 being fixedly coupled to a rear end of the motor housing 2308 via bolts 2318. The pump housing 2306 is fluidly coupled to the piping 2304 such that fluid can flow through the motor housing 2308, the back plate 2310, the compressor collector 2312 and the piping 2304.

In the example shown in fig. 23, the pump system 2300 includes a motor 2320, the motor 2320 being positioned in the motor housing 2308. In fig. 23, a rotor 2322 of a motor 2320 is fixed to a shaft 2324 (e.g., a motor shaft). Accordingly, motor 2320 drives rotation of shaft 2324. The pump system 2300 further includes a cooling jacket 2315, the cooling jacket 2315 surrounding the motor housing 2308 to prevent overheating of the motor 2320.

The shaft 2324 is supported by a first rolling element bearing 2325 (e.g., a rear rolling element bearing) and a second rolling element bearing 2327 (e.g., a front rolling element bearing), both the first rolling element bearing 2325 and the second rolling element bearing 2327 being lubricated with oil. In the example shown in fig. 23, oil that lubricates the first rolling element bearing 2325 and the second rolling element bearing 2327 is mixed with an additive. In particular, the additives increase the viscosity of the oil, thereby improving the cohesive and adhesive properties associated with the oil.

In the example shown in fig. 23, the rear end of the shaft 2324 extends beyond the rear end of the motor housing 2308. Thus, the cover 2316 includes a notch or cavity 2317, with the rear end of the shaft 2324 disposed in the notch or cavity 2317. The first rolling element bearing 2325 is positioned in a bearing cup 2326 provided in the motor housing 2308. Specifically, the bearing cup 2326 may be press-fit into the bearing cup 2326 and supported by the shoulder 2328 of the motor housing 2308. To assist in interlocking the first rolling element bearing 2325 to the shaft 2324, the first rolling element bearing 2325 includes a collar 2330 that extends from a rear side of the first rolling element bearing 2325 and is clamped around the shaft 2324. Additionally, a preload spring 2332 is positioned between the bearing cup 2326 and the front side of the first rolling element bearing 2325 to help maintain the position of the first rolling element bearing 2325 within the bearing cup 2326. Further, a sub-cap 2334 is coupled to the rear end of the bearing cup 2326 via a screw 2336. Thus, sub-cap 2334 includes an aperture through which shaft 2324 extends.

The second rolling element bearing 2327 is press-fitted in the back plate 2310. To maintain the position of the second rolling element bearing 2327 on the shaft 2324, the second rolling element bearing 2327 includes a collar 2337, the collar 2337 extending from a front side of the second rolling element bearing 2327 and clamped around the shaft 2324. The rear end of the second rolling element bearing 2327 is positioned against a shoulder 2338 of the back plate 2310 and a ridge 2339 in the shaft 2324.

In the example shown in fig. 23, the impeller 2340 is coupled to a front end of the shaft 2324 such that the impeller 2340 rotates with the shaft 2324 to pump fluid through the tube 2304. Specifically, to couple the impeller 2340 to the shaft 2324, a portion of the rear end of the impeller 2340 is wedged and secured to the internal groove of the shaft 2324. Alternatively, the rear end of the impeller 2340 may include a slot, and the shaft 2324 may extend into the slot of the impeller 2340 to rotatably couple the shaft 2324 and the impeller 2340. Additionally, the rear end of the impeller 2340 is coupled to the support plate 2342. In some examples, support plate 2342 is screwed onto shaft 2324 to further increase the coupling strength between impeller 2340 and shaft 2324.

Accordingly, both the impeller 2340 and the rotor 2322 of the motor 2320 are mounted on the shaft 2324. As a result, the size of the pump system 2300 and/or the number of components for driving the impeller 2340 is minimized or otherwise reduced. Further, the output of the pump system 2300 (e.g., the output pressure and/or flow rate of fluid exiting the pump system 2300) may be increased because the rotation of the impeller 2340 is independent of the magnetic coupling encountering increased eddy current losses at higher rotational speeds.

During operation, supercritical fluid (e.g., scco 2, etc.) flows through an inlet 2344 of the pump system 2300 and is driven by the impeller 2340. Specifically, impeller 2340 drives supercritical fluid toward tube 2304. When the supercritical fluid encounters a higher pressure, a portion of the supercritical fluid escapes into the motor housing 2308. For example, supercritical fluid can flow between the support plate 2342 and the back plate 2310. Further, the supercritical fluid may pass through the second rolling element bearing 2327, where the supercritical fluid mixes with oil that lubricates the second rolling element bearing 2327 before being dispersed throughout the motor housing 2308. Thus, the supercritical fluid may be further mixed with oil that lubricates the first rolling element bearing 2325. As a result, a mixture of supercritical fluid and oil is formed in the motor housing 2308. In addition, as the supercritical fluid continues to flow into the motor housing 2308, the pressure increases and the mixture is pushed back into the compressor collector 2312. In some examples, the mixture flows through slots 2345 in shaft 2324, with slots 2345 in shaft 2324 aligned with slots 2346 in impeller 2340 to enable the mixture to flow into compressor collector 2312 and be driven into pipe 2304 by impeller 2340. Additionally or alternatively, the mixture may flow into the compressor collector 2312 between the support plate 2342 and the back plate 2310.

In fig. 23, in response to being pumped into a tube 2304, a mixture of supercritical fluid and oil encounters a first separator 2302. In fig. 23, the separator 2302 is a cartridge filter including an inner cartridge 2347 and an outer cartridge 2348. Specifically, the first separator 2302 includes interconnected concentric cylinders 2347, 2348 formed at least in part of an oil absorbing material. In some examples, the oil absorbing material includes at least one powder, such as talc, aluminum starch, rice starch, silica, and the like. In some examples, the oil absorbing material includes at least one polymer, such as polyurethane, polypropylene, polyethylene, crosslinked polymer, and the like. The inner barrel 2347 and outer barrel 2348 may include baffles to increase the rate at which oil in the mixture contacts the surface of the separator 2302. The separator 2302 is manufactured, for example, via shaping and/or additive manufacturing of a metal plate.

In some examples, separator 2302 includes a first conduit and a second conduit. For example, the first conduit may be positioned above and fluidly coupled with the second fluid conduit. Further, the first fluid conduit may include a baffle, and the second fluid conduit may include an oil absorbing material, as discussed in further detail below.

In some examples, the first separator 2302 includes separate cylindrical filters positioned in series or parallel in the tube 2304. For example, the first separator 2302 may include a first cylindrical filter positioned above a second cylindrical filter.

As the mixture of supercritical fluid and oil flows through the separator 2302, the separator 2302 absorbs the oil. As a result, the conduit 2304 carries only supercritical fluid into the heat transfer bus 202. In fig. 1, the rear end of separator 2302 is positioned against plate 2350. Specifically, plate 2350 includes grooves in which separator 2302 is positioned. Further, plate 2350 is coupled to the exterior of motor housing 2308 via one or more bolts 2352. Additionally or alternatively, plate 2350 may be coupled to tube 2304. When operation of the pump system 2300 is stopped or paused, the plate 2350 may be removed to allow for cleaning and/or replacement of the separator 2302.

Further, the oil separated from the supercritical fluid by the first separator 2302 can fall into a secondary conduit 2354 (e.g., oil collection conduit), the secondary conduit 2354 being positioned below the first separator 2302. The secondary conduit 2354 is fluidly connected to an inlet 2356 in the motor housing 2308. Thus, the oil may return to the motor housing 2308, providing lubrication to the first and second rolling element bearings 2325, 2327.

As a result, the first separator 2302 enables the supercritical fluid to be mixed with the oil without affecting the thermal energy transfer capacity of the supercritical fluid. Further, the number of components in the pump system 2300, the size of the pump system 2300, and/or the cost of the pump system 2300 may be minimized or otherwise reduced. Further, the first separator 2302 enables the motor 2320 to directly drive the impeller 2340 via the shaft 2324, which may enable the impeller 2340 to operate at a higher rotational speed, thereby increasing the pressure and/or flow rate at which the supercritical fluid is driven through the heat transfer bus 202. Thus, the first separator 2302 may increase the rate at which supercritical fluid is to be transported through the heat transport bus, thereby increasing the rate at which thermal energy is transferred between the supercritical fluid and the working fluid.

Fig. 24 illustrates another example pump system 2400, the example pump system 2400 including a second example separator 2402 (e.g., a second stationary separator, a cone filter, etc.). In fig. 24, the second separator 2402 includes oil absorbing material formed in a conical geometry instead of the cylindrical geometry of the first separator 2302 of fig. 23. The second separator 2402 may be positioned horizontally or vertically in the tube 2304 depending on the position of the heat transfer bus 202 relative to the tube 2304. In fig. 2, to maintain the position of the second separator 2402, a flange 2404 of the second separator 2402 is press fit into the tube 2304. Alternatively, second separator 2402 may be coupled to tube 2304 via screws and/or any other means for coupling.

In fig. 24, in response to the supercritical fluid mixing with oil lubricating the first and second rolling element bearings 2325, 2327 in the motor housing 2308, the impeller 2340 drives the mixture through the second separator 2402, the second separator 2402 absorbing the oil in the mixture while enabling the supercritical fluid to enter the heat transfer bus 202. Thus, the second separator 2402 enables the conduit 2304 to provide only supercritical fluid to the heat transfer bus 202, although the supercritical fluid was previously contaminated with oil from the first and second rolling element bearings 2325, 2327.

Similar to the first example separator 2302 of fig. 23, the second separator 2402 includes baffles through which the mixture flows. Thus, the baffle prevents the mixture from having a straight flow path through the second separator 2402, thereby ensuring that the oil in the mixture contacts the oil absorbing material in the baffle. In some examples, a sump conduit is positioned below the second separator 2402 to enable oil to be returned to the sump supply and/or the motor housing 2308 via an inlet 2356 in the motor housing 2308. Specifically, the density of the oil is such that the oil falls through baffles in the second separator 2402 and into the oil collection pipe, as discussed in further detail below.

Fig. 25 illustrates another example pump system 2500, the example pump system 2500 including a second example separator 2402 and a third example separator 2502 (e.g., dynamic separator, rotating separator, cyclone, etc.) positioned in a pipe 2304. In fig. 25, third separator 2502 is positioned in line with second separator 2402 in tube 2304. Specifically, third separator 2502 is positioned upstream (e.g., forward) of second separator 2402 in conduit 2304, such that a mixture of supercritical fluid and oil is encountered prior to second separator 2402.

In fig. 25, a third separator 2502 includes a motor 2504 and a cyclone 2506. Further, the cyclone 2506 is mounted on rolling element bearings 2508 coupled to the tube 2304. In some examples, rolling element bearing 2508 includes a solid lubricant (e.g., silver coating, graphite, molybdenum disulfide, etc.) to avoid adding oil to the mixture. In some examples, the swirler 2506 is mounted via foil bearings or any other bearing that enables the swirler to rotate without the use of a lubricant.

Thus, motor 2504 drives the rotation of cyclone 2506. Further, the rotation of the cyclone 2506 causes the oil droplets in the mixture to encounter centrifugal force. In particular, because the density of the oil is higher compared to supercritical fluid, the rotation of the cyclone 2506 causes the oil droplets in the mixture to encounter increased centrifugal force compared to supercritical fluid. In addition, the cyclone 2506 includes holes or apertures facing the periphery of the tube 2304, as discussed in further detail below. As a result, the third separator 2502 causes oil droplets to move toward the inner surface of the cyclone 2506 and/or the periphery of the tube 2304 while the supercritical fluid remains within the middle portion of the tube 2304. Further, the third separator 2502 may cause oil droplets to adhere to the inner surface of the tube 2304. In some examples, the oil droplets contact and lubricate rolling element bearing 2508. In some examples, third separator 2502 is implemented in conduit 2304 without second separator 2402. In this example, third separator 2502 allows the oil itself to be removed from the mixture.

In fig. 25, oil droplets advancing through the third separator 2502 in the tube 2304 are absorbed by the second separator 2402. Advantageously, the shape of the second separator 2402 provides a greater surface area for the oil absorbing material toward the perimeter of the tube 2304. Thus, the higher centrifugal force encountered by the oil droplets drives the oil droplets into the outer portion 2510 of the second separator 2402, the outer portion 2510 of the second separator 2402 being larger than the tip portion 2512 of the second separator 2402. As a result, the tip portion 2512 remains relatively clear, which reduces the impact of the second separator 2402 on the flow properties of the supercritical fluid as it enters the heat transfer bus 202.

Fig. 26 illustrates another example pump system 2600, the example pump system 2600 including a second example separator 2402. Additionally or alternatively, the pump system 2600 can include a first separator 1902 and/or a third separator 2502. In fig. 26, the pump system 2600 includes a first shaft 2602 (e.g., a motor shaft), the first shaft 2602 being coupled to a rotor 2322 of the motor 2320. The first shaft 2602 is mounted in the motor housing via a first rolling element bearing 2325 and a second rolling element bearing 2604 (e.g., an intermediate rolling element bearing). In fig. 26, the second rolling element bearing 2604 is positioned in a bearing holder 2606, the bearing holder 2606 being fixed within the motor housing 2308.

Further, the pump system 2600 includes a carrier shaft 2608, the carrier shaft 2608 being coupled to a front end of a first shaft 2602 extending through a second rolling element bearing 2604. Specifically, the rear end of the carrier shaft 2608 is concentrically positioned about the front end of the first shaft 2602. The carrier shaft 2608 may be coupled to the first shaft 2602 via a clamp, press fit, or any other means for coupling. Further, the forward end of the carrier shaft 2608 extends through a gearbox 2609 (e.g., a planetary gearbox). The gearbox 2609 includes a carrier shaft 2608, a planetary gear 2610, a ring gear 2612, and a sun gear 2614, as discussed further in connection with fig. 27.

The carrier shaft 2608 extends radially outward from the first shaft 2602 and is rotatably coupled to the planet gears 2610 of the gearbox 2609. Accordingly, the carrier shaft 2608 drives rotation of the planet gears 2610, which in turn causes rotation of the sun gear 2614. Further, the ring gear 2612 enables the planet gears 2610 to transmit more torque to the sun gear 2614. The ring gear 2612 is fixedly positioned in the motor housing 2308. For example, the ring gear 2612 may be integral with the motor housing 2308 or coupled to the motor housing 2308 via a press fit, screws, or any other means for coupling.

A sun gear 2614 is defined in a rear end of a second shaft 2616 (e.g., an impeller shaft), the second shaft 2616 being coupled to an impeller 2340. In fig. 26, the second shaft 2616 is supported by a third rolling-element bearing 2618 (e.g., a front rolling-element bearing) that is positioned in the back plate 2310. For example, the third rolling element bearing 2618 may be clamped onto the second shaft 2616 and coupled to the back plate 2310 via a press fit.

Accordingly, the planetary gear 2610 drives the rotation of the impeller 2340. As a result, the carrier shaft 2608, the planet gears 2610, the ring gear 2612, and the sun gear 2614 provide gear reduction that enables the impeller 2340 to be driven at a rotational speed that is greater than the rotational speed of the first shaft 2602. Further, the gearbox 2609 enables the flow rate output and/or pressure output of the pump system 2600 to be increased, thereby enabling improved thermal energy transfer between the supercritical fluid and the working fluid. Further, the second separator 2402 and/or the first separator 2302 and/or the third separator 2502, when implemented in the pump system 2600, enable magnetic coupling to be avoided while still using rolling element bearings 2325, 2604, 2618, and in turn enable the gearbox 2609 to provide gear reduction that operates the impeller 2340 at a higher angular velocity.

Fig. 27 shows a cross section A-A of the gearbox 2609 of fig. 26. In fig. 27, the carrier shaft 2608 is coupled to the planetary gear 2610 via respective brackets 2702 and rings 2704, the respective brackets 2702 and rings 2704 being rotatably coupled to an inner periphery of the planetary gear 2610. Thus, the carrier 2702 and the ring 2704 cause the planet gears 2610 to rotate about the sun gear 2614. Further, the planetary gears 2610 can rotate relative to the respective rings 2704. Thus, as the carrier shaft 2608 rotates the planet gears 2610 about the sun gear 2614, the ring gear 2612 rotates the planet gears 2610 relative to the respective rings 2704. In fig. 27, the ring gear 2612 is fixedly coupled to the inner surface of the motor housing 2308 so as not to rotate within the motor housing 2308. For example, the ring gear 2612 may be fixed within the motor housing 2308 via a press fit, screws, or any other means for coupling.

In some examples, the bracket 2702 and the ring 2704 can be rotatably coupled to the carrier shaft 2608 and, in turn, fixedly coupled to the planet gears 2610. In this example, the carrier 2702 and the ring 2704 rotate with the planet gears 2610 as the carrier shaft 2608 moves the planet gears 2610 around the sun gear 2614.

During operation, rotor 2322 of motor 2320 of fig. 26 drives rotation of first shaft 2602. Further, the first shaft 2602 drives rotation of the carrier shaft 2608, which rotates the planetary gear 2610. Further, the planetary gear 2610 rotates the sun gear 2614. Further, the engagement between the planet gears 2610 and the ring gear 2612 enables the planet gears 2610 to transfer more torque to the sun gear 2614 without encountering slippage. Thus, the gearbox 2609 enables the impeller 2340 of fig. 26 to rotate at a greater speed due to the gear reduction provided by the gearbox 2609.

Fig. 28 illustrates another example pump system 2800, the example pump system 2800 including a second example separator 2402. Additionally or alternatively, the pump system 2600 can include the first separator 2302 and/or the third separator 2502. In fig. 28, a pump system 2800 includes a first bearing assembly 2802 and a second bearing assembly 2804 to support a shaft 2324 that drives rotation of an impeller 2340.

The first bearing assembly 2802 is positioned in the bearing cup 2326 and, in turn, supports a rear portion of the shaft 2324. The first bearing assembly 2802 includes a damper 2806 (e.g., squeeze film damper) and a first rolling element bearing 2808, the first rolling element bearing 2808 being positioned between the damper 2806 and the shaft 2324. Specifically, damper 2806 includes an outer race 2810 coupled to bearing cup 2326. For example, outer race 2810 may be coupled to bearing cup 2326 via a press fit, screws, and/or any other means for coupling. Further, damper 2806 includes an inner race 2812 and piston rings 2814, piston rings 2814 being positioned between outer race 2810 and inner race 2812. In particular, piston ring 2814 includes an oil film of squeeze to dampen movement of inner race 2812 relative to outer race 2810. Further, inner race 2812 defines an outer portion of a first rolling element bearing 2808 that is coupled to shaft 2324. Additionally, an inner portion of the first rolling-element bearing 2808 may be coupled to the shaft 2324 via a clip 2813, the clip 2813 extending from a rear side of the first rolling-element bearing 2808. Furthermore, the first rolling element bearing 2808 may be supported within the bearing cup 2326 via a preloaded coil spring 2815.

The second bearing assembly 2804 is positioned in a back plate 2817 that is coupled to the motor housing 2308. The second bearing assembly 2804 includes a spring finger 2816, a squirrel cage 2818, and a second rolling element bearing 2820. In fig. 28, the cylindrical rolling elements of the squirrel cage 2818 are in contact with the shaft 2324 and thus support the shaft 2324. Further, spring fingers 2816 are coupled to back plate 2817 and a non-rotating portion of squirrel cage 2818. Thus, spring finger 2816 provides damping of non-rotational movement of shaft 2324. The second rolling element bearing 2820 is positioned rearward of the cage 2818. Specifically, a non-rotating portion of the second rolling-element bearing 2820 (e.g., an outer portion of the second rolling-element bearing 2820) is coupled to a non-rotating portion of the squirrel cage 2818. For example, the squirrel cage 2818 can be coupled to the second rolling element bearing 2820 via a press fit, screws, and/or any other means for coupling.

As a result, the first and second bearing assemblies 2802 and 2804 provide damping support for the rear portion of the shaft 2324 and the front portion of the shaft 2324, respectively. Accordingly, the first and second bearing assemblies 2802, 2804 reduce vibration movement of the shaft 2324 that may otherwise be caused when the rotor 2322 drives the shaft 2324 at a higher speed.

Fig. 29 is a schematic representation of the support provided by the first bearing assembly 2802 and the second bearing assembly 2804 of fig. 28. In fig. 29, a first bearing assembly 2802 supports a portion of a shaft 2324 disposed rearward of a motor 2320 with a first stiffness. Further, the second bearing assembly 2804 supports a portion of the shaft 2324 disposed between the motor 2320 and the impeller 2340 with a second stiffness that is less than the first stiffness. Specifically, the first bearing assembly 2802 provides a support with a greater stiffness to stabilize the rear end of the shaft 2324. Further, the second bearing assembly 2804 provides support to the shaft 2324 with less centripetal force to minimize or otherwise reduce resistance caused by the rotational speed of the second bearing assembly 2804 with respect to the shaft 2324. Thus, the first bearing assembly 2802 may act as a stabilizer while the second bearing assembly 2804 acts as a guide for the shaft 2324. Accordingly, the first and second bearing assemblies 2802, 2804 provide support that can dampen non-rotational movement of the shaft 2324 while also reducing resistance to rotational speed of the shaft 2324.

Fig. 30A-C illustrate an example embodiment of a rotary separator (e.g., third separator 2502) that may be implemented in the pump system 2500 of fig. 25 and/or any other heat transfer pump system.

Fig. 30A illustrates a first example rotating separator 3002 (e.g., a first cyclone, third separator 2502 of fig. 25) positioned in a conduit 3003 (e.g., conduit 2304). In fig. 30A, the conduit 3003 is fluidly coupled to a secondary conduit 3004, the secondary conduit 3004 being connected to an oil supply, as discussed in further detail below. In FIG. 30A, the first rotating separator 3002 includes a shaft 3006 and buckets 3008 extending radially outward from the shaft 3006. During operation of the first rotational separator 3002, a motor (e.g., motor 2504) may drive the rotation of the shaft 3006 and the buckets 3008. As a result, the vanes 3008 cause the oil 3010 (e.g., oil droplets) to encounter increased centrifugal force as compared to the supercritical fluid 3012 (e.g., supercritical carbon dioxide) flowing through the tubes 3003. Thus, when the first rotating separator 3002 allows supercritical fluid 3012 to flow through the middle portion of the tube 2304, rotation of the vanes 3008 causes the oil 3010 to move toward the perimeter of the tube 3003. Thus, the first rotating separator 3002 separates the oil 3010 from the flow of supercritical fluid 3012. Further, the first rotating separator 3002 causes at least a portion of the oil 3010 to move into the secondary conduit 3004, where the oil 3010 may be collected and/or recirculated to lubricate bearings, such as the first and second rolling element bearings 2325, 2327, 2808, 2820 of fig. 23-26 and/or 28. In some examples, the rotational speed of the first rotational separator 3002 is based on a flow rate within the conduit 3003 and/or a pressure within the conduit 3003.

Fig. 30B illustrates a second example rotating separator 3020 (e.g., a second cyclone, a conical cyclone, the third separator 2502 of fig. 25, etc.) positioned in the conduit 3003. The second rotary separator 3020 is a rotatable cone having a bore 3022. Specifically, the axial end of the second rotary separator 3020 is open to enable the supercritical fluid 3012 to flow through the intermediate portion of the conduit 3003. As the second rotary separator 3020 rotates, the higher density of oil compared to the supercritical fluid 3012 causes the oil 3010 to encounter a greater centrifugal force than the supercritical fluid 3012. As a result, the second rotary separator 3020 removes the oil 3010 from the flow path of the supercritical fluid 3012. Specifically, as the supercritical fluid 3012 flows through the second rotary separator 3020, the increased centrifugal force may cause the oil 3010 to adhere to the second rotary separator 3020. Additionally or alternatively, when supercritical fluid 3012 flows through second rotating separator 3020, the rotational flow velocity created by apertures 3022 as a result of rotation of second rotating separator 3020 may cause oil 3010 to flow through apertures 3022 in second rotating separator 3020 and adhere to conduit 3003 and/or flow through secondary conduit 3004.

The size and/or shape of the holes 3022 may be based on the flow rate to be encountered in the conduit 3003, the pressure to be encountered in the conduit 3003, the rotational speed of the second rotational separator 3020, the location of the respective holes 3022 relative to the inner surface of the conduit 3003, and/or the location of the holes 3022 relative to the secondary conduit 3004. Additionally or alternatively, the rotational speed of the second rotational separator 3020 may be based on the flow rate encountered in the conduit 3003 and/or the pressure encountered within the conduit 3003. For example, the size of the bore 3022, the shape of the bore 3022, and/or the rotational speed of the second rotary separator 3020 may increase the centrifugal force and rotational flow speed encountered by the oil 3010 such that the oil 3010 is driven into the secondary conduit 3004. Similar to the first rotating separator 3002 of fig. 30A, the second rotating separator 3020 may be driven by a motor (e.g., motor 2504).

Fig. 30C illustrates a third example rotating separator 3040 (e.g., a third cyclone, third separator 2502 of fig. 25) positioned in a duct 3003. The third rotating separator 3040 includes a shaft 3042, helical blades 3044 extending from the shaft 3042, and a cone 3046 positioned about the shaft 3042. Similar to the second rotary separator 3020, the cone 3046 includes an aperture 3048. In fig. 30C, the shaft 3042 and, in turn, the helical blades 3044 are rotatable. In some examples, cone 3046 is stationary. In some examples, the cone 3046 rotates in a direction opposite to the direction of rotation of the shaft 3042. That is, the shaft 3042 is capable of rotating in a first direction (e.g., clockwise), and the cone 3046 may be stationary or rotating in a second direction opposite the first direction (e.g., counterclockwise).

In fig. 30C, rotation of the shaft 3042, the helical blades 3044, and/or the conical shell 3046, and the density of the oil 3010 relative to the supercritical fluid 3012 are such that the oil 3010 encounters a first centrifugal force that is greater than a second centrifugal force encountered by the supercritical fluid 3012. Further, the holes 3048 in the cone 3046 cause the oil 3010 to encounter swirl velocities. Thus, the swirl velocity may cause the oil 3010 to pass through the holes 3048 at a greater velocity and, in turn, adhere to the tube 3003 with a greater force. In some examples, the swirl velocity encountered by the oil 3010 increases the likelihood of the oil 3010 entering the secondary conduit 3004. For example, a greater velocity of the oil 3010 caused by the swirl velocity may enable the oil 3010 to move the secondary conduit 3004 at a faster rate. Specifically, the size, shape, and/or number of apertures 3048 may be such that oil 3010 is driven directly into secondary conduit 3004 in the path. In addition, the swirl velocity minimizes or otherwise reduces movement of the oil 3010 caused by the flow of the supercritical fluid 3012 in the conduit 3003.

Fig. 31A-C illustrate example embodiments of static separators (e.g., first separator 2302, second separator 2402) that may be implemented in the pump systems 2300, 2400, 2500 of fig. 23-25, and/or any other heat transfer pump system.

Fig. 31A illustrates at least a portion of a first example static separator 3102 (e.g., a first example filter, a first separator 2302, a second separator 2402). The first static separator 3102 includes a baffle 3104, the baffle 3104 defining at least one flow path through the first static separator 3102. The baffle 3104 may be formed via sheet metal and/or additive manufacturing. The baffle 3104 includes an oil absorbing material 3105 such as polyurethane, polypropylene, polyethylene, cross-linked polymer, talc, aluminum starch, rice starch, and/or silica.

In the example shown in fig. 31A, a baffle 3104 defines a first flow path 3106A and a second flow path 3106B through which a mixture of supercritical fluid 3012 and oil 3010 can flow. In particular, a first flow path 3106A is defined between a first baffle 3104A and a second baffle 3104B. Further, a second flow path 3106B is defined between the second baffle 3104B and the third baffle 3104C. In fig. 31A, the first flow path 3106A is adjacent to the second flow path 3106B in a circumferential direction defined by the first static separator 3102. Additionally or alternatively, the first flow path 3106A may be adjacent to the second flow path 3106B in a radial direction defined by the first static separator 3102. As the oil 3010 contacts the baffles 3104, the oil absorbing material 3105 of the baffles 3104 causes the oil 3010 to adhere to the baffles 3104 as the supercritical fluid 3012 continues to flow between the baffles 3104.

In some examples, the weight of the oil 3010 eventually causes the oil 3010 to fall off of the baffle 3104. For example, as the oil 3010 accumulates in the baffle 3104, the oil 3010 may fuse together, which increases the weight of the oil 3010 and, in turn, causes the oil 3010 to fall off the baffle 3104. Specifically, the oil absorbing material 3105 of the baffle 3104 may include additives that are mixed with the oil to make the oil 3010 more viscous. Additionally or alternatively, rolling element bearings using oil may include additives that make the oil 3010 more viscous. Thus, the baffle 3104 may allow improved cohesion and adhesion properties associated with the oil 3010 to increase the likelihood that the oil droplets 3010 will be bonded together in response to contacting the baffle 3104.

Accordingly, one or more conduits (e.g., secondary conduit 3004) fluidly connected to the oil supply and/or motor housing 2308 may be positioned below baffle 3104 to enable oil 3010 to be reused. Furthermore, the position of the conduit may be based on the geometry of the baffle 3104 such that the oil 3010 exiting the baffle 3104 falls directly into the conduit. For example, gravity may cause oil 3010 to accumulate in baffle 3104 at one or more lower height points, and in turn, oil 3010 may drip into the tubing from the lower height. Additionally or alternatively, one or more different portions of the baffle 3104 may include oil absorbing material 3105, and in turn, the position of the conduit may be based on the position of the portion of the baffle 3104 that includes the oil absorbing material 3105 and thus collects oil 3010.

In some examples, the oil absorbing material of the baffle 3104 does not include additives that make the oil 3010 more viscous when the oil 3010 is to be collected and maintained in the first static separator 3102 until the first static separator 3102 encounters maintenance or replacement. In this example, the baffle 3104 reduces the likelihood of an increase in weight of the oil droplets 3010, thereby minimizing or otherwise reducing the likelihood of the oil droplets 3010 falling off of the baffle 3104. Further, to prevent the oil 3010 from escaping the first static separator 3102, the first static separator 3102 may include an increased number of circumferential layers defined by baffles 3104. Thus, the outer peripheral layer defined by the baffle 3104 may catch oil 3010 that managed to fall from the corresponding inner peripheral layer of the baffle 3104. Additionally or alternatively, the collection container may be positioned at least partially around the outermost layer of the baffle 3104 (e.g., around a bottom portion of the outermost layer) such that the collection container may catch oil 3010 that passes through the baffle 3104 and falls off the baffle 3104. Thus, the first static separator 3102 may prevent the oil 3010 from escaping.

Fig. 31B illustrates another example embodiment of a first static separator 3102. In fig. 31B, the first static separator 3102 includes a baffle 3104, with the baffle 3104 oriented vertically rather than horizontally, as shown in fig. 31A. The baffle 3104 forms a flow path 3107, the flow path 3107 preventing the oil 3010 from flowing through the first static separator 3102 without contacting the oil absorbing material 3105. Thus, the oil absorbing material 3105 absorbs the oil 3010 as the mixture of supercritical fluid 3012 and oil 3010 flows between the baffles 3104. Further, the weight of the oil 3010 and the vertical orientation of the baffle 3104 enable the absorbed oil 3010 to collect at the bottom portion 3110 of the baffle 3104. Thus, the location where the oil 3010 will fall from the baffle 3104 is limited by the size of the bottom portion 3110 of the baffle 3104. Further, a collection conduit (e.g., secondary conduit 3004) may be positioned below bottom portion 3110 of baffle 3104 to collect oil 3010 falling from baffle 3104. Thus, the collected oil 3010 may be redirected to a reservoir for storage and/or to the motor housing 2308 for lubrication, as discussed below in connection with fig. 35.

Fig. 31C shows a second example static separator 3120 (e.g., second filter, first separator 2302, second separator 2402). The second static separator 3120 includes a baffle 3122, the baffle 3122 forming a primary flow path 3124. Further, the second static separator 3120 includes an oil collection conduit 3126, with the oil collection conduit 3126 forming a secondary flow path 3128 below the baffle 3122. The secondary flow path 3128 may be connected to an oil supply and/or may recirculate the oil 3010 back to the motor housing 2308 such that the oil 3010 may be returned to the rolling element bearings 2325, 2327, 2808, 2820 of fig. 23-26 and/or 28 for lubrication through oil conduits, as discussed below in connection with fig. 35.

In fig. 31C, connector conduit 3130 connects secondary flow path 3128 to primary flow path 3124. In some examples, the oil collection pipe 3126 is directly connected to one or more lowest elevation points of the baffle 3122. In such an example, the second static separator 3120 does not require a connector conduit 3130 to couple the secondary flow path 3128 to the primary flow path 3124.

In fig. 31C, a mixture of supercritical fluid 3012 and oil 3010 enters inlet 3132 of primary flow path 3124. The first portion 3134 of the baffle 3122 allows the mixture to flow downward. Further, the second portion 3136 of the baffle 3122 transitions the mixture from a downward flow to a horizontal flow. The second portion 3136 of the baffles 3122 includes a lowest point of the respective baffle 3122 from which the connector conduit 3130 extends. Further, the gravity and higher density of the oil 3010 as compared to the supercritical fluid 3012 causes the oil 3010 to continue to flow downward through the second portion 3136 of the baffle 3122 while the supercritical fluid 3012 transitions to a horizontal flow. As a result, the oil 3010 flows through the connector tubing 3130 and into the oil collection tubing 3126, which enables the oil 3010 to be collected and/or reused. In addition, the third portion 3138 of the baffle 3122 may cause the supercritical fluid 3012 separated from the oil 3010 to flow upward. Although the example shown in fig. 31C uses four baffles 3122, any number of baffles 3012 may be used to separate supercritical fluid 3012 from oil 3010 given the operating parameters of the associated pump systems 2300, 2400, 2500, 2600, 2800.

Fig. 32 is a schematic representation of a first example layout 3200 that may be used with the pump systems 2300, 2400, 2500, 2600, 2800 of fig. 23-26 and/or 28. In fig. 32, supercritical fluid flowing through pump inlet 3202 is driven by impeller 3204 (e.g., a low head impeller). A first portion of the supercritical fluid flows through an outlet 3206 of a compressor housing 3207 and into a conduit 3209. In turn, the injector 3211 helps pull the supercritical fluid through conduit 3209 toward a downstream heat transfer bus (e.g., heat transfer bus 202 of fig. 3).

In addition, a second portion of the supercritical fluid flows through impeller 3204, around shaft 3213 and into motor housing 3208. Thus, the second portion of the supercritical fluid flows through, mixes with the oil used to lubricate the rolling element bearings used to support the shaft 3213. In addition, a second portion of the supercritical fluid flows through the gas-to-gas seal 3210 before the gas-to-oil seal 3212 stops the flow. Further, the mixture of supercritical fluid and oil collected by the supercritical fluid exits through an outlet 3214 of the motor housing 3208 and merges with the first portion of the supercritical fluid in a conduit 3209. Then, an oil separator 3216 (e.g., the first separator 2302 of fig. 23, the second separator 2402 of fig. 24-26 and 28, the third separator of fig. 25, the first, second and third rotating separators 3002, 3020, 3040 of fig. 30A-C, and/or the first and second static separators 3102, 3120 of fig. 31A-C) positioned in conduit 3209 separates the oil in the mixture from the supercritical fluid and enables the supercritical fluid to continue through conduit 3209 toward the heat transfer bus 202 while retaining the oil. In some examples, another conduit may be positioned below the oil separator 3216 to transport oil collected by the oil separator 3216 back to the oil supply and/or the motor housing 3208, where it may be used to lubricate rolling element bearings, as discussed below in connection with fig. 35.

Fig. 33 is a schematic representation of a second example layout 3300 that may be used with the pump systems 2300, 2400, 2500, 2600, 2800 of fig. 23-26 and/or 28. In a second example arrangement 3300, an oil separator 3216 is positioned in a return conduit 3302, the return conduit 3302 being fluidly connected to the motor housing 3208 and the compressor housing 3207 at a pump inlet 3202. Thus, the mixture of the second portion of the supercritical fluid and the oil flows through the return conduit 3302, and the oil separator 3216 separates the oil from the supercritical fluid at the return conduit 3302. Thus, the supercritical fluid may flow back into the compressor housing 3207 and, in turn, be driven by the impeller 3204. Further, a valve 3304 is positioned in the return conduit 3302 to prevent supercritical fluid entering through the inlet 3202 from flowing through the return conduit 3302.

Fig. 34 is a schematic representation of a third example layout 3400 of the pump systems 2300, 2400, 2500, 2600, 2800 of fig. 23-26 and/or 28. In a third example arrangement 3400, the return conduit 3302 includes a fuel tank 3402 upstream of an oil separator 3216. Thus, as the oil in the mixture flows through the oil tank 3402, the oil in the mixture may be attracted to the oil stored in the oil tank 3402. In particular, the oil in the mixture may be mixed with additives as described above (e.g., within the rolling element bearings 2325, 2327, 2808, 2820 of fig. 23-26 and/or 28 that may be used to mount the shaft 3213) that increase the adhesive and cohesive properties of the oil. As a result, the increased adhesion and cohesion of the oil in the mixture may enable the oil in the mixture to be pulled into the stored oil. Further, the stored oil may be positioned below the return conduit 3302 such that gravity helps to move the oil in the mixture into the oil tank 3402 while a second portion of the supercritical fluid continues to flow through the return conduit 3302.

Fig. 35 is a schematic representation of a fourth example layout 3500 of the pump systems 2300, 2400, 2500, 2600, 2800 of fig. 23-26 and 28. In the fourth example arrangement 3500, oil separated from the supercritical fluid by an oil separator 3216 enters an oil conduit 3502 (e.g., secondary flow path 3128 of fig. 31C). Further, the oil passes through the oil filter 3504 and enters the oil supply 3506. Further, the oil pump 3508 may pump fluid from the oil supply 3506 into the pump 3510, where it may lubricate bearings (e.g., rolling element bearings 2325, 2327, 2808, 2820 of fig. 23-26 and/or 28) in the pump 3510. Further, an oil purge line 3512 may carry a portion of the mixture from the pump 3510 to the oil filter 3504. For example, the oil purge conduit 3512 may be fluidly coupled to the oil collection conduit 3126 (fig. 31C) to receive oil flowing through the secondary flow path 3128 (fig. 31C). Additionally or alternatively, the oil purge conduit 3512 may be positioned to receive oil 3010 (fig. 31A-C) falling from baffles 3104, 3104A, 3104B, 3104C (fig. 31A-B) of the first example static separator 3102. As a result, oil can enter the oil supply 3506. Additionally, a release conduit 3514 connected to the oil supply 3506 allows any supercritical fluid entering the oil supply 3506 to be released into the atmosphere. In particular, the release conduit 3514 includes a release valve 3516, the release valve 3516 allowing fluid to be released in response to encountering a pressure greater than a pressure threshold.

In some examples, the pump system 2300, 2400, 2500, 2600, 2800 includes a device for compressing a fluid. For example, the means for compressing fluid may be implemented by impeller 406 of fig. 4, impeller 2340 of fig. 23-26 and/or 28, impeller 3204 of fig. 32-33, and/or any other impeller described herein.

In some examples, the pump system 2300, 2400, 2500, 2600, 2800 includes means for housing means for compressing. For example, the means for receiving may be implemented by the compressor collector 408 of fig. 4, the pump housing 2306 of fig. 23-26 and/or 28, the motor housing 2308 of fig. 23-4 and/or 28, the compressor housing 3207 of fig. 32-33 and/or the motor housing 3208 of fig. 32-33.

In some examples, the pump system 2300, 2400, 2500, 2600, 2800 includes a device for transferring a fluid. For example, the means for transferring fluid may be implemented by the heat transfer bus 202 of fig. 2, the fluid conduit 402 of fig. 4, the tube 2304 of fig. 23-26 and 28, the tube 3003 of fig. 30A-C, the tube 3209 of fig. 32, the tube 3302 of fig. 33-34, and/or any other pump output tube disclosed herein.

In some examples, the pump system 2300, 2400, 2500, 2600, 2800 includes a device for separating a supercritical fluid and oil. For example, the means for separating may be implemented by the first separator 2302 of fig. 23, the second separator 2402 of fig. 24-26 and 28, the third separator 2506 of fig. 25, the first, second and/or third rotating separators 3002, 3020, 3040 of fig. 30A-C, and/or the first and/or second static separators 3102, 3120 of fig. 31A-C.

In some examples, the pump system 2300, 2400, 2500, 2600, 2800 includes means for rotating the means for compressing. For example, the means for rotating may be implemented by the motor 2320 of fig. 23-26 and/or 28 and/or the shaft 2324 of fig. 23-26 and/or 28.

In some examples, the pump system 2300, 2400, 2500, 2600, 2800 includes means for increasing the angular velocity of the means for compressing relative to the means for rotating. For example, the means for increasing the angular velocity of the means for compressing may be implemented by the gearbox 2609 of fig. 26-27.

In some examples, the pump system 2300, 2400, 2500, 2600, 2800 includes a first means for radially supporting the means for rotating. The first means for radially supporting may comprise a first stiffness. For example, the first means for radially supporting may be implemented by the first bearing assembly 2802 of fig. 28 and/or 29.

In some examples, the pump system 2300, 2400, 2500, 2600, 2800 includes a second means for radially supporting the means for rotating. The second means for radially supporting may comprise a second stiffness different (e.g. less) than the first stiffness. For example, the second means for supporting may be implemented by the second bearing assembly 2804 of fig. 28 and/or 29.

Example oil lubrication pump architectures having one or more oil separators are disclosed herein. The example pump systems disclosed herein include an oil separator to enable a fluid (e.g., a heat exchange fluid, such as a supercritical fluid (e.g., scco 2, etc.)) to be mixed with and subsequently separated from oil. The oil separator enables the fluid to mix with the oil while reducing the safety risks associated with the transfer of thermal energy encountered by the fluid. Thus, the oil separator enables the impeller to be driven directly by the motor without a shroud separating the fluid from the motor. Furthermore, the oil separator enables the number and/or complexity of components in the pump system to be reduced.

Axial flux motor driven pump system for pressurizing fluid in a closed loop system

As described above with reference to fig. 4, operation of some example fluid pump systems and centrifugal fluid pump systems have a motor (e.g., motor 410) axially connected to an impeller (e.g., impeller 406) via an impeller shaft (e.g., impeller shaft 466). The example motor 410 shown in fig. 4 includes a stator to generate torque on a rotor via magnetic force. An example stator includes windings of copper wire, known as electromagnetic coils, that surround ferromagnetic cores, poles, and/or bars oriented perpendicular to the axis of rotation of the rotor. The electromagnetic coils are tightly wound around the poles such that they run parallel to the axis of rotation of the rotor. When a current flows through the electromagnetic coil, a magnetic field is generated that flows around the electromagnetic coil perpendicular to the direction of current flow according to faraday's law of induction. Thus, if the electromagnetic coil is wound parallel to the rotational axis of the motor, the magnetic field generated by the electromagnetic coil flows perpendicular to the rotational axis of the motor. Because the stator of the example motor 410 produces a magnetic field that runs perpendicular or radial to the rotational axis of the motor 410, the example motor 410 that drives the rotor shaft 438 may be referred to as a radial flux motor.

In contrast to radial flux motors (e.g., motor 410), axial flux motors include electromagnetic coils and/or windings oriented perpendicular to the rotational axis of the motor and/or rotor. The orientation of the electromagnetic coil windings is such that the electromagnetic coil produces a magnetic field that flows parallel to the axis of rotation of the motor and/or rotor. Since the magnetic flux direction is parallel to the axis of rotation, the stator and rotor in an axial flux motor are designed as discs, plates, etc., which increase the distance of the permanent magnets in the rotor from the axis of rotation and also reduce the axial length of the axial flux motor. The stator and rotor of a radial flux motor use electromagnetic coils and permanent magnets that are axially longer than those in an axial flux motor because the radial flux motor relies on stronger magnetic forces to produce the same torque as the axial flux motor. Since the axial flux motor is able to apply magnetic force to the rotor at a greater distance from the axis of rotation than the radial flux motor, and since torque is the product of force and distance, the axial flux motor can produce the same torque on the rotor as the radial flux motor because the electromagnetic coil and permanent magnet are further away from the axis of rotation. This means that an axial flux motor may be axially shorter but radially larger than a radial flux motor while still generating the same overall torque.

In examples disclosed herein, an axial flux motor is used to drive a pump system that pressurizes fluid in a closed loop system. In some examples, the fluid is a supercritical fluid. In some examples, the supercritical fluid is supercritical carbon dioxide (scco 2). In some examples, the closed loop system is a thermal management system (e.g., thermal management system 200 of fig. 3) that uses scco 2 to transfer thermal energy between heat exchangers (e.g., heat source heat exchanger 206 and/or heat sink heat exchanger 208 of fig. 3). In examples disclosed herein, because the CG of the example axial-flux motor-driven pump system is closer to the mounting flange than the radial-flux motor-driven pump system, there is less torque or torque acting on the pump system and the mounting flange due to gravity, which reduces vibration and damage over time of the axial-flux motor-driven pump system relative to the radial-flux motor-driven pump system.

For the drawings disclosed herein, like numbers refer to like elements throughout. Fig. 36 illustrates a cross-sectional view of an axial flux motor driven pump system 3600 ("pump system 3600") for pressurizing a fluid (e.g., supercritical fluid (scco 2)) in a closed-loop system (e.g., thermal management system 200 of fig. 3). In some examples, pump system 3600 is used to pump scco 2 through a thermal management system on an aircraft (e.g., aircraft 10 of fig. 1) and/or a gas turbine engine (e.g., gas turbine engine 100 of fig. 2). As shown in fig. 36, pump system 3600 includes impeller 3602, impeller shaft 3604, radial impeller bearing 3606, pump housing 3608, housing bolt 3609, magnetic coupling 3610, inner hub 3612, outer hub 3614, barrier can 3616, barrier can bolt 3617, coupling shaft 3618, rotor shaft 3620, spline interface 3622, stator 3624, rotor 3626, radial motor bearing 3628, motor housing 3630, and mounting flange 3632. Some of the architectures included in the example pump system 3600 may be used in other pump systems described above, such as the pump system 900 of fig. 9, the pump systems 2300-2600, 2800 of fig. 23-26, 28.

The example pump system 3600 shown in fig. 36 includes an impeller 3602 to pressurize an example fluid (e.g., scco 2) in an example closed-loop system (e.g., the thermal management system 200 of fig. 3). The example impeller 3602 is a component of the pump system 3600 that is connected to the impeller shaft 3604 and rotates at the same rotational speed as the impeller shaft 3604. In some examples, the impeller 3602 is the same as or similar to impellers used in centrifugal pumps and includes vanes and/or blades to deflect an incoming fluid flow radially outward into an outlet flow line. The example impeller 3602 converts mechanical power of an electric motor (e.g., the stator 3624 and the rotor 3626) into hydrodynamic force of a flowing fluid.

The example pump system 3600 shown in fig. 36 includes an impeller shaft 3604 to transfer torque from a motor (e.g., stator 3624, rotor 3626, and rotor shaft 3620) to the impeller 3602. In some examples, the impeller shaft 3604 is a hollow shaft to conserve mass and includes a central rod along the rotational axis of the impeller shaft 3604 to maintain axial alignment of the impeller shaft 3604. In some examples, the impeller shaft 3604 is fabricated via additive and/or subtractive manufacturing from a metallic material (e.g., titanium, aluminum alloy, etc.) and/or a composite material (e.g., carbon fiber,Etc.). The example impeller shaft 3604 is constructed as multiple parts included in an assembly, however, in some examples, the impeller shaft 3604 is manufactured as a single part and/or a pre-assembled structure.

The example pump system 3600 shown in fig. 36 includes a radial impeller bearing 3606 to support radial loads (e.g., weight, forced oscillation, etc.) of the impeller shaft 3604. The example radial impeller bearing 3606 shown in fig. 36 is a rolling element bearing that includes an inner race, an outer race, and rolling elements (e.g., balls, cylinders, etc.). Since the radial impeller bearing 3606 shown in fig. 36 is a rolling element bearing, the example radial impeller bearing 3606 can support radial and thrust loads of the impeller shaft 3604. For example, the impeller shaft 3604 may be attached to the inner ring of the radial impeller bearing 3606 such that the impeller shaft 3604 cannot move too far in the axial direction (e.g., less than one millimeter (mm)). The example radial impeller bearing 3606 includes a dry lubricant (e.g., silver coating, graphite, molybdenum disulfide, etc.) to reduce friction between the inner ring, outer ring, and rolling elements without risk of contaminating the fluid pressurized by the pump system 3600. In some examples, the radial impeller bearing 3606 includes a liquid lubricant (e.g., an oil-based lubricant, a water-based lubricant, a silicon-based lubricant, etc.) to reduce friction between the inner ring, the outer ring, and the rolling elements, and the pump system 3600 includes an oil separator (e.g., the oil separator 3216 of fig. 32-35) to remove the liquid lubricant of the radial impeller bearing 3606 from the fluid (e.g., the scco 2).

In some examples, the radial impeller bearing 3606 is a foil bearing that supports the radial load of the impeller shaft 3604. For the example where the radial impeller bearing 3606 is a foil bearing, the radial impeller bearing 3606 includes a journal liner and a spring loaded foil. For the example in which the radial impeller bearing 3606 is a foil bearing, the spring loaded foil supports the radial load of the impeller shaft 3604 during start-up and stop of the pump system 3600. For the example in which the radial impeller bearing 3606 is a foil bearing, as the angular velocity of the impeller shaft 3604 increases, the working fluid (e.g., air, nitrogen, argon, etc.) is pulled into the journal liner due to the viscous effects of the working fluid and the increase in working fluid pressure within the example radial impeller bearing 3606. For the example in which the radial impeller bearing 3606 is a foil bearing, once the working fluid pressure within the journal liner increases to a certain threshold (e.g., 100 force pounds per square inch (psi)), the spring loaded foil is pushed outward and the working fluid pressure fully supports the radial load of the impeller shaft 3604. For the example where the radial impeller bearing 3606 is a foil bearing, the radial impeller bearing 3606 does not support the axial load of the impeller shaft 3604 and does not use a liquid lubricant. Thus, if the example radial impeller bearing 3606 is a foil bearing, the example impeller shaft 3604 includes one or more shafts and/or one or more discs that are attached to the impeller shaft 3604, oriented perpendicular to the axis of rotation, and protrude radially outward from the impeller shaft 3604, similar to the thrust shafts 532, 632, 742 of fig. 5, 6, and/or 7. In some examples, if the radial impeller bearing 3606 is a foil bearing, the example pump system 3600 includes a thrust bearing (e.g., thrust bearings 534, 634, 744 of fig. 5, 6, and/or 7) to support axial loads of the impeller shaft via interfacing with the example thrust shaft.

The example pump system 3600 shown in fig. 36 includes a pump housing 3608 to support a radial impeller bearing 3606. The example pump housing 3608 prevents the radial impeller bearing 3606 from moving too far (e.g., less than 0.1 mm) in the radial or axial direction. In the example shown in fig. 36, the pump housing 3608 includes three separate portions that are assembled together via fasteners (e.g., bolts, screws, adhesive, etc.). In some examples, portions of the pump housing 3608 are separately manufactured via additive manufacturing and/or subtractive manufacturing prior to assembly. In some examples, the pump housing 3608 is a single part that is manufactured via additive manufacturing and/or subtractive manufacturing. The example pump housing 3608 is secured to the example motor housing 3630 via housing bolts 3609. Although two housing bolts 3609 are shown in fig. 36, two or more housing bolts 3609 may be included in the pump system 3600.

The example pump system 3600 shown in fig. 36 includes a magnetic coupling 3610 to connect the impeller shaft 3604 to the coupling shaft 3618. The example magnetic coupling 3610 of fig. 36 is the same as and/or similar to the example magnetic couplings 526, 626, 720 shown in fig. 5, 6, and/or 7 and transfers torque from the coupling shaft 3618 to the impeller shaft 3604 via magnetic force. In some examples, inner hub 3612 of magnetic coupling 3610 includes a first set of permanent magnets and outer hub 3614 of magnetic coupling 3610 includes a second set of permanent magnets. The example first set of permanent magnets and the example second set of permanent magnets alternate polarity about the axis of rotation of the impeller shaft 3604 and/or the coupling shaft 3618, and the attractive magnetic force between the first set of magnets and the second set of magnets causes the outer hub 3614 to drive rotation of the inner hub 3612.

The example pump system 3600 shown in fig. 36 includes a barrier tank 3616 to help prevent fluid from contacting the rotor 3626, stator 3624, and/or other portions and/or components that affect operability of the motor. The example barrier tank 3616 shown in fig. 36 includes metallic and/or non-metallic materials and may be the same as and/or similar to the example barrier tanks 536, 636, 728 of fig. 5-7, 1500 of fig. 15, and/or 1900 of fig. 19. The example barrier tank 3616 is secured to the pump housing 3608 via barrier tank bolts 3617. In some examples, the barrier can 3616 is connected to the pump housing 3608 via a barrier can bolt 3617 and/or other fastener (such as a screw, pin, rod, pin, adhesive, magnetic force, interference fit, etc.).

The example pump system 3600 shown in fig. 36 includes a coupling shaft 3618 to receive an outer hub 3614 of a magnetic coupling 3610 and transfer torque from a rotor shaft 3620 to an impeller shaft 3604 via the magnetic coupling 3610. In some examples, the coupling shaft 3618 includes an outer hub 3614 and/or a second set of permanent magnets. The example coupling shaft 3618 of fig. 36 interacts with the rotor shaft 3620 via a splined interface 3622. In some examples, coupling shaft 3618 and rotor shaft 3620 include splines (e.g., teeth, ridges, V-shaped cuts, etc.) that physically interlock to form spline interface 3622. Spline interface 3622 is a physical connection where rotor shaft 3620 splines apply a force to coupling shaft 3618 splines and, in turn, transfer torque from rotor shaft 3620 to coupling shaft 3618 at spline interface 3622. Example spline interface 3622 causes coupling shaft 3618 to rotate at the same rate as rotor shaft 3620.

The example pump system 3600 shown in fig. 36 includes a stator 3624, a rotor 3626, and radial motor bearings 3628 to provide mechanical power to the pump system 3600. The stator 3624, rotor 3626, and radial motor bearing 3628 of the example pump system 3600 are included in an axial flux motor of the system operating as described previously above. In some examples, stator 3624 includes an electromagnetic coil surrounding a core of ferrous material (e.g., soft iron, nickel, cobalt, etc.) such that the electromagnetic coil continues perpendicular to the axis of rotation and generates a magnetic flux parallel to the axis of rotation. The example stator 3624 supports and/or houses the example radial motor bearing 3628 such that the radial motor bearing 3628 does not move too far (e.g., less than 0.005 inches) from an intended position of the radial motor bearing 3628 in the pump system 3600 due to radial and/or axial forces generated by the rotor 3626 and/or the rotor shaft 3620. The example rotor 3626 includes a first rotor disk positioned on a front side of the stator 3624 and a second rotor disk positioned on a rear side of the stator 3624. The example first rotor disk and the example second rotor disk include permanent magnets, and magnetic flux generated by the example stator 3624 attracts and/or repels the permanent magnets. The example stator 3624 generates heat due to electrical resistance in the electromagnetic coil. In some examples, cooling channels, liners, pipes, jackets, etc. with flowing liquid coolant (e.g., water, oil, deionized water, quench glycol, dielectric fluid, heat exchange fluid such as supercritical fluid (e.g., scco 2, etc.) are included in the stator 3624 and/or surround the stator 3624 to transfer heat to the liquid coolant. In some examples, cooling fins and/or vents are secured to the stator 3624 to transfer heat to ambient air.

The example rotor 3626 of the pump system 3600 is attached to the example rotor shaft 3620 via fasteners (e.g., bolts, pins, dowels, adhesive, magnetic force, interference fit, etc.). In some examples, rotor 3626 is also attached to an inner race and/or an outer race of radial motor bearing 3628. The example pump system 3600 shown in fig. 36 includes an example radial motor bearing 3628 to support radial loads (e.g., weight, forced oscillations, etc.) generated by the rotor shaft 3620. The example radial motor bearing 3628 of fig. 36 also supports radial loads of the rotor 3626 via mechanical connections (e.g., fasteners, adhesives, magnetic forces, interference fits, etc.) between the rotor 3626 and the rotor shaft 3620. The example radial motor bearing 3628 is a rolling element bearing that uses a liquid lubricant (e.g., oil-based lubricant, water-based lubricant, silicon-based lubricant, etc.) to reduce friction between the inner race, outer race, and/or rolling elements of the radial motor bearing 3628. The example rotor 3626 and/or the example rotor shaft 3620 generate radial and axial loads that are supported by radial motor bearings 3628. Additionally or alternatively, thrust bearings may be used with axial flux motors to support axial loads generated by rotor 3626 and/or rotor shaft 3620. Additionally or alternatively, the axial flux motor may include thrust bearings to support axial loads generated by rotor 3626 and/or rotor shaft 3620.

The example pump system 3600 shown in fig. 36 includes a motor housing 3630 to support a stator 3624 and/or a pump housing 3608 of the pump system 3600. In some examples, motor housing 3630 is an additive and/or subtractive manufacturing portion to house stator 3624, rotor 3626, radial motor bearing 3628, rotor shaft 3620, coupling shaft 3618, barrier can 3616, outer hub 3614, inner hub 3612, magnetic coupling 3610, a portion of mounting flange 3632, and/or a portion of pump housing 3608. In the example shown in fig. 36, motor housing 3630 includes different portions that are separately manufactured (e.g., by additive manufacturing and/or subtractive manufacturing) and assembled together (e.g., via bolts, adhesives, pins, and/or interference fits) to house stator 3624, rotor 3626, radial motor bearing 3628, rotor shaft 3620, coupling shaft 3618, barrier can 3616, outer hub 3614, inner hub 3612, magnetic coupling 3610, a portion of mounting flange 3632, and/or a portion of pump housing 3608 without interfering with stator 3624, rotor 3626, radial motor bearing 3628, motor housing 3630, and/or mounting flange 3632.

The example pump system 3600 shown in fig. 36 includes a mounting flange 3632 to mount the example pump system 3600 to a surface (e.g., a wall, an assembly bar, a beam, etc.). The example mounting flange 3632 includes holes through which fasteners (e.g., bolts, pins, clamps, etc.) can be fitted and attach the mounting flange 3632 to a mounting surface. The mounting flange 3632 of fig. 36 is made of a material (e.g., aluminum, steel, titanium, etc.) that is strong enough to withstand bending and/or shear stresses that may be imposed on the mounting flange 3632 by the pump system 3600 during operation and/or non-operation. The motor housing 3630 is connected to the mounting flange 3632 via one or more fasteners (e.g., bolts, adhesives, interference fits, etc.), and may be fastened to the mounting flange 3632 prior to the example mounting flange 3632 being mounted to a mounting surface. In some examples, the motor housing 3630 and the mounting flange 3632 are the same portion via additive manufacturing and/or subtractive manufacturing. In some examples, the mounting flange 3632 is not included in the pump system 3600 and the motor housing 3630 directly contacts the mounting surface. Additionally or alternatively, the example motor housing 3630 includes holes (e.g., threaded holes, clearance holes, etc.), in which one or more fasteners (e.g., bolts, pins, interference fits, etc.) can fit to attach the pump system 3600 to a mounting surface.

Fig. 37 illustrates a cross-sectional view of an axial flux motor driven pump system 3700 ("pump system 3700") for pressurizing a fluid (e.g., supercritical fluid (scco 2)) in a closed loop system (e.g., thermal management system 200 of fig. 3). In some examples, pump system 3700 is used to pump the scco 2 through a thermal management system on an aircraft (e.g., aircraft 10 of fig. 1) and/or a gas turbine engine (e.g., gas turbine engine 100 of fig. 2). As shown in fig. 37, pump system 3700 includes impeller 3702, impeller shaft 3704, radial impeller bearing 3706, pump housing 3708, housing bolts 3709, piston seal 3710, rotor shaft 3720, spline interface 3722, stator 3724, rotor 3726, radial motor bearing 3728, motor housing 3730, and mounting flange 3732.

The example pump system 3700 shown in fig. 37 includes an impeller 3702 to pressurize an example fluid (e.g., scco 2) in an example closed loop system (e.g., the thermal management system 200 of fig. 3). The example impeller 3702 is a component of the pump system 3700 that is connected to the impeller shaft 3704 and rotates at the same rotational speed as the impeller shaft 3704. In some examples, impeller 3702 is the same as or similar to impellers used in centrifugal pumps and includes vanes and/or blades to deflect an incoming fluid flow radially outward into an outlet flow line. The example impeller 3702 converts mechanical power of the motor (e.g., the stator 3724 and the rotor 3726) into hydrodynamic force of a flowing fluid.

The example pump system 3700 shown in fig. 37 includes an impeller shaft 3704 to transfer torque from the motor (e.g., stator 3724, rotor 3726, and rotor shaft 3720) to the impeller 3702. In some examples, the impeller shaft 3704 is a hollow shaft to conserve mass and includes a central rod along the rotational axis of the impeller shaft 3704 to maintain axial alignment of the impeller shaft 3704. In some examples, the impeller shaft 3704 is fabricated via additive and/or subtractive manufacturing from a metallic material (e.g., titanium, aluminum alloy, etc.) and/or a composite material (e.g., carbon fiber,Etc.). The example impeller shaft 3704 is constructed as multiple parts included in an assembly, however, in some examples, the impeller shaft 3704 is manufactured as a single part and/or as a pre-assembled structure.

The example pump system 3700 shown in fig. 37 includes radial impeller bearings 3706 to support radial loads (e.g., weight, forced oscillation, etc.) of the impeller shaft 3704. The example radial impeller bearing 3706 shown in fig. 37 is a rolling element bearing that includes an inner race, an outer race, and rolling elements (e.g., balls, cylinders, etc.). Since the radial impeller bearing 3706 shown in fig. 37 is a rolling element bearing, the example radial impeller bearing 3706 can support the radial and thrust loads of the impeller shaft 3704. For example, the impeller shaft 3704 may be attached to the inner race of the radial impeller bearing 3706 such that the impeller shaft 3704 cannot move too far in the axial direction (e.g., less than 0.005 inches). The example radial impeller bearing 3706 includes a dry lubricant (e.g., silver coating, graphite, molybdenum disulfide, etc.) to reduce friction between the inner ring, outer ring, and rolling elements without risk of contaminating the fluid pressurized by the pump system 3700. In some examples, radial impeller bearing 3706 includes a liquid lubricant (e.g., oil-based lubricant, water-based lubricant, silicon-based lubricant, etc.) to reduce friction between the inner ring, outer ring, and rolling elements, and pump system 3700 includes an oil separator (e.g., oil separator 3216 of fig. 32-35) to remove the liquid lubricant of radial impeller bearing 3706 from the fluid (e.g., scco 2).

In some examples, the radial impeller bearing 3706 is a foil bearing that supports the radial load of the impeller shaft 3704. For examples in which radial impeller bearing 3706 is a foil bearing, radial impeller bearing 3706 includes a journal liner and a spring loaded foil. For the example where the radial impeller bearing 3706 is a foil bearing, the spring loaded foil supports the radial load of the impeller shaft 3704 during start-up and shut-down of the pump system 3700. For examples in which radial impeller bearing 3706 is a foil bearing, as the angular velocity of impeller shaft 3704 increases, the working fluid (e.g., air, nitrogen, argon, etc.) is pulled into the journal liner due to the viscous effects of the working fluid and the increase in working fluid pressure within example radial impeller bearing 3706. For the example where radial impeller bearing 3706 is a foil bearing, once the working fluid pressure within the journal liner increases to a certain threshold (e.g., 100 force pounds per square inch (psi)), the spring loaded foil is pushed outward and the working fluid pressure fully supports the radial load of impeller shaft 3704. For examples in which radial impeller bearing 3706 is a foil bearing, radial impeller bearing 3706 does not support the axial load of impeller shaft 3704 and no liquid lubricant is used. Thus, if the example radial impeller bearing 3706 is a foil bearing, the example impeller shaft 3704 includes one or more shafts and/or one or more discs attached to the impeller shaft 3704, oriented perpendicular to the axis of rotation, and protruding radially outward from the impeller shaft 3704, similar to the thrust shafts 532, 632, 742 of fig. 5, 6, and/or 7. In some examples, if the radial impeller bearing 3706 is a foil bearing, the example pump system 3700 includes a thrust bearing (e.g., thrust bearings 534, 634, 744 of fig. 5, 6, and/or 7) to support the axial load of the impeller shaft via interfacing with the example thrust shaft.

The example pump system 3700 shown in fig. 37 includes a pump housing 3708 to support a radial impeller bearing 3706. The example pump housing 3708 prevents the radial impeller bearing 3706 from moving too far in a radial or axial direction (e.g., less than 0.005 inches). In the example shown in fig. 37, the pump housing 3708 includes three separate portions that are assembled together via fasteners (e.g., bolts, screws, adhesive, etc.). In some examples, portions of the pump housing 3708 are separately manufactured via additive manufacturing and/or subtractive manufacturing prior to assembly. In some examples, the pump housing 3708 is a single part that is manufactured via additive manufacturing and/or subtractive manufacturing. The example pump housing 3708 is secured to the example motor housing 3730 via housing bolts 3709. Although two housing bolts 3709 are shown in fig. 37, two or more housing bolts 3709 may be included in the pump system 3700.

The example pump system 3700 shown in fig. 37 includes a piston seal 3710 to seal fluid away from an axial flux motor that includes a stator 3724, a rotor 3726, a radial motor bearing 3728, a motor housing 3730, and/or a mounting flange 3732. In some examples, the piston seal 3710 prevents fluid from entering the axial flux motor and/or motor housing 3730, and in some examples, the piston seal 3710 allows a very small amount of fluid (e.g., less than 0.01 fluid ounces) to enter the motor housing 3730 when the example pump system 3700 is operating. In some examples, the piston seal 3710 of the example pump system 3700 is a single-acting piston seal that contains pressure on one side of the seal and prevents fluid from flowing from the high pressure side to the low pressure side. The example piston seal 3710 is located in and/or attached to a slot cut into an inner surface of the rotor shaft 3720. In some examples, the fluid is scco 2 pressurized to at least 1000 pounds per square inch (psi) and a piston seal 3710 is included in the rotor shaft 3720 to withstand the pressure differential between the fluid and the air pressure within the axial flux motor and prevent and/or inhibit the fluid from contacting the stator 3724 and/or the rotor 3726.

The example pump system 3700 shown in fig. 37 includes a rotor shaft 3720 to transfer torque from an axial flux motor (e.g., rotor 3726) to an impeller shaft 3704 via a splined interface 3722. In some examples, impeller shaft 3704 and rotor shaft 3720 include splines (e.g., teeth, keys, ridges, V-shaped cutouts, etc.) and/or serrations that physically interlock to form spline interface 3722. Spline interface 3722 is a physical connection where rotor shaft 3720 splines apply a force to impeller shaft 3704 splines and, in turn, transfer torque from rotor shaft 3720 to impeller shaft 3704. The example spline interface 3722 causes impeller shaft 3704 to rotate at the same rate as rotor shaft 3720.

The example pump system 3700 shown in fig. 37 includes a stator 3724, a rotor 3726, and radial motor bearings 3728 to provide mechanical power to the pump system 3700. The stator 3724, rotor 3726, and radial motor bearings 3728 of the example pump system 3700 are included in an axial flux motor of the system operating in accordance with the previous description above. In some examples, the stator 3724 includes an electromagnetic coil surrounding a core of ferrous material (e.g., soft iron, nickel, cobalt, etc.) such that the electromagnetic coil is aligned perpendicular to the axis of rotation and generates a magnetic flux parallel to the axis of rotation. The example stator 3724 supports and/or houses the example radial motor bearing 3728 such that the radial motor bearing 3728 does not move too far (e.g., less than 0.005 inches) from the intended position of the radial motor bearing 3728 in the pump system 3700 due to the radial and/or axial forces generated by the rotor 3726 and/or the rotor shaft 3720. The example rotor 3726 includes a first rotor disk positioned on a front side of the stator 3724 and a second rotor disk positioned on a rear side of the stator 3724. The example first rotor disk and the example second rotor disk include permanent magnets, and the magnetic flux generated by the example stator 3724 attracts and/or repels the permanent magnets. The example stator 3724 generates heat due to electrical resistance in the electromagnetic coil. In some examples, cooling channels, liners, tubes, jackets, etc. with flowing liquid coolant (e.g., water, oil, deionized water, quench glycol, dielectric fluid, heat exchange fluid such as supercritical fluid (e.g., scco 2, etc.) are included in the stator 3724 and/or surround the stator 3724 to transfer heat to the liquid coolant. In some examples, cooling fins and/or vents are secured to the stator 3724 to transfer heat to ambient air.

The example rotor 3726 of the pump system 3700 is attached to the example rotor shaft 3720 via fasteners (e.g., bolts, pins, dowels, adhesives, magnetic forces, interference fits, etc.). In some examples, rotor 3726 is also attached to an inner race and/or an outer race of radial motor bearing 3728. The example pump system 3700 shown in fig. 37 includes example radial motor bearings 3728 to support radial loads (e.g., weight, forced oscillations, etc.) generated by the rotor shaft 3720. The example radial motor bearing 3728 of fig. 37 also supports radial loads of the rotor 3726 via mechanical connections (e.g., fasteners, adhesives, magnetic forces, interference fits, etc.) between the rotor 3726 and the rotor shaft 3720. The example radial motor bearing 3728 is a rolling element bearing that uses a liquid lubricant (e.g., oil-based lubricant, water-based lubricant, silicon-based lubricant, etc.) to reduce friction between the inner race, outer race, and/or rolling elements of the radial motor bearing 3728. The example rotor 3726 and/or the example rotor shaft 3720 generate radial and axial loads supported by the radial motor bearings 3728. Additionally or alternatively, the axial flux motor may include thrust bearings to support axial loads generated by rotor 3726 and/or rotor shaft 3720.

The example pump system 3700 shown in fig. 37 includes a motor housing 3730 to support the stator 3724 and/or pump housing 3708 of the pump system 3700. In some examples, the motor housing 3730 is an additive and/or subtractive manufacturing portion to house the stator 3724, the rotor 3726, the radial motor bearings 3728, the rotor shaft 3720, the piston seal 3710, a portion of the impeller shaft 3704, a portion of the mounting flange 3732, and/or a portion of the pump housing 3708. In the example shown in fig. 37, the motor housing 3730 includes different portions that are separately manufactured (e.g., by additive manufacturing and/or subtractive manufacturing) and assembled together (e.g., via bolts, adhesives, pins, and/or interference fits) to house the stator 3724, rotor 3726, radial motor bearing 3728, rotor shaft 3720, piston seal 3710, a portion of the impeller shaft 3704, a portion of the mounting flange 3732, and/or a portion of the pump housing 3708 without interfering with the stator 3724, rotor 3726, radial motor bearing 3728, motor housing 3730, and/or mounting flange 3732 in a manner that deviates from the optimal mode use of the example pump system 3700.

The example pump system 3700 shown in fig. 37 includes a mounting flange 3732 to mount the example pump system 3700 to a surface (e.g., wall, assembly bar, beam, etc.). The example mounting flange 3732 includes holes through which fasteners (e.g., bolts, pins, clamps, etc.) can be fitted and attach the mounting flange 3732 to a mounting surface. The mounting flange 3732 of fig. 37 is made of a material (e.g., aluminum, steel, titanium, etc.) that is strong enough to withstand bending and/or shear stresses that the pump system 3700 may exert on the mounting flange 3732 during operation and/or non-operation. The motor housing 3730 is connected to the mounting flange 3732 via one or more fasteners (e.g., bolts, adhesives, interference fits, etc.), and may be fastened to the mounting flange 3732 prior to the example mounting flange 3732 being mounted to a mounting surface. In some examples, the motor housing 3730 and the mounting flange 3732 are the same part via additive manufacturing and/or subtractive manufacturing. In some examples, the mounting flange 3732 is not included in the pump system 3700 and the motor housing 3730 directly contacts the mounting surface. Additionally or alternatively, the example motor housing 3730 includes holes in which one or more fasteners (e.g., bolts, pins, interference fits, etc.) may fit to attach the pump system 3700 to a mounting surface.

In some examples, the pump systems 3600, 3700 include a device for increasing kinetic energy of a fluid. For example, the means for adding may be implemented by the impellers 3602, 3702 and/or the impeller shafts 3604, 3704 of fig. 36 and/or 37. In some examples, the means for adding may include a motor, an impeller shaft, and/or an impeller.

In some examples, the pump systems 3600, 3700 include a means for providing torque. For example, the means for providing torque may be implemented by the stators 3624, 3724, the rotors 3626, 3726, and/or the coupling shaft 3618 of fig. 36 and/or 37. In some examples, the means for providing torque may include an electric motor, a stator, and/or a rotor.

In some examples, the pump systems 3600, 3700 include means for mounting the pump systems 3600, 3700. For example, the means for mounting may be implemented by the mounting flanges 3632, 3732 and/or the motor housings 3630, 3730 of fig. 36 and/or 37. In some examples, the means for mounting may include a flange, a housing, a plate, a fastener, and/or a support structure.

In some examples, the pump systems 3600, 3700 include means for sealing. For example, the means for sealing may be implemented by barrier can 3616 of fig. 36 and/or piston seal 3710 of fig. 37. In some examples, the means for sealing may include a barrier can, a shroud, a piston seal, a gas-tight seal, a gasket, and/or a diaphragm.

In some examples, the pump systems 3600, 3700 include means for a first connection. For example, the means for first connection may be implemented by magnetic coupling 3610 of fig. 36 and/or spline interface 3722 of fig. 37. In some examples, the means for first connecting may include a magnetic coupling, a mechanical coupling, a fastener (e.g., a bolt, an adhesive, an interference fit, a weld, etc.), and/or a spline interface.

In some examples, the pump systems 3600, 3700 include means for coupling. For example, the means for coupling may be implemented by magnetic coupling 3610 of fig. 36. In some examples, the means for coupling may include a magnetic coupling and/or a mechanical coupling (e.g., a fastener, an adhesive, an interference fit, etc.).

In some examples, the pump systems 3600, 3700 include means for a second connection. For example, the means for second connection may be implemented by the spline interface 3622 of fig. 36. In some examples, the means for second connecting may include a spline interface, a mechanical coupling, a magnetic coupling, and/or a mechanical fastener.

In some examples, the pump systems 3600, 3700 include means for supporting. For example, the means for supporting may be implemented by the pump housing 3608, 3708, the motor housing 3630, 3730, the radial impeller bearing 3606, 3706, and/or the radial motor bearing 3628, 3728 of fig. 36 and/or 37. In some examples, the means for supporting may include an additively manufactured housing, a subtractively manufactured housing, a rolling element bearing, and/or a foil bearing.

In some examples, the pump systems 3600, 3700 include a means for transferring heat. In some examples, the means for transferring may include a cooling jacket (e.g., cooling jacket 416 of fig. 4, cooling jackets 514, 614, 714 of fig. 5-7, etc.), cooling fins, cooling vents, and/or coolant flow lines.

In some examples, the pump systems 3600, 3700 include means for attaching. In some examples, the means for attaching may include mechanical fasteners (e.g., bolts, pins, screws, etc.) and/or magnetic couplings. In some examples, the means for attaching includes a configuration of the first housing (e.g., pump housing 3608, 3708 of fig. 36, 37) that is removable from the second housing (e.g., motor housing 3630, 3730 of fig. 36, 37).

In some examples, the pump systems 3600, 3700 include a means for separation. For example, the means for separating may be implemented by the oil separator 3216 of fig. 32-35. In some examples, the means for separating may include an oil separator, a filter, an extractor, and/or a purifier.

Example axial flux motor driven pump systems for pressurizing fluid in a closed loop system are disclosed herein. The example axial flux motor driven pump systems disclosed herein include an axial flux motor to provide torque to the pump while reducing the axial length of the pump system and moving the center of gravity closer to the mounting flange relative to the example radial flux motor driven pump system. The example axial flux motor drive pump systems disclosed herein thereby reduce moment forces acting on the pump system and/or mounting flange due to weight, forced oscillations, and/or vibrations, which in turn reduces wear and/or damage to the pump system. The example axial flux motor driven pump systems disclosed herein include pumps designed as line replaceable units that include pump housings that can be removed from the pump system without removing the entire pump system from a mounting surface. Thus, the example axial flux motor driven pump system is easier to maintain and/or repair than a radial flux motor driven pump system.

From the foregoing, it will be appreciated that example systems, methods, apparatus, and articles of manufacture have been disclosed that increase the pressure and/or flow rate at which a fluid pump may drive a fluid (e.g., a heat transfer fluid, such as a supercritical fluid (e.g., scco 2, etc.)). In particular, the example systems, methods, apparatus, and articles of manufacture disclosed herein enable impellers to be driven at greater angular velocities, which in turn enable fluids to reach higher pressures and/or flow rates. Further, examples disclosed herein enable pumps and/or pump systems to operate with fewer components and/or smaller components, which enables costs of the pumps or pump systems to be minimized or otherwise reduced.

The foregoing examples of pumps may be used with heat transfer systems. While each of the example pumps or pump systems disclosed above have certain features, it should be understood that the particular features of one example pump or pump system need not be specific to that example. Rather, any of the features described above and/or depicted in the drawings may be combined with any of the examples, in addition to or in place of any of the other features of the examples. Features of one example are not mutually exclusive with features of another example. Rather, the scope of the present disclosure includes any combination of any features.

Further aspects of the disclosure are provided by the subject matter of the following clauses:

example methods, apparatus, systems, and articles of manufacture to pressurize a fluid in a closed loop system are disclosed herein. Further examples and combinations thereof include the following:

example 1 includes a pump system for pressurizing fluid within a closed loop transmission bus, the pump system comprising: an electric motor comprising a rotor shaft and a stator; a pump including an impeller coupled to an impeller shaft; a drive wheel attached to the rotor shaft, wherein the drive wheel is radially connected to a driven wheel; and a coaxial magnetic coupling connecting the driven wheel to at least one of the impeller shaft or the drive wheel to the rotor shaft, wherein the coaxial magnetic coupling includes an outer hub, an inner hub, and a barrier canister hermetically sealing a portion of the pump system from the fluid.

Example 2 includes the pump system of any preceding clause, wherein the rotor shaft generates a first torque, the drive wheel transmits the first torque to the driven wheel, and the driven wheel generates a second torque.

Example 3 includes the pump system of any preceding clause, wherein the drive wheel has a first diameter, wherein the driven wheel has a second diameter, and wherein the first diameter is greater than the second diameter.

Example 4 includes the pump system of any preceding clause, wherein the drive wheel is a first gear, wherein the driven wheel is a second gear, and wherein the first gear is radially connected to the second gear via interlocking gear teeth.

Example 5 includes the pump system of any preceding clause, wherein the drive wheel is a first pulley, wherein the driven wheel is a second pulley, and wherein the first pulley is radially connected to the second pulley via a drive belt.

Example 6 includes the pump system of any preceding clause, wherein the stator is inside the rotor shaft, the rotor shaft configured as the drive wheel to transmit a first torque to the driven wheel, the driven wheel generating a second torque.

Example 7 includes the pump system of any preceding clause, wherein the pump system includes one or more additive manufacturing housings to frame at least one of the stator, the rotor shaft, the impeller shaft, or the coaxial magnetic coupling, wherein the one or more additive manufacturing housings support at least one or more radial bearings or one or more thrust bearings, the one or more additive manufacturing housings configuring the impeller shaft axis and the rotor shaft axis to be parallel and on separate planes.

Example 8 includes the pump system of any preceding clause, wherein the one or more radial bearings comprise at least one of foil bearings, rolling element bearings, hydrostatic bearings, or hydrodynamic bearings, the one or more radial bearings supporting one or more radial loads generated by at least one of the impeller shaft, the rotor shaft, the coaxial magnetic coupling, the drive wheel, or the driven wheel.

Example 9 includes the pump system of any preceding clause, wherein the one or more thrust bearings comprise at least one of foil bearings, rolling element bearings, hydrostatic bearings, or hydrodynamic bearings, the one or more thrust bearings supporting one or more thrust loads generated by at least one of the impeller shaft, the rotor shaft, the coaxial magnetic coupling, the drive wheel, or the driven wheel.

Example 10 includes the pump system of any preceding clause, wherein the one or more additive manufacturing housings comprise one or more cooling jackets that emit heat from the electric motor to at least one of ambient air or a fluid coolant.

Example 11 includes a pump system for pressurizing fluid within a closed loop transmission bus, the pump system comprising: an electric motor comprising a rotor shaft and a stator, wherein the stator causes a first angular velocity of the rotor shaft; a pump comprising an impeller coupled to an impeller shaft, wherein the impeller shaft rotates at a second angular velocity, and wherein the pump increases the kinetic energy of the fluid; a drive wheel fixed to the rotor shaft, wherein the drive wheel is radially connected to a driven wheel; and a coaxial magnetic coupling at least one of coupling the driven wheel to the impeller shaft or coupling the drive wheel to the rotor shaft, wherein the coaxial magnetic coupling includes an outer hub, an inner hub, and a barrier canister hermetically sealing a portion of the pump system from the fluid.

Example 12 includes the pump system of any preceding clause, wherein the drive wheel transmits the first angular velocity to the driven wheel, the driven wheel rotating at the second angular velocity.

Example 13 includes the pump system of any preceding clause, wherein the drive wheel has a first diameter, wherein the driven wheel has a second diameter, and wherein the first diameter is greater than the second diameter.

Example 14 includes the pump system of any preceding clause, wherein the drive wheel is a first gear, wherein the driven wheel is a second gear, and wherein the first gear is radially connected to the second gear via interlocking gear teeth.

Example 15 includes the pump system of any preceding clause, wherein the drive wheel is a first pulley, wherein the driven wheel is a second pulley, and wherein the first pulley is radially connected to the second pulley via a drive belt.

Example 16 includes the pump system of any preceding clause, wherein the stator is inside the rotor shaft, wherein the rotor shaft includes one or more gear teeth protruding outward on the rotor shaft, the drive wheel transmitting the first angular velocity to the driven wheel, the driven wheel rotating at the second angular velocity.

Example 17 includes the pump system of any preceding clause, wherein the pump system includes one or more additive manufacturing housings to frame at least one of the stator, the rotor shaft, the impeller shaft, or the coaxial magnetic coupling shaft, the one or more additive manufacturing housings supporting at least one or more radial bearings or one or more thrust bearings, the one or more additive manufacturing housings configuring the impeller shaft axis and the rotor shaft axis to be parallel and on separate planes.

Example 18 includes the pump system of any preceding clause, wherein the one or more radial bearings comprise at least one of foil bearings, rolling element bearings, hydrostatic bearings, or hydrodynamic bearings, the one or more radial bearings supporting one or more radial loads generated by at least one of the impeller shaft, the rotor shaft, the coaxial magnetic coupling, the drive wheel, or the driven wheel.

Example 19 includes the pump system of any preceding clause, wherein the one or more thrust bearings comprise at least one of foil bearings, rolling element bearings, hydrostatic bearings, or hydrodynamic bearings, the one or more thrust bearings supporting one or more thrust loads generated by at least one of the impeller shaft, the rotor shaft, the coaxial magnetic coupling, the drive wheel, or the driven wheel.

Example 20 includes the pump system of any preceding clause, wherein the one or more additive manufacturing housings comprise a cooling jacket to dissipate heat from the motor to at least one of ambient air or a fluid coolant.

Example 21 includes a pump system for pressurizing fluid within a closed loop transmission bus, the pump system comprising: means for rotating a drive wheel, wherein the means for rotating applies a first torque on the drive wheel, and wherein the means for rotating generates a first angular velocity of the drive wheel based on the first torque; means for accelerating the flow rate of the fluid, wherein the means for accelerating rotates the impeller shaft at a second angular velocity based on a second torque; means for converting the first torque of the drive wheel to the second torque of a driven wheel, wherein the means for converting generates the second angular velocity of the driven wheel based on the second torque; and means for at least one of connecting the driven wheel to the impeller shaft or connecting the drive wheel to a rotor shaft, wherein the means for connecting hermetically seals a portion of the pump system from the fluid.

Example 22 includes the pump system of any preceding clause, wherein the means for connecting transfers at least one of the first torque or the second torque from a first shaft to a second shaft.

Example 23 includes the pump system of any preceding clause, further comprising means for framing at least one of the stator, the rotor shaft, the impeller shaft, or the coaxial magnetic coupling, wherein the means for framing supports at least one or more radial bearings or one or more thrust bearings, and wherein the means for framing configures the impeller shaft axis and the rotor shaft axis to be parallel and on separate planes.

Example 24 includes the pump system of any preceding clause, wherein the means for framing transfers heat from the motor to at least one of ambient air or fluid coolant.

Example 25 includes a pump system for pressurizing fluid within a closed loop transmission bus, the pump system comprising: a pump, the pump comprising an impeller; an electric motor comprising a rotor shaft connected to the impeller; a first bearing supporting the rotor shaft in a first operating speed range, the first bearing coupled to the inner race; a second bearing supporting the rotor shaft at a second operating speed range, the rotor shaft coupled to an outer race; and one or more diagonal bracing elements configured to: engaging the inner race with the outer race over the first operating speed range; and separating the inner race from the outer race in the second operating speed range.

Example 26 includes the pump system of any preceding clause, wherein the first bearing is a rolling element bearing, including at least one of an angular contact ball bearing, a hybrid ceramic bearing, a tapered roller bearing, a deep groove single ball bearing, a double ball bearing, or a spherical bearing.

Example 27 includes the pump system of any preceding clause, wherein the first bearing is lubricated by an oil lubricant, further comprising a separator separating the oil lubricant from the fluid, a portion of the oil lubricant being mixed with the fluid.

Example 28 includes the pump system of any preceding clause, wherein the second bearing is a foil bearing.

Example 29 includes the pump system of any preceding clause, wherein in response to rotation of the rotor shaft in a first direction about a rotor axis in the first operating speed range, the one or more sprag elements rotate about a sprag rotation axis in a second direction, the second direction being different than the first direction.

Example 30 includes the pump system of any preceding clause, wherein in response to rotation of the rotor shaft in a first direction about a rotor axis in the second operating speed range, the one or more sprag elements rotate about a sprag rotation axis in a second direction, the second direction being the same as the first direction.

Example 31 includes the pump system of any preceding clause, wherein the one or more diagonal bracing elements are configured to rotate in the second direction in response to centrifugal forces acting on a portion of the one or more diagonal bracing elements, the centrifugal forces generated in response to the pump system operating in the second operating speed range.

Example 32 includes the pump system of any preceding clause, wherein the one or more diagonal strut elements comprise at least one of a solid lubricant comprising a silver coating or an oil mist lubricant.

Example 33 includes the pump system of any preceding clause, wherein the first operating speed range includes tangential speeds less than a foil bearing start-up speed.

Example 34 includes the pump system of any preceding clause, wherein the second operating speed range includes tangential speeds greater than foil bearing start-up speeds.

Example 35 includes the pump system of any preceding clause, further comprising a thrust bearing supporting a thrust load generated by the rotor shaft, the thrust bearing comprising at least one of a thrust foil bearing or a thrust magnetic bearing.

Example 36 includes an integrated bearing system to dynamically support a shaft in a pump system that pressurizes fluid within a closed loop transmission bus, the integrated bearing system comprising: a shaft connected to an impeller of the pump system; a first bearing supporting the shaft in a first operating speed range, the first bearing coupled to the inner race; a second bearing supporting the shaft over a second fluid speed range, the shaft coupled to the outer race; and one or more diagonal bracing elements configured to: engaging the inner race with the outer race over the first operating speed range; and separating the inner race from the outer race in the second operating speed range.

Example 37 includes the integrated bearing system of any preceding clause, wherein the first bearing is a rolling element bearing, including at least one of an angular contact ball bearing, a hybrid ceramic bearing, a tapered roller bearing, a deep groove single ball bearing, a double ball bearing, or a spherical bearing.

Example 38 includes the integrated bearing system of any preceding clause, wherein the first bearing is lubricated by an oil lubricant, further comprising a separator separating the oil lubricant from the fluid, a portion of the oil lubricant being mixed with the fluid.

Example 39 includes an integrated bearing system of any preceding clause, wherein the second bearing is a foil bearing.

Example 40 includes the integrated bearing system of any preceding clause, wherein in response to rotation of the shaft in a first direction about an axis in the first operating speed range, the one or more sprag elements rotate about a sprag rotation axis in a second direction, the second direction being different from the first direction.

Example 41 includes the integrated bearing system of any preceding clause, wherein in response to rotation of the shaft in a first direction about a rotor axis in the second operating speed range, the one or more sprag elements rotate about a sprag rotation axis in a second direction, the second direction being the same as the first direction.

Example 42 includes the integrated bearing system of any preceding clause, wherein the one or more sprag elements are configured to rotate in the second direction in response to centrifugal forces acting on a portion of the one or more sprag elements, the centrifugal forces generated in response to the pump system operating in the second operating speed range.

Example 43 includes the pump system of any preceding clause, wherein the one or more diagonal strut elements comprise at least one of a solid lubricant comprising a silver coating or an oil mist lubricant.

Example 44 includes the pump system of any preceding clause, wherein the first operating speed range includes tangential speeds less than a foil bearing start-up speed.

Example 45 includes the pump system of any preceding clause, wherein the second operating speed range includes tangential speeds greater than foil bearing start-up speeds.

Example 46 includes a pump system for pressurizing fluid within a closed loop supercritical transport bus, the pump system comprising: means for increasing the kinetic energy of the fluid flowing through the pump system; means for providing torque to a rotor shaft of the pump system; first means for supporting the rotor shaft in a first operating speed range; second means for supporting the rotor shaft in a second operating speed range; and means for engaging the inner race with the outer race over said first operating speed range.

Example 47 includes the pump system of any preceding clause, wherein the means for engaging separates the inner race from the outer race based on centrifugal force generated by the rotor shaft in response to the rotor shaft rotating in a first direction about a rotor axis in the second operating speed range.

Example 48 includes the pump system of any preceding clause, wherein the means for engaging rotates about a sprag rotation axis in a second direction in response to the rotor shaft rotating about a rotor axis in the second operating speed range, the second direction being the same as the first direction.

Example 49 includes the pump system of any preceding clause, further comprising means for separating one or more liquids from the fluid, the one or more liquids comprising oil.

Example 50 includes a shroud for a pump, comprising: an inner shell layer comprising a first non-metallic material; a shell layer comprising the first or second non-metallic material; and a metal core shell positioned between the inner shell and the outer shell.

Example 51 includes a shroud of any preceding clause, wherein the metal core shell is electroformed.

Example 52 includes a shroud of any preceding clause, wherein at least one of the inner shell layer or the outer shell layer is formed via thermal spraying.

Example 53 includes a shroud of any of the preceding clauses, wherein the inner shell layer is formed via at least one of molding or casting.

Example 54 includes a shield of any preceding clause, wherein the first non-metallic material and the second non-metallic material comprise at least one of a ceramic, a polymer, or a composite material.

Example 55 includes the shield of any preceding clause, wherein the inner shell layer comprises a first thickness, the outer shell layer comprises the first thickness or a second thickness, and the metal core shell layer comprises a third thickness that is greater than the first thickness and the second thickness.

Example 56 includes a shroud of any of the preceding clauses, wherein the inner shell layer includes ridges extending away from a cavity defined by the shroud, the ridges being spaced apart along a perimeter of the inner shell layer.

Example 57 includes a shroud of any preceding clause, wherein an outer surface of the metal core shell layer is in full contact with an inner surface of the outer shell layer.

Example 58 includes a canned motor pump, comprising: a first shaft; a second shaft positioned at least partially about the first shaft, the second shaft magnetically engaged with the first shaft; and a shroud positioned between the first shaft and the second shaft, the shroud comprising: a metal core layer; a first non-metallic layer positioned between the metallic core layer and the first axis; and a second non-metallic layer positioned between the metallic core layer and the second shaft.

Example 59 includes a canned motor pump of any preceding clause, wherein the metal core layer comprises at least one of nickel or cobalt.

Example 60 includes a canned motor pump of any preceding clause, wherein the first non-metallic layer includes a first portion having a first thickness and a second portion having a second thickness, the second thickness being greater than the first thickness.

Example 61 includes the pump system of any preceding clause, wherein the metal core layer includes a first portion having a first outer diameter and a second portion having a second outer diameter.

Example 62 includes the canned motor pump of any preceding clause, wherein the first non-metallic layer and the second non-metallic layer comprise at least one of a ceramic material, a composite material, or a polymeric material.

Example 63 includes a canned motor pump of any preceding clause, wherein the first non-metallic layer and the second non-metallic layer comprise at least one of aluminum oxide, zirconium oxide, or silicon.

Example 64 includes a canned motor pump of any preceding clause, wherein the shroud includes a flange, further comprising a retainer ring to secure the flange against a housing of the canned motor pump.

Example 65 includes a magnetically driven pump, comprising: means for containing a fluid; means for compressing said fluid; and means for sealing the means for containing, said means for sealing comprising: a first means for insulating, the first means for insulating defining an inner surface of the means for sealing; a second means for insulating, the second means for insulating defining an outer surface of the means for sealing; and means for supporting said first means for insulating and said second means for insulating, said means for supporting filling an area defined between said first means for insulating and said second means for insulating.

Example 66 includes a magnetically driven pump of any preceding clause, wherein the means for supporting is electroformed on the first means for insulating.

Example 67 includes a magnetically driven pump of any preceding clause, wherein at least one of the first means for insulating or the second means for insulating is formed via thermal spraying.

Example 68 includes the magnetically driven pump of any preceding clause, wherein at least one of the first means for insulating or the means for supporting comprises means for reinforcing.

Example 69 includes the magnetically driven pump of any preceding clause, wherein the fluid is a first means for dissipating heat in contact with the first means for insulating, further comprising a second means for dissipating heat in contact with the second means for insulating.

Example 70 includes a method of manufacturing a shroud for a canned motor pump, comprising: forming an inner shell layer; electroforming a core shell layer on an outer surface of the inner shell layer; and forming an outer shell layer on an outer surface of the core shell layer.

Example 71 includes a method of manufacturing a shroud for a canned motor pump, comprising: forming an inner shell layer; forming an outer shell layer; and electroforming a core shell layer on an outer surface of the inner shell layer or on an inner surface of the outer shell layer.

Example 72 includes the method of any preceding clause, wherein forming the inner shell layer includes at least one of molding, casting, or thermally spraying the inner shell layer.

Example 73 includes the method of any of the preceding clauses, wherein forming the inner shell layer includes forming ribs protruding from an outer surface of the inner shell layer.

Example 74 includes the method of any preceding clause, wherein forming the outer shell layer comprises thermally spraying the outer shell layer on the outer surface of the core shell layer.

Example 75 includes the method of any preceding clause, wherein at least one of forming the inner shell layer or forming the outer shell layer comprises machining or grinding an inner surface of the inner shell layer or an outer surface of the outer shell layer.

Example 76 includes the canned motor pump of any preceding clause, wherein the first non-metallic layer includes a first thickness and a second thickness greater than the first thickness, the first thickness and the second thickness alternating in a circumferential direction defined by the first non-metallic layer.

Example 77 includes the canned motor pump of any preceding clause, further comprising an O-ring positioned between the barrier can and the retainer ring.

Example 78 includes the canned motor pump of any preceding clause, wherein the retainer ring is coupled to the housing via a bolt.

Example 79 includes a canned motor pump of any preceding clause, wherein the retainer ring includes a first portion having a first diameter and a second portion having a second diameter, the second diameter being smaller than the first diameter, the flange including a third diameter between the first diameter and the second diameter.

Example 80 includes the canned motor pump of any preceding clause, wherein the first portion of the retainer ring interfaces with the housing and the second portion of the retainer ring is separated from the housing by a distance corresponding to a thickness of the flange such that when the retainer ring is coupled to the housing, the second portion of the retainer ring presses the flange against the housing.

Example 81 includes a canned motor pump of any preceding clause, wherein the first non-metallic layer is in contact with a first fluid and the second non-metallic layer is in contact with a second fluid, the second fluid being different than the first fluid, wherein the barrier can exchanges thermal energy with at least one of the first fluid or the second fluid.

Example 82 includes the magnetically driven pump of any preceding clause, wherein the first means for insulating includes a circumferentially spaced rib extending away from a cavity defined by the means for sealing.

Example 83 includes a shroud of any preceding clause, wherein the metal core shell comprises a thickness as small as 0.005 inches.

Example 84 includes a shroud of any of the preceding clauses, wherein an inner surface of the metal core shell layer is in full contact with an outer surface of the inner shell layer.

Example 85 includes a shroud for a fluid pump, comprising: an inner shell layer comprising a thermoplastic composite or a metal; and an outer shell layer comprising a composite material.

Example 86 includes a shroud of any preceding clause, wherein the inner shell layer comprises a nickel-based alloy.

Example 87 includes a shroud of any preceding clause, wherein the thermoplastic composite is a polyamide-imide.

Example 88 includes a shroud of any preceding clause, wherein the thermoplastic composite is polyetheretherketone.

Example 89 includes the shroud of any preceding clause, wherein the inner shell layer is formed via a machined stem of the thermoplastic composite material.

Example 90 includes a shroud of any preceding clause, wherein the outer shell layer is formed in multiple layers on the inner shell layer.

Example 91 includes a shroud of any preceding clause, wherein the inner shell layer is electroformed on an inner surface of the outer shell layer.

Example 92 includes a shroud of any of the preceding clauses, wherein the composite material includes an epoxy.

Example 93 includes a shroud of any of the preceding clauses, wherein the composite material includes at least one of carbon fibers or graphite fibers.

Example 94 includes a shroud of any of the preceding clauses, wherein at least one of the carbon fibers or the graphite fibers is positioned in more than one orientation.

Example 95 includes a shield of any preceding clause, wherein the composite includes fibers positioned in a first orientation, a second orientation, a third orientation, and a fourth orientation, the second orientation being different than the first orientation, the third orientation being different than the first orientation and the second orientation, the fourth orientation being different than the first orientation, the second orientation, and the third orientation.

Example 96 includes the shroud of any preceding clause, wherein the first orientation is substantially orthogonal to the second orientation.

Example 97 includes the shroud of any of the preceding clauses, wherein the third orientation is substantially orthogonal to the fourth orientation.

Example 98 includes a shroud of any of the preceding clauses, wherein the outer shell layer includes a thickness between 25 mils and 150 mils.

Example 99 includes a magnetically driven pump, comprising: a first shaft; a second shaft positioned at least partially about the first shaft, the second shaft magnetically engaged with the first shaft; and a shroud positioned between the first shaft and the second shaft, the shroud comprising: a composite shell layer; and a liner positioned along an inner surface of the composite shell, the liner comprising a thermoplastic or a metal.

Example 100 includes a magnetically driven pump of any preceding clause, wherein the composite encasement includes an aperture.

Example 101 includes a magnetically driven pump of any preceding clause, wherein the composite encasement comprises fibers and an epoxy.

Example 102 includes a magnetically driven pump of any preceding clause, wherein the fibers are positioned in at least three different orientations.

Example 103 includes a magnetically driven pump of any preceding clause, wherein the fiber comprises at least one of carbon or graphite.

Example 104 includes a magnetically driven pump of any preceding clause, wherein a ratio of eddy current loss caused by the shroud to a thickness of the liner is less than 0.06.

Example 105 includes a magnetically driven pump of any preceding clause, wherein the liner comprises a nickel-chromium based alloy.

Example 106 includes a shroud for a canned motor pump, the shroud comprising: a composite shell layer comprising first fibers in a first orientation and second fibers in a second orientation, the first orientation being substantially orthogonal to the second orientation; and an inner shell layer comprising a thermoplastic or a metal.

Example 107 includes a shroud of any preceding clause, wherein the composite shell layer includes third fibers in a third orientation and fourth fibers in a fourth orientation, the third orientation being substantially orthogonal to the fourth orientation.

Example 108 includes a method of forming a shroud for a magnetically driven pump, the method comprising: forming a shell layer; machining an inner surface of the shell; and forming a liner along the inner surface of the shell layer.

Example 109 includes the method of any preceding clause, wherein forming the shell layer comprises molding the shell layer.

Example 110 includes the method of any preceding clause, wherein forming the shell layer includes orienting the fibers in more than one orientation.

Example 111 includes the method of any preceding clause, wherein forming the shell layer includes bonding the fibers via an epoxy resin.

Example 112 includes the method of any preceding clause, wherein forming the liner comprises electroforming the liner on the inner surface of the shell layer.

Example 113 includes the method of any preceding clause, wherein forming the liner comprises injection molding the liner on the inner surface of the shell layer.

Example 114 includes a method of forming a shroud for a magnetically driven pump, the method comprising: forming an inner shell layer; and laminating an outer shell layer on an outer surface of the inner shell layer.

Example 115 includes the method of any preceding clause, wherein the inner shell layer is formed via a machined stem of thermoplastic.

Example 116 includes the method of any preceding clause, wherein laminating the outer shell layer comprises laminating a first layer of the outer shell layer over the outer surface of the inner shell layer, and laminating a second layer of the outer shell layer over the first layer.

Example 117 includes the method of any preceding clause, further comprising thermosetting the first layer before laminating the second layer on the first layer.

Example 118 includes the method of any preceding clause, further comprising orienting fibers in at least one of the first layer or the second layer.

Example 119 includes the method of any preceding clause, further comprising orienting fibers in at least one of the first layer or the second layer in more than one orientation.

Example 119 includes the method of any preceding clause, wherein orienting the fibers comprises positioning a first set of fibers in a first orientation, and positioning a second set of fibers in a second orientation, the second orientation being substantially orthogonal to the first orientation.

Example 120 includes the method of any preceding clause, wherein orienting the fibers further comprises positioning a third set of fibers in a third orientation different from the first orientation and the second orientation, and positioning a fourth set of fibers in a fourth orientation substantially orthogonal to the third orientation.

Example 121 includes the method of any preceding clause, wherein the inner shell layer is formed via electroforming.

Example 122 includes a shroud of any preceding clause, wherein the inner shell layer comprises a thickness as small as 2 mils.

Example 123 includes a magnetically driven pump of any preceding clause, wherein the shroud is subjected to an absolute pressure of 6400 pounds per square inch.

Example 124 includes a magnetically driven pump of any preceding clause, wherein the fibers are positioned in at least three different orientations.

Example 125 includes a pump system to pressurize a supercritical fluid within a closed loop heat transfer bus, the pump system comprising: a pump housing; a conduit fluidly coupled to the pump housing, a first portion of the conduit comprising a mixture of oil and the supercritical fluid, and a second portion of the conduit comprising the supercritical fluid; and a separator positioned in a third portion of the conduit between the first portion of the conduit and the second portion of the conduit, the separator separating the oil in the mixture from the supercritical fluid.

Example 126 includes a pump system of any preceding clause, wherein the separator includes a rotatable shaft and vanes extending from the rotatable shaft.

Example 127 includes a pump system of any preceding clause, wherein the separator comprises a conical cyclone comprising open axial ends and holes in a surface between the open axial ends.

Example 128 includes a pump system of any preceding clause, wherein the separator comprises: a rotatable shaft comprising a vane; and a housing positioned about the rotatable shaft, the housing including an aperture facing the rotatable shaft.

Example 129 includes the pump system of any preceding clause, wherein the housing is stationary within the conduit.

Example 130 includes the pump system of any preceding clause, wherein the rotatable shaft rotates in a first direction and the housing rotates in a second direction opposite the first direction.

Example 131 includes the pump system of any preceding clause, wherein the separator comprises a cyclone and a filter positioned in series in the third portion of the conduit.

Example 132 includes the pump system of example 1, wherein the conduit is fluidly coupled to the first portion of the pump housing and the second portion of the pump housing.

Example 133 includes the pump system of any preceding clause, further comprising: a rotatable shaft disposed within the pump housing; a motor coupled to the rotatable shaft; and an impeller coupled to one end of the rotatable shaft.

Example 134 includes the pump system of any preceding clause, wherein the rotatable shaft is mounted in the pump housing via a rolling element bearing, wherein the rolling element bearing is lubricated with the oil.

Example 135 includes the pump system of any preceding clause, wherein the one end of the rotatable shaft is a first end, wherein the rotatable shaft includes a second end opposite the first end, a first portion of the rotatable shaft disposed between the first end and the motor, a second portion of the rotatable shaft disposed between the second end and the motor, further comprising: a first bearing coupled to the first portion of the rotatable shaft, the first bearing comprising a first stiffness; and a second bearing coupled to the second portion of the rotatable shaft, the second bearing comprising a second stiffness that is greater than the first stiffness.

Example 136 includes the pump system of any preceding clause, further comprising: a first rotatable shaft disposed in the pump housing; a motor coupled to the first rotatable shaft; a second rotatable shaft disposed within the pump housing; a gearbox rotatably coupling the first rotatable shaft and the second rotatable shaft, wherein the gearbox is lubricated with the oil; and an impeller coupled to one end of the second rotatable shaft.

Example 137 includes a pump system to pressurize a supercritical fluid within a closed loop heat transfer bus, the pump system comprising: a pump housing; a conduit fluidly coupled to the pump housing to transport the supercritical fluid and oil; and a separator comprising an oil absorbing material positioned in the conduit to separate the oil from the supercritical fluid.

Example 138 includes the pump system of any preceding clause, wherein the oil absorbing material comprises at least one of a polymer or a powder.

Example 139 includes a pump system of any of the preceding clauses, wherein the separator includes a baffle.

Example 140 includes a pump system of any preceding clause, wherein the baffle is formed via sheet metal or additive manufacturing.

Example 141 includes the pump system of any preceding clause, wherein the separator comprises a first conduit fluidly coupled to a second conduit below the first conduit, the second conduit comprising the oil absorbing material.

Example 142 includes a pump system of any preceding clause, wherein the oil is mixed with an additive to increase the viscosity of the oil.

Example 143 includes a pump system for pressurizing a supercritical fluid within a closed loop heat transfer bus, the pump system comprising: means for compressing a fluid, wherein the fluid comprises a supercritical fluid and an oil; means for containing said means for compressing a fluid; means for transferring the fluid coupled to the means for containing; and means for separating the supercritical fluid and the oil positioned in the means for transporting.

Example 144 includes the pump system of any preceding clause, further comprising: means for rotating said means for compressing fluid; and means for increasing the angular velocity of the means for compressing fluid relative to the means for rotating.

Example 145 includes the pump system of any preceding clause, further comprising an eductor in the first portion of the conduit.

Example 146 includes a pump system of any preceding clause, wherein the vane is a helical vane.

Example 147 includes the pump system of any preceding clause, wherein the first portion of the conduit is fluidly coupled to the first portion of the pump housing and the second portion of the pump housing.

Example 148 includes the pump system of any preceding clause, wherein the first portion of the conduit is fluidly coupled to the first portion of the pump housing, and wherein the second portion of the conduit is fluidly coupled to the second portion of the pump housing.

Example 149 includes the pump system of any preceding clause, wherein the one end of the rotatable shaft is a first end, wherein the rotatable shaft includes a second end opposite the first end, a first portion of the rotatable shaft disposed between the first end and the motor, a second portion of the rotatable shaft disposed between the second end and the motor, further comprising a squirrel cage coupled to the first portion of the rotatable shaft and a damper coupled to the second portion of the rotatable shaft.

Example 150 includes the pump system of any preceding clause, wherein the oil absorbing material comprises at least one of polyurethane, polypropylene, polyethylene, cross-linked polymer, talc, aluminum starch, rice starch, or silica.

Example 151 includes the pump system of any preceding clause, further comprising: means for rotating the means for compressing, wherein the means for rotating is separated from the means for compressing by a first distance; a first means for supporting the means for rotating, the first means for supporting comprising a first stiffness, wherein the first means for supporting is separated from the means for compressing by a second distance, the second distance being greater than the first distance; and a second means for supporting the means for rotating, the second means for supporting comprising a second stiffness different from the first stiffness, wherein the second means for supporting is separated from the means for compressing by a third distance, the third distance being less than the first distance.

Example 152 includes a pump system, comprising: a pump housing; a rotatable shaft disposed in the pump housing; a motor coupled to the rotatable shaft in the pump housing; an impeller coupled to one end of the rotatable shaft; an oil lubricated bearing, the oil lubricated bearing mounting the rotatable shaft; a conduit fluidly coupled to the pump housing; and a separator positioned in the conduit to separate oil from other fluids transported via the conduit.

Example 153 includes a pump system to pressurize fluid within a closed loop fluid transfer bus, the pump system comprising: an impeller coupled to an impeller shaft; an axial flux motor, the axial flux motor comprising a rotor; a rotor shaft connected to the rotor, wherein the rotor shaft is coupled to the impeller shaft; a seal that inhibits contact between the fluid and the axial flux motor; a first housing, the first housing framing the impeller shaft; and a second housing that frames the axial flux motor, wherein the second housing is separate from the first housing.

Example 154 includes the pump system of any preceding clause, wherein the rotor shaft is connected to the impeller shaft via a spline interference.

Example 155 includes the pump system of any preceding clause, wherein the seal is a piston seal ring mounted on the second housing, wherein the impeller shaft is configured to fit within the piston seal ring.

Example 156 includes the pump system of any preceding clause, wherein the impeller shaft is a first shaft, wherein a second shaft is coupled to the first shaft, and wherein the second shaft is connected to the rotor shaft via a spline interference.

Example 157 includes the pump system of any of the preceding clauses, wherein the first shaft is coupled to the second shaft via a coaxial magnetic coupling, wherein the coaxial magnetic coupling comprises an outer hub and an inner hub, wherein the outer hub and the inner hub comprise one or more permanent magnets.

Example 158 includes the pump system of any preceding clause, wherein the seal is a barrier tank mounted between the inner hub and the outer hub of the coaxial magnetic coupling, the barrier tank comprising at least one of a metallic material and a non-metallic material.

Example 159 includes the pump system of any preceding clause, further comprising one or more rolling element bearings supporting the radial load and the thrust load generated by the rotor shaft in the second housing, wherein the one or more rolling element bearings are lubricated via at least one of an oil lubricant or a solid lubricant.

Example 160 includes the pump system of any preceding clause, wherein the rolling element bearing is lubricated via the oil lubricant, further comprising a separator separating the oil lubricant from the fluid, a portion of the oil lubricant being mixed with the fluid.

Example 161 includes the pump system of any preceding clause, further comprising at least one or more rolling element bearings or one or more gas foil bearings to support radial and thrust loads generated by the impeller shaft in the first housing, wherein the one or more rolling element bearings are lubricated via at least one of an oil lubricant or a solid lubricant.

Example 162 includes a pump system of any preceding clause, wherein heat generated by the stator is transferred to at least one of oil or water.

Example 163 includes a pump system to pressurize fluid within a closed loop fluid transfer bus, the pump system comprising: means for increasing the kinetic energy of the fluid flowing through the pump system; means for providing torque to a rotor shaft of the pump system; means for mounting the pump system, wherein the means for mounting frames an axial flux motor, wherein the means for mounting frames at least one of an impeller, an impeller shaft, or a coaxial magnetic coupling separate from the axial flux motor; and means for sealing the fluid from contact with the axial flux motor.

Example 164 includes the pump system of any preceding clause, further comprising a first means for connecting the impeller shaft and the rotor shaft.

Example 165 includes a pump system of any preceding clause, wherein the impeller shaft is a first shaft, further comprising means for coupling the first shaft to a second shaft.

Example 166 includes the pump system of any preceding clause, further comprising a second means for connecting the second shaft and the rotor shaft.

Example 167 includes the pump system of any preceding clause, further comprising means for supporting at least one of a radial load or a thrust load generated by at least one of the rotor shaft, the impeller shaft, or the coaxial magnetic coupling.

Example 168 includes the pump system of any preceding clause, further comprising means for transferring heat from the axial flux motor to at least one of oil, water, or ambient air.

Example 169 includes the pump system of any preceding clause, further comprising means for attaching the first housing to the second housing, wherein the means for attaching is configured to enable the first housing to be removed from the second housing.

Example 170 includes the pump system of any preceding clause, further comprising means for separating one or more liquids from the fluid, the one or more liquids comprising oil.

Example 171 includes a pump system for pressurizing fluid within a closed loop fluid transfer bus, the pump system comprising: an impeller coupled to an impeller shaft; an axial flux motor, the axial flux motor comprising a rotor; a rotor shaft connected to the rotor, wherein the rotor shaft is coupled to the impeller shaft; a seal that inhibits contact between the fluid and the axial flux motor; a first housing, the first housing framing the impeller shaft; and a second housing that frames the axial flux motor, wherein the second housing is separate from the first housing.

Example 172 includes a pump system of any preceding clause, wherein the second housing includes a mounting flange that mounts the pump system to a mounting surface.

Example 173 includes the pump system of any preceding clause, further comprising a first line replaceable unit secured to the second housing, the first line replaceable unit comprising at least one of the impeller, the impeller shaft, the first housing, a coaxial magnetic coupling, and a second shaft, wherein the second shaft is coupled to the impeller shaft via the coaxial magnetic coupling, wherein the second housing is a second line replaceable unit comprising at least one of the axial flux motor or the rotor shaft, and wherein the first line replaceable unit is configured to be removable from the second line replaceable unit.

The following claims are hereby incorporated into this detailed description by reference. Although certain example systems, methods, apparatus, and articles of manufacture have been disclosed herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all systems, methods, apparatus, and articles of manufacture fairly falling within the scope of the appended claims.

Claims

1. A pump system for pressurizing a fluid within a closed loop transmission bus, the pump system comprising:

a pump, the pump comprising an impeller;

an electric motor comprising a rotor shaft connected to the impeller;

a first bearing supporting the rotor shaft in a first operating speed range, the first bearing coupled to the inner race;

a second bearing supporting the rotor shaft at a second operating speed range, the rotor shaft coupled to an outer race; and

one or more diagonal bracing elements configured to:

engaging the inner race with the outer race over the first operating speed range; and is also provided with

Separating the inner race from the outer race in the second operating speed range.

2. The pump system of claim 1, wherein the first bearing is a rolling element bearing comprising at least one of an angular contact ball bearing, a hybrid ceramic bearing, a tapered roller bearing, a deep groove single ball bearing, a double ball bearing, or a spherical bearing.

3. The pump system of claim 2, wherein the first bearing is lubricated by an oil lubricant, further comprising a separator that separates the oil lubricant from the fluid, a portion of the oil lubricant being mixed with the fluid.

4. The pump system of claim 1, wherein the second bearing is a foil bearing.

5. The pump system of claim 1, wherein the one or more sprag elements rotate about a sprag rotation axis in a second direction, the second direction being different from the first direction, in response to the rotor shaft rotating about a rotor axis in the first operating speed range.

6. The pump system of claim 1, wherein the one or more sprag elements rotate about a sprag axis of rotation in a second direction in response to the rotor shaft rotating about a rotor axis in the second operating speed range, the second direction being the same as the first direction.

7. The pump system of claim 6, wherein the one or more diagonal bracing elements are configured to rotate in the second direction in response to centrifugal forces acting on a portion of the one or more diagonal bracing elements, the centrifugal forces generated in response to the pump system operating in the second operating speed range.

8. The pump system of claim 1, wherein the one or more diagonal strut elements comprise at least one of a solid lubricant comprising a silver coating or an oil mist lubricant.

9. An integrated bearing system for dynamically supporting a shaft in a pump system, wherein the pump system pressurizes fluid within a closed loop transmission bus, the integrated bearing system comprising:

a shaft connected to an impeller of the pump system;

a first bearing supporting the shaft in a first operating speed range, the first bearing coupled to the inner race;

a second bearing supporting the shaft over a second fluid speed range, the shaft coupled to the outer race; and

one or more diagonal bracing elements configured to:

10. The integrated bearing system of claim 9, wherein the first bearing is a rolling element bearing comprising at least one of an angular contact ball bearing, a hybrid ceramic bearing, a tapered roller bearing, a deep groove single ball bearing, a double ball bearing, or a spherical bearing.