The present invention relates to a turbine current generator. The present invention is used in the sector of extracting energy from moving fluids in order to supply measurement systems, sensors and/or similar electrical/electronic devices directly or through storage systems.

The object of the present invention therefore lends itself to being used both in the oil sector with particular reference to the exploitation and exploration of oil fields and in any other sector in which the movement of fluids is envisaged, such as for example in aqueducts, in systems of distribution of fluids which may also be under pressure.

As is known, there are various processes and devices intended for the recovery of electrical energy from sources commonly available in the environment. An example of such devices can be found in turbines and/or impellers intended for the conversion of the kinetic energy possessed by a moving fluid into electrical energy.

From document CN201902238U a current generator is known which provides for an impeller immersed in a fluid flowing inside a pipe.

With reference to document CN107575334, current generators are described which are housed externally to the pipes where the fluid flows from which the energy to be converted into electrical energy is drawn. Each current generator is provided with one or more impellers that lie inside the reference pipe being immersed in the flowing fluid. Each impeller is connected to the respective current generator by means of a shaft that crosses the pipe itself from inside out.

Document US2014117669 also describes and illustrates different solutions of current generators whose body and some components are housed outside the reference pipes, while the relative impellers are arranged inside the pipes in such a way as to be driven in motion by the fluid flowing in them. Also in this case, the shaft of each impeller crosses the relative pipe from inside out. Also from document CN201874727U an impeller of a current generator is known which is arranged inside a pipe crossed by a fluid and provided with a shaft that crosses the pipe from inside out. With reference to document GB201218534, a current generator is known which provides one or more impellers arranged in series inside a pipe where a fluid flows. The components used to convert kinetic/mechanical energy into electrical energy are also arranged inside or integrated into the pipe. In fact, some essential components of the current generator are mounted on the rotor of the impellers, while other components are instead arranged on respective stators that enclose the impellers inside the respective pipe. Although the known current generators propose different solutions for converting the kinetic/mechanical energy possessed by a fluid moving inside a pipe into electrical energy, the Applicant has found that they are not, however, free from some drawbacks and can be improved under various aspects, mainly in relation to the use of current generators under conditions of extraction of fluids at high pressure (about 700 bar) and temperature (about 200°C) that flow inside ducts and pipes with reduced section (not exceeding 20mm), to the overall sealing of the ducts and pipes in the points where the current generators are installed, to the overall dimensions of the ducts and pipes at the points where the current generators are installed, to the overall dimensions of the current generator.

In particular, the Applicant has found that known current generators are badly suited to work in environments characterized by high pressures and temperatures, such as those under which one must normally operate during the exploitation and exploration of oil fields.

In fact, all known solutions whose current generators are positioned outside the pipes with their respective impellers arranged inside the latter are subject to significant sealing problems at the crossing of the transmission shafts of the walls of the pipes, which are notably sharpened under conditions of high pressures. Moreover, since these current generators need suitable transmission mechanisms between the impellers and the essential parts of the same which reside outside the pipes, they are particularly cumbersome, consequently also increasing the overall dimensions of the pipes. The main object of the present invention is to provide a current generator capable of solving the problems encountered in the prior art.

A further object of the present invention is to provide a current generator which lends itself to work effectively even under conditions of high pressure, for example at about 700 bar, and at temperatures, for example at about 200°C.

It is also an object of the present invention to provide a compact current generator that can be housed inside pipes, even with small dimensions, such as for example pipes whose section does not exceed 20mm.

It is a further object of the present invention to provide a current generator capable of ensuring the overall dimensions of the pipes on which it is installed. These specified and yet further purposes are substantially achieved by a turbine current generator, as expressed and described in the following claims.

By way of example, the description of a preferred but not exclusive embodiment of a turbine current generator, in accordance with the present invention, is now reported.

Such description will be made hereinbelow with reference to the accompanying drawings, provided for indicative purposes only and therefore not limiting, wherein:

Figure 1 is a front view of a turbine current generator, in accordance with the present invention;

Figure 2 is a section of the turbine current generator taken along the plane II-II of Figure 1;

Figure 3 is a further front view of the turbine current generator of Figures 1 and 2; Figure 4 is a section of the turbine current generator taken along the plane IV-IV of Figure 3;

Figure 5 is a schematic perspective view of a flexible laminar structure for supporting a plurality of windings present in the generator of Figures 1 to 4; Figure 6 is a schematic cross section of the flexible laminar structure of Figure 5 represented in relation to a hollow bearing cylinder of the generator of Figures 1 to 4, to form the stator of the latter one;

Figures 7 to 11 are schematic views of portions of the flexible laminar structure in which it is possible to view a series of conductive tracks of the windings of the generator of Figures 1 to 4.

With reference to the attached figures, the number 1 indicates overall a turbine current generator, according to the present invention. The turbine current generator is of the type comprising a stator and a rotor.

In detail, the current generator 1 comprises a hollow bearing cylinder 2 which can be engaged inside a pipe or a duct for the transit (not shown as it is known) of a fluid, in particular a pressurised fluid transit duct deriving from the drilling and/or the exploration of an oil field.

The current generator 1 also comprises a hollow rotating cylinder 3 which is rotatably and coaxially engaged inside the hollow bearing cylinder 2 and defines a respective transit cylindrical chamber 4 for a fluid.

As is visible in Figures 2 and 4, the hollow bearing cylinder 2 and the hollow rotating cylinder 3 define, at least partially, at least a cylindrical gap 5 which develops between the hollow bearing cylinders 2 and the hollow rotating cylinders 3.

The electric generator 1 further comprises magnetic or electromagnetic components 6 operatively engaged to the hollow bearing cylinder 2 and/or to the hollow rotating cylinder 3 to generate at least an electric current during the rotation of the hollow rotating cylinder 3 inside the hollow bearing cylinder 2.

Still with reference to Figures 2 and 4, the current generator 1 is provided with at least one impeller 7 arranged in the transit cylindrical chamber 4 of the hollow rotating cylinder 3 according to a position aligned with a longitudinal axis X of the latter.

In accordance with the embodiments shown in Figures 2 and 4, the current generator 1 is provided with a plurality of impellers 7 arranged in the transit cylindrical chamber 4 of the hollow rotating cylinder 3 according to positions aligned with the longitudinal axis X of the latter.

Advantageously, the impellers 7 are engaged inside the hollow rotating cylinder 3 so as to rotate integrally with the latter upon the action of a fluid which runs through the transit cylindrical chamber 4 of the hollow rotating cylinder 3 and acts on each impeller 7.

In detail, each impeller 7 is fixed to an internal surface 3a of the hollow rotating cylinder 3 by means of respective peripheral portions 7a so as to rotate the hollow cylinder 3 when the impellers are induced in rotation by the transit of a fluid in the transit cylindrical chamber 4.

Still with reference to Figures 2 and 4, the turbine current generator 1 comprises at least one flow rectifier 8 arranged in the transit cylindrical chamber 4 of the hollow rotating cylinder 3, preferably a plurality of flow rectifiers 8 arranged in the transit cylindrical chamber 4 of the hollow rotating cylinder 3. The impellers 7 and the rectifiers 8 are interleaved so to alternate along the longitudinal development of the hollow rotating cylinder 3.

The turbine current generator 1 further comprises a static support shaft 9 developing axially inside the transit cylindrical chamber 4 of the hollow rotating cylinder 3.

The impellers 7 are rotatably engaged on the static support shaft 9 so to rotate, integrally with the hollow rotating cylinder 3, around the longitudinal axis X of the latter. Each flow rectifier 8 is instead fixed on the static support shaft 9 so that it remains stationary, together with the latter, with respect to the impellers 7 and to the hollow rotating cylinder 3.

As is visible in Figures 2 and 4, the static support shaft 9 is engaged, at its ends 9a, 9b, to a first and a second support shank 10, 11 which respectively define the inlet 4a and the outlet 4b of the transit cylindrical chamber 4 of the hollow rotating cylinder 3.

In particular, each support shank 10, 11 comprises a substantially cylindrical body 10a, 11a inside which a plurality of supports 10b, lib develop radially and converge in a central circular seat 10c, lie in which the relative end 9a, 9b of the static support shaft 9 is inserted. The supports 10b, lib of the first and second support shank 10, 11 are interleaved with corresponding transit openings lOd, lid (Figure 4) through which the advancing fluid is free to enter the transit cylindrical chamber 4 and to exit from the same. As is visible in Figures 2 and 4, the turbine current generator 1 comprises a first bearing 12 operatively interposed between the first support shank 11, the hollow bearing cylinder 2 and the hollow rotating cylinder 3 and a second bearing 13 operatively interposed between the second support shank 11, the hollow bearing cylinder 2 and the hollow rotating cylinder 3. The bearings 12,

13 are of such a type as to ensure the insulation of the cylindrical gap 5 with respect to the transit cylindrical chamber 4 of the hollow rotating cylinder 3, partly defining this cylindrical gap 5. With particular reference to the aforementioned magnetic or electromagnetic components 6, a first magnetic or electromagnetic component 6a, preferably a plurality of first magnetic or electromagnetic components 6a, are engaged, in particular fixed, for example by gluing, to an internal surface 2a of the hollow bearing cylinder 2 inside the cylindrical gap 5.

In accordance with a preferred embodiment of the present invention shown in Figures 5 to 11, the first magnetic or ferromagnetic components 6a comprise a plurality of windings 6c (Figures 5, 7 and 8) each having a substantially flat structure.

In detail, each winding 6c comprises a series of conductive tracks 6d which define a laminar and flexible printed circuit. Advantageously, the conductive tracks 6d of each winding 6c develop mainly parallel to each other, having substantially orthogonal connecting sections 6e. Furthermore, the conductive tracks 6d of each winding 6c develop in a concentrated manner on at least two superimposed planes or layers.

Preferably, the conductive tracks 6d of each winding 6c are incorporated in, or supported by, a flexible laminar structure 16 which can also assume a cylindrical or semi- cylindrical configuration.

Advantageously, the flexible laminar structure 16 which supports the conductive tracks 6d of the windings 6c can assume a rolled or wound configuration (Figures 5 and 6) having superimposed structural portions. In this way, the flexible laminar structure has high degrees of mechanical strength to pressure and considerably simplifies the assembly steps of the electric generator 1.

In order to insulate the windings 6c especially at the superimposed portions of the structure, it is appropriate to apply at least one insulating lacquer on the conductive tracks 6d of the windings 6c and, consequently, on both faces of the flexible laminar structure 16.

According to a preferred configuration of the present invention, the conductive tracks 6d of each winding 6c are grouped on respective structural sectors 16a of the flexible laminar structure 16 which each have a substantially rectangular shape.

As visible in Figures 7 and 8, the structural sectors 16a of the flexible laminar structure 16 are arranged side by side along a respective long side 16b.

In accordance with this embodiment, each winding 6c develops from one of the sides, preferably a long side 16b, of the respective structural sector 16a of the flexible laminar structure 16, extending substantially parallel to the respective perimeter of this structural sector 16a, from the periphery 16c towards a central area 16d of the same.

At the central area 16d of the respective structural sector 16a of the flexible laminar structure 16, the respective winding 6c develops from a plane or layer to the other one in which it develops substantially parallel to the perimeter of the respective structural sector 16a from the central area 16d to the periphery 16c of the same.

As is visible in Figures 7 and 8, the windings 6c of each structural sector 16a of the flexible laminar structure 16 are electrically connected in series or in parallel with each other by means of corresponding connection bridges 6f.

With reference to Figures 5 and 7-11, the flexible laminar structure 16 comprises at least one electrical connection appendix 16e, substantially flat, along which one or more electrical connection tracks 6g for connecting the windings 6c to at least another component of the electric generator 1 develop. In accordance with a preferred solution of the present invention, the flexible laminar structure 16 comprises at least one film made of an insulating material, such as for example polyimide capable of remaining stable in a range of temperatures between -269°C and 400°C. The flexible laminar structure 16 also has two upper and lower copper layers.

In accordance with a preferred solution of the present invention, the polyimide layer has a thickness of not less than 17pm, while the two copper layers each have a thickness of not less than 25pm.

The thinnest flexible laminar structure 16 has a thickness of not less than 0.067 mm.

Advantageously, the flexible laminar structure 16 is positioned according to a rolled or wound configuration (Figures 5 and 6) in the cylindrical gap 5 and fixed to the internal surface 2a of the hollow bearing cylinder 2, preferably by gluing.

Alternatively, it is possible to provide two or more flexible laminar structures 16 having different circumferences which are fixed, the widest one, against the internal surface 2a of the hollow bearing cylinder 2, the least wide, against the widest one. Advantageously, the hollow bearing cylinder 2 which, together with the flexible laminar structure 16 constitutes the stator of the generator 1, is made of a ferromagnetic material, suitable for being machined or sintered into simple shapes with low saturation levels compared to those of the main magnetic steels, such as some iron- and nickel-based magnetic metal alloys or metal alloys with high magnetic permeability. Alternatively, the hollow bearing cylinder 2 could also be made of a plastic material to limit the losses in the iron in the event that the productivity of the turbine is particularly low.

A second magnetic or electromagnetic component 6b is engaged with the hollow rotating cylinder 3 to face towards the cylindrical gap 5 at the first magnetic or electromagnetic component 6a.

In accordance with a preferred solution of the invention, the second magnetic or ferromagnetic component 6b comprises a plurality of permanent magnets which are fixed, preferably by gluing, on an external surface 3b of the hollow rotating cylinder 3.

Each permanent magnet has a substantially parallelepiped shape, preferably with a rectangular base and is housed in a respective seat obtained on the external surface 3b of the hollow rotating cylinder 3.

Each permanent magnet is advantageously sectioned along its longitudinal or axial development into a plurality of pieces in order to reduce losses due to eddy currents. It is preferable that the permanent magnets are made of a material with a low thermal coefficient, such as for example Samarium-Cobalt.

In order for the position of the permanent magnets on the hollow rotating cylinder 3 to be ensured even during high rotation speeds of the latter, it is possible to provide bandaging or containment structures (not shown in the accompanying figures) that have a cylindrical external surface.

Alternatively, in order to give the permanent magnets an overall cylindrical surface without structural discontinuities, it is possible to apply a resin or similar material capable of giving the hollow rotating cylinder 3 and permanent magnets assembly a continuous cylindrical external surface, thus reducing to the minimum the resistance to rotation of the rotor by any fluid present in the gap 5.

The hollow rotating cylinder 3 acts as a flow guide for the magnetic flow supported by the permanent magnets. Advantageously, the hollow rotating cylinder 2 is made of a ferromagnetic material capable of withstanding mechanical loads and the attacks of chemical agents.

Preferably, the hollow rotating cylinder 2 is made of a ferromagnetic material having a relative permeability greater than 100, so as to offer an adequate flow path to the permanent magnets it houses and to achieve a low magneto-motive force drop. In detail, the hollow rotating cylinder 2 is made of a stainless steel or, for example, of a nickel alloy which materials allow an adequate compromise between thickness and level of magnetic saturation and suitable mechanical characteristics . As regards the arrangement of the first and second magnetic components 6a, 6b, it should be considered that for the purposes of the present invention it is not excluded in any way to provide that the permanent magnets are applied to the internal surface 2a of the hollow bearing cylinder 2 and the windings are arranged on the hollow rotating cylinder 3 or to provide that the respective windings are applied both on the hollow bearing cylinder 2 and on the hollow rotating cylinder 3. According to an advantageous aspect of the present invention, the cylindrical gap 5 is hermetically insulated with respect to the transit cylindrical chamber 4 of the hollow rotating cylinder 3 and is occupied, at least partially, by a dielectric fluid, preferably a dielectric oil.

As visible in Figures 2 and 4, the cylindrical gap 5 comprises at least one connection channel 14 which has a first connection port 14a confluent in the cylindrical gap 5 and a second connection port 14b confluent in the transit chamber 4 at the outlet 4b and at the second support shank 11. In detail, the cylindrical gap 5 is provided with a plurality of connection channels 14 each having a first communication port 14a and a second communication port 14b. A pressure compensation device 15 is operatively arranged inside each connection channel 14.

In particular, each compensation device 15 comprises at least one compensation chamber 15a in fluid communication with the respective connection channel 14 between the first connection port 14a and the second connection port 14b, operatively occupied by at least one compensation piston 15b.

Each compensation device 15 is designed to reduce the overall volume of the cylindrical gap 5 as the pressure in the transit cylindrical chamber 4 of the hollow rotating cylinder 3 increases.

In this way, each compensation device 15 keeps the pressure difference between the cylindrical gap 5 and the transit cylindrical chamber 4 of the hollow rotating cylinder 3 constant, preferably between -1 bar and +1 bar, even more preferably substantially equal to 0 bar. The current generator according to the present invention solves the problems observed in the known technique and achieves important advantages. First of all, the current generator described above lends itself to work effectively even under conditions of high pressure, for example at about 700 bar, and of temperature, for example at about 200°C.

Furthermore, the structural configuration of the turbine current generator described above gives the generator itself significantly reduced overall dimensions resulting extremely compact.

Finally, it should be considered that the structural configuration of the generator described above allows the application thereof inside the pipes and/or ducts for which it is intended, thus avoiding any sealing problem normally due to mechanical bodies and/or transmissions passing through these pipes.