Cross-Reference to Related Applications

[0001] This application claims priority to U.S. Provisional Patent Application Serial No. 61/405,065, which was filed October 20, 2010. The priority application is hereby incorporated by reference in its entirety into the present application.

Background

[0002] A coupling is used to transfer torque between two shafts. In some instances, it is desirable for the two shafts to rotate at different speeds. Gearbox couplings are known in the art to couple two shafts, while allowing the two shafts to rotate at different speeds. However, gearbox couplings tend to require frequent maintenance and have a relatively short lifespan due to the constant frictional contact of the gears.

[0003] Magnetic couplings are also used to transfer torque between two shafts. In contrast to gearbox couplings, the moving parts in a magnetic coupling do not come into contact. Rather, the torque is transferred between the magnetic coupling components via magnetism. As a result, coupling wear is eliminated, leading to higher reliability and lower maintenance. Conventional magnetic couplings, however, are configured to transfer torque between two shafts such that the rotational speed of each shaft is equal, and this is disadvantageous for those configurations where different shaft speeds are desired.

[0004] There is a need, therefore, for a magnetic coupling configured to transfer torque between two shafts while allowing the two shafts to rotate at different speeds.

Summary of the Invention

[0005] Embodiments of the disclosure may provide a magnetic coupling. The magnetic coupling may include a rotatable driving connector having a first magnet assembly coupled thereto, and a rotatable driven connector having a second magnet assembly coupled thereto. The driven connector may be configured to slip predictably with respect to the driving connector based on a controllable amount of torque transferred between the driving and driven connectors.

[0006] Embodiments of the disclosure may also provide a compressor system. The compressor system may include a first shaft coupled to and driven by a first driver. A compressor may be coupled to the first shaft and configured to rotate at a speed of the first shaft. A driving connector may also be coupled to the first shaft. A driven connector may be magnetically coupled to the driving connector, and the driven connector may be configured to slip predictably with respect to the driving connector based on an amount of torque transferred between the driving and driven connectors. A second shaft may be coupled to the driven connector. A rotary separator may be coupled to the second shaft and configured to rotate at a speed of the second shaft. A control system may be coupled to the magnetic coupling and configured to transmit a signal to the magnetic coupling controlling the amount of torque transferred between the driving and driven connectors.

[0007] Embodiments of the disclosure may also provide a method for transferring torque through a magnetic coupling. The method may include driving a first shaft with a driver. The method may also include transferring a controlled amount of torque between magnetically coupled driving and driven connectors such that the driven connector is configured to slip predictably with respect to the driving connector. The driving connector may be coupled to the first shaft and the driven connector may be coupled to a second shaft.

Brief Description of the Drawings

[0008] The present disclosure is best understood from the following detailed description when read with the accompanying Figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

[0009] Figure 1 illustrates a cross-sectional view of an exemplary magnetic coupling, according to one or more embodiments of the disclosure. [0010] Figure 2 illustrates a cross-sectional view of another exemplary magnetic coupling, according to one or more embodiments of the disclosure.

[0011] Figure 3 illustrates a block diagram of an exemplary compressor system, according to one or more embodiments of the disclosure.

[0012] Figure 4 illustrates an exemplary method for controlling the amount of torque transferred between first and second shafts, according to one or more embodiments of the disclosure.

Detailed Description

[0013] It is to be understood that the following disclosure describes several exemplary embodiments for implementing different features, structures, or functions of the invention. Exemplary embodiments of components, arrangements, and configurations are described below to simplify the present disclosure, however, these exemplary embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference numerals and/or letters in the various exemplary embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various exemplary embodiments and/or configurations discussed in the various Figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, the exemplary embodiments presented below may be combined in any combination of ways, i.e., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure.

[0014] Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Further, in the following discussion and in the claims, the terms "including" and "comprising" are used in an open-ended fashion, and thus should be interpreted to mean "including, but not limited to." All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope. Furthermore, as it is used in the claims or specification, the term "or" is intended to encompass both exclusive and inclusive cases, i.e., "A or B" is intended to be synonymous with "at least one of A and B," unless otherwise expressly specified herein.

[0015] Figure 1 illustrates a cross-sectional view of an exemplary magnetic coupling 100, according to one or more embodiments of the disclosure. The exemplary magnetic coupling 100 includes a first, driving connector 1 12 coupled to a first shaft 1 10, and a second, driven connector 122 coupled to a second shaft 120. The driving connector 1 12 includes a first shaft mount 1 14 and a first magnet assembly 1 16 coupled to the first shaft mount 1 14. The driven connector 122 includes a second shaft mount 124 and a second magnet assembly 126 coupled to the second shaft mount 124. A magnetic field gap 102 is disposed between the driving connector 1 12 and the driven connector 122 such that the driving connector 1 12 does not come into contact with the driven connector 122.

[0016] The driving connector 1 12 and the driven connector 122 may be arranged in any configuration that has a magnetic engagement that enables rotational slip between the connectors 1 12,122 in a predictable and/or controllable manner. In at least one embodiment, the driving connector 1 12 and the driven connector 122 are arranged in a radial configuration with one connector 1 12,122 disposed radially inside the other connector 1 12,122. Further, the connectors 1 12,122 may be substantially concentric. As shown, the driven connector 122 is disposed radially inside the driving connector 1 12, and the second magnet assembly 126 is disposed radially inside the first magnet assembly 1 16. In another embodiment, the driving connector 1 12 and the driven connector 122 are arranged in an axial configuration with one connector 1 12,122 facing the other connector 1 12,122 (not shown). In the axial configuration, the magnet assemblies 1 16,126 may be planar and have any shape including circular, rectangular, or the like. It will be appreciated that other magnetic coupling 100 configurations may be used without departing from the scope of the disclosure.

[0017] The first and second magnet assemblies 1 16,126 may each include one or more permanent magnets, one or more electromagnets, a ferrous material, a nonferrous electro- conductive material, or the like. The first and second magnet assemblies 1 16, 126 generate a magnetic field that transfers rotational movement, i.e. , torque, from the driving connector 1 12 to the driven connector 122 by magnetically coupling the driving connector 1 12 to the driven connector 122. A predetermined (maximum) amount of torque must be transferred from the driving connector 1 12 to the driven connector 122 for the two connectors 1 12,122 to rotate at the same speed. Thus, if the predetermined (maximum) amount of torque is transferred from the driving connector 1 12 to the driven connector 122, the two connectors 1 12,122 will rotate at the same speed. However, if the amount of torque transferred from the driving connector 1 12 to the driven connector 122 falls below the predetermined (maximum) amount, a predictable amount of slippage will occur within the magnetic coupling 100. This may allow the driven connector 122 to rotate at a slower speed than the driving connector 1 12, and thus, the second shaft 120 may rotate at a slower speed than the first shaft 1 10.

[0018] In at least one embodiment, the first and second magnet assemblies 1 16,126 may be electromagnets, and the amount of torque transferred between the driving and driven connectors 1 12,122 may be varied according to the amount of power supplied to the electromagnets 1 16,126. Thus, as the amount of power is increased, the amount of torque transferred between the connectors 1 12,122 is increased until the predetermined (maximum) amount of torque is transferred. As the amount of power is decreased, the amount of torque transferred between the connectors 1 12,122 is decreased . When the amount of power supplied to the first and second magnet assemblies is not enough to generate the predetermined (maximum) amount of torque, i.e., the amount required for the connectors 1 12,122 to rotate at the same speed, the amount of power supplied to the first and second magnet assemblies 1 16,126 may control the ratio of the rotational speed of the driving connector 1 12 to the rotational speed of the driven connector 122.

[0019] In at least one embodiment, a fluid 104, such as a ferrofluid, may be disposed within the gap 102 between the first and second magnet assemblies 1 16,126. The ferrofluid 104 is a liquid that becomes magnetized in the presence of a magnetic field, such as the magnetic field generated by the first and second magnet assemblies 1 16,126. The ferrofluid 104 may be or include a colloidal mixture including ferromagnetic orferrimagnetic particles suspended in a carrier fluid, such as an organic fluid, water, or the like. The particles may include a surfactant coating which prevents the particles from agglomerating in the presence of magnetic forces. In at least one embodiment, the fluid 104 may include a magnetorheological fluid, an electrorheological fluid, or the like.

[0020] In at least one embodiment, one or more seals 130,132 may be positioned (at any location) to maintain the ferrofluid 104 within the gap 102 or in the magnetic coupling 100 in general. As shown, a first seal 130 may be positioned between the first and second shaft mounts 1 14,124 on a first side of the magnet assemblies 1 16,126, and a second seal 132 may be positioned between the first and second shaft mounts 1 14,124 on a second side of the magnet assemblies 1 16,126. In at least one embodiment, the first seal 130 may be omitted. In another embodiment, the second seal 132 may be positioned between the first shaft mount 1 14 and the second shaft 120 (not shown). The seals 130,132 may be any type of seal known to be capable of confining a fluid in a particular area of a rotating machine. However, as may be appreciated, the type and arrangement of the seals 130,132 may vary depending on the application.

[0021] The amount of torque that is transferred from the driving connector 1 12 to the driven connector 122 may be directly dependent on the concentration of the magnetic field or magnetic flux between the first and second magnet assemblies 1 16,126. For example, as the concentration of the magnetic flux decreases, the amount of torque transferred from the driving connector 1 12 to the driven connector 122 also decreases. Other factors that may affect the amount of torque that is transferred from the driving connector 1 12 to the driven connector 122 are the size of the gap 102, the material of the magnet assemblies 1 16,126, and the size of the loads 220,230 (see Figure 2) coupled to the first and second shafts 1 10,120.

[0022] An energy or other force may be applied to the ferrofluid 104 to change the state or status of the ferrofluid 104, and as a result, increase or decrease the torque transferred between the driving and driven connectors 1 12,122. The energy may enable the ferrofluid 104 to increase the concentration of the magnetic flux, thereby increasing the torque transfer from the driving connector 1 12 to the driven connector 122. Likewise, the energy may enable the ferrofluid 104 to decrease the concentration of the magnetic flux, thereby decreasing the torque transfer from the driving connector 1 12 to the driven connector 122. Thus, as the energy applied to the ferrofluid 104 may increase or decrease the concentration of the magnetic flux, the energy may control whether enough torque is transferred between the connectors 1 12,122 so that the connectors 1 12,122 rotate at the same speed, or whether slippage occurs within the magnetic coupling 100 and the connectors 1 12,122 rotate at different speeds. Moreover, when less than the predetermined (maximum) amount of torque is transferred from the driving connector 1 12 to the driven connector 122, and the connectors 1 12,122 are rotating at different speeds, the ratio of the rotational speed of the driving connector 1 12 to the rotational speed of the driven connector 122 may correspond to (and be controlled by) the amount of energy applied to the ferrofluid 104.

[0023] In at least one embodiment, the energy may be an electrical current. In another embodiment, the energy may be a magnetic field generated by at least one of the magnet assemblies 1 16,126 or an external magnet (not shown). As can be appreciated, other types of energy may be used without departing from the scope of the disclosure.

[0024] Figure 2 illustrates a cross-sectional view of another exemplary magnetic coupling 200, similar in some respects to the magnetic coupling 100 described above in Figure 1 . Accordingly, the magnetic coupling 200 may be best understood with reference to Figure 1 , wherein like numerals correspond to like components and therefore will not be described again in detail. Unlike the magnetic coupling 100, however, the magnetic coupling 200 may include one or more closed containment assemblies 230 positioned in the gap 102 and having the ferrofluid 104 disposed therein. One or more arms or other attachment devices 232 may be coupled to or integral with the containment assembly 230 and configured to position the containment assembly 230 within the gap 102 such that it is stationary and does not contact the driving or driven connectors 1 12, 122. The arms 232 may extend axially and/or radially and be coupled to one or more stationary components (not shown) proximate the magnetic coupling 200. In at least one embodiment, the arms 232 may be an annular structure extending circumferentially around the driven connector 122. As neither the containment assembly 230 nor the ferrofluid 104 is in contact with the connectors 1 12, 122, the containment assembly 230 may act as a pressure barrier and provide isolation between the connectors 1 12, 122. The containment assembly 230 may be made from a material that will not affect the magnetic flux in the gap 102, such as a composite material or the like.

[0025] Figure 3 illustrates a block diagram of an exemplary compressor system 300, according to one or more embodiments of the disclosure. In at least one embodiment, a driver 310 may be coupled to and drive the first shaft 1 10. The driver 310 may be a turbine, a motor, or the like. A compressor 320 may be coupled to the first shaft 1 10 (as shown) or the second shaft 120, and may be configured to rotate at the same speed as the shaft 1 10,120 to which it is coupled. The compressor 320 may be a centrifugal compressor, axial compressor, reciprocating compressor, supersonic compressor, or the like. A rotary separator 330 may be coupled to the first shaft 1 10 or the second shaft 120 (as shown), and may be configured to rotate at the same speed as the shaft 1 10,120 to which it is coupled. The rotary separator 330 is configured to separate a fluid stream into a substantially gaseous output and a substantially liquid output. The compressor 320 is fluidly coupled with the rotary separator 330 such that the substantially gaseous output from the rotary separator 330 flows into the compressor 320 for compression.

[0026] The rotary separator 330 may have a different optimal rotating speed than the compressor 320. A control system 340 may be coupled to the magnetic coupling 100, the compressor 320, and/or the rotary separator 330. The control system 340 may be configured to receive a signal from the rotary separator 330, the compressor 320, or an operator (not shown) and to transmit a signal to the magnetic coupling 100 directing it to maintain, increase, or decrease the torque transferred by the magnetic coupling 100. For example, if the compressor 320 and rotary separator 330 are coupled to the first and second shafts 1 10,120, respectively (as shown), the control system 340 may receive a signal requesting a slower rotational speed for the rotary separator 330, and the control system 340 may transmit a signal to the magnetic coupling 100 directing it to decrease the torque. In at least one embodiment, the signal may control the power supplied to the electromagnetic magnet assemblies 1 16,126. In another embodiment, the signal may control the amount of energy applied to the ferrofluid 104.

[0027] Figure 4 illustrates an exemplary method 400 for transferring torque through a magnetic coupling, according to one or more embodiments of the disclosure. The method 400 may include driving a first shaft with a driver, as shown at 402. The method 400 may also include transferring a controlled amount of torque between magnetically coupled driving and driven connectors such that the driven connector is configured to slip predictably with respect to the driving connector, as shown at 404. The driving connector may be coupled to the first shaft and the driven connector being coupled to a second shaft.

[0028] The foregoing has outlined features of several embodiments so that those skilled in the art may better understand the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the present disclosure.