Controlling multiple electric stators

Patent metadata

Field	Value
Publication number	US-10840788-B2
Application number	US-201715857476-A
Country	US
Kind code	B2
Filing date	Dec 28, 2017
Priority date	Dec 28, 2017
Publication date	Nov 17, 2020
Grant date	Nov 17, 2020

Abstract

A first electric stator surrounds a first electric rotor and is configured to cause the first electric rotor to rotate or generate electricity in the first electric stator when the first electric rotor rotates. The first electric stator includes a first set of electric windings. A second electric stator surrounds the second electric rotor and is configured to cause the second electric rotor to rotate or generate electricity in the second electric stator when the second electric rotor rotates. The second electric stator includes a second set of electric windings. The second electric stator is electrically coupled to the first electric stator. A controller is electrically coupled to both the first electric stator and the second electric stator. The controller is configured to exchange an electric current with a combination of the first electric stator and the second electric stator.

First claim

What is claimed is:

1. An electric machine comprising:
a first electric rotor;
a first electric stator surrounding the first electric rotor and configured to cause the first electric rotor to rotate or generate electricity in the first electric stator when the first electric rotor rotates, the first electric stator comprising a first set of electric multi-phase windings defining multiple electrical phases;
a second electric rotor rotatably coupled to an end of the first electric rotor;
a second electric stator surrounding the second electric rotor and configured to cause the second electric rotor to rotate or generate electricity in the second electric stator when the second electric rotor rotates, the second electric stator comprising a second set of multi-phase electric windings defining multiple electrical phases, the second electric stator being electrically coupled to the first electric stator; and
a controller electrically coupled to both the first electric stator and the second electric stator, the controller configured to exchange an electric current with a combination of the first electric stator and the second electric stator,
wherein the first electric stator and the second electric stator comprise a seal configured to isolate either the first electric stator or the second electric stator from an outside, downhole environment, and
wherein an inner surface of the seal and an outer surface of the first electric rotor and the second electric rotor define an annulus exposed to the outside environment.

2. The electric machine of claim 1 , wherein a coupling used to rotatably couple the first electric rotor and the second electric rotor comprises a spline coupling comprising longitudinal splines.

3. The electric machine of claim 1 , wherein the controller comprises a variable speed drive or a variable speed rectification system.

4. The electric machine of claim 1 , wherein the first electric rotor and the second electric rotor comprise permanent magnets rotors.

5. The electric machine of claim 4 , wherein the first electric rotor and the second electric rotor are configured so that a magnetic field of the first electric rotor is angularly out-of-phase with a magnetic field of the second electric rotor.

6. The electric machine of claim 5 , wherein the first electric rotor and the second electric rotor are up to 15 degrees angularly displaced from one another.

7. The electric machine of claim 5 , wherein the first electric rotor and the second electric rotor are angularly displaced by an amount calculated based on an expected angular displacement under torsional load.

8. The electric machine of claim 4 , wherein the first electric rotor and the second electric rotor are configured so that a magnetic field of the first electric rotor is angularly in-phase with a magnetic field of the second electric rotor.

9. The electric machine of claim 1 , wherein the first electric stator and the second electric stator are configured to be angularly out-of-phase with one another.

10. The electric machine of claim 9 , wherein the first electric stator and the second electric stator are up to 15 degrees angularly displaced from one another.

11. The electric machine of claim 9 , wherein the first electric stator and the second electric stator are angularly displaced by an amount calculated based on an expected relative angular displacement of the electric rotors under torsional load.

12. The electric machine of claim 1 , wherein the first electric stator and the second electric stator are configured to be angularly in-phase with one another.

13. The electric machine of claim 1 , wherein the electric machine is a downhole-type electric machine.

14. The electric machine of claim 1 , further comprising a radial bearing positioned at an interface between the first electric stator and the second electric stator, the radial bearing configured to support the first electric rotor and the second electric rotor.

15. The electric machine of claim 14 , wherein the radial bearing comprises a magnetic radial bearing.

16. The electric machine of claim 14 , wherein the radial bearing comprises two separate radial bearings, the first radial bearing supporting the first electric rotor and the second radial bearing supporting the second electric rotor.

17. A method of controlling the electric machine of claim 1 in a downhole environment, comprising:
rotating the first rotor housed within the first electric stator;
rotating the second rotor housed within the second electric stator, while an end of the second rotor is mechanically coupled to the end of the first rotor, and while the second stator is electrically coupled to the first electric stator; and
exchanging an electric current between the controller and a combination of the first stator and the second stator.

18. The method of claim 17 , further comprising isolating the first electric stator and the second electric stator from an outside environment with the seal positioned at least along an inner circumference of at least one of the stators.

19. The method of claim 18 , further comprising exposing the annulus to the outside environment.

20. The method of claim 19 , further comprising supporting the first rotor and the second rotor within the first electric stator and the second electric stator with a radial bearing.

21. The method of claim 20 , further comprising exposing the radial bearing to the outside environment.

22. The method of claim 20 , wherein the radial bearing comprises a radial bearing rotor and a radial bearing stator, the method further comprising exposing the radial bearing rotor to the outside environment.

23. The electric machine of claim 1 , wherein the seal is a first seal, the electric machine further comprising a second seal connected to the first seal by a butt joint.

24. An electric machine comprising:
a first electric rotor;
a first electric stator surrounding the first electric rotor, the first electric rotor being configured to drive or be driven by the first electric stator, the first electric stator comprising a first set of electric multi-phase windings defining multiple electrical phases;
a second electric rotor rotatably configured to rotate in unison with the first electric rotor;
a second electric stator surrounding the second electric rotor, the second electric stator comprising a second set of electric multi-phase windings defining multiple electrical phases, the second electric stator being electrically coupled to the first electric stator, the second electric rotor being configured to drive or be driven by the second electric stator; and
a controller electrically coupled to both the first electric stator and the second electric stator, the controller configured to exchange an electric current with a combination of the first electric stator and the second electric stator, and
wherein the first electric stator and the second electric stator comprise a seal configured to isolate either the first electric stator or the second electric stator from an outside, downhole environment, and
wherein an inner surface of the seal and an outer surface of the first electric rotor and the second electric rotor define an annulus exposed to the outside environment.

25. The electric machine of claim 24 , wherein the controller comprises a variable speed drive or a variable speed rectification system.

26. The electric machine of claim 24 , wh

Assignees

• Upwing Energy Llc

Inventors

• Mcmullen Patrick
• Artinian Herman
• Chen Kuo-Chiang
• Zheng Liping

Classifications

• E21B4/04 Primary

  Electric drives (E21B4/12 takes precedence) · CPC title

• H02K5/132

  Submersible electric motors (H02K5/128 takes precedence) · CPC title

• H02K16/00

  Machines with more than one rotor or stator {(machines for transmitting mechanical power from a driving shaft to a driven shaft and comprising structurally interrelated motor and generator parts H02K51/00; permanent magnet machines with multiple rotors or stators relatively rotated for vectorially combining the excitation fields or the armature voltages H02K21/029)} · CPC title

• H02P1/00

  Arrangements for starting electric motors or dynamo-electric converters (starting of synchronous motors with electronic commutators H02P6/20, H02P6/22; starting dynamo-electric motors rotating step by step H02P8/04; vector control H02P21/00) · CPC title

• H02K5/1285

  of the submersible type · CPC title