Electric Submersible Pump Rotor Assembly with Bearing Spacer Configured for Thrust Washer Support

This application is a continuation-in-part of and claims priority to U.S. patent application Ser. No. 18/644,477 filed Apr. 24, 2024, the entire contents of which are incorporated herein by reference.

Not applicable.

This disclosure relates generally to the field of pumping. More particularly, this disclosure relates to the field of electric submersible pumps for use downhole in a well. Still more particularly, this disclosure relates to an electric submersible pump rotor assembly with a hydrodynamic bearing.

Electric submersible pump (ESP) assemblies may be used to artificially lift fluid to the surface, for example in deep wells such as oil or water wells. ESP assemblies are commonly used in the oil and gas industry to extract fluids from underground reservoirs. By way of example, the artificial lift provided by ESP assemblies may be useful in situations when the reservoir does not have sufficient energy to allow the well to naturally produce effectively, or when an additional boost to production of the well is desired.

A typical ESP assembly comprises, from bottom to top, an electric motor, a seal unit, a pump intake, and a pump (e.g. typically a centrifugal pump), which are all mechanically connected together with shafts and shaft couplings. The electric motor supplies torque to the shafts, which provides power to the centrifugal pump. The electric motor is isolated from a wellbore environment by a housing and by the seal unit. The seal unit can act as an oil reservoir for the electric motor. The oil can function both as a dielectric fluid and as a lubricant in the electric motor. The seal unit also may provide pressure equalization between the electric motor and the wellbore environment.

The centrifugal pump is configured to transform mechanical torque received from the electric motor via a drive shaft to fluid pressure which can lift fluid up the wellbore. For example, the centrifugal pump typically has rotatable impellers within stationary diffusers. A shaft extending through the centrifugal pump is operatively coupled to the motor, and the impellers of the centrifugal pump are rotationally coupled to the shaft. In use, the motor can rotate the shaft, which in turn can rotate the impellers of the centrifugal pump relative to and within the stationary diffusers, thereby imparting pressure to the fluid within the centrifugal pump. The electric motor is generally connected to a power source located at the surface of the well using a cable and a motor lead extension. The ESP assembly is placed into the well and usually is inside a well casing. In a cased completion, the well casing separates the ESP assembly from the surrounding formation. In operation, perforations in the well casing allow well fluid to enter the well casing and flow to the pump intake for transport to the surface.

It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.

As used herein, orientation terms “upstream,” “downstream,” “up,” and “down” are defined relative to the direction of flow of well fluid in the well casing. “Upstream” is directed counter to the direction of flow of well fluid, towards the source of well fluid (e.g., towards perforations in well casing through which hydrocarbons flow out of a subterranean formation and into the casing). “Downstream” is directed in the direction of flow of well fluid, away from the source of well fluid. “Down” is directed counter to the direction of flow of well fluid, towards the source of well fluid. “Up” is directed in the direction of flow of well fluid, away from the source of well fluid.

Disclosed embodiments relate generally to rotor assemblies for an ESP motor (e.g. for use with a pump to form an ESP assembly for use downhole in a well to pump formation fluids from the well formation to the surface), with the rotor assemblies being configured to address differential thermal expansion and the related issues arising therefrom.

Turning now to, an exemplary producing well environmentis described. In an embodiment, the environmentcomprises a wellheadabove a wellborelocated at the surface. A casingis provided within the wellbore. For convenience of reference,provides a directional reference comprising three coordinate axes—an X-axiswhere positive displacements along the X-axisare directed into the sheet and negative displacements along the X-axisare directed out of the sheet; a Y-axiswhere positive displacements along the Y-axisare directed upwards on the sheet and negative displacements along the Y-axisare directed downwards on the sheet; and a Z-axiswhere positive displacements along the Z-axisare directed rightwards on the sheet and negative displacements along the Z-axisare directed leftwards on the sheet. In the embodiment of, the Y-axisis approximately parallel to a central axis of a vertical portion of the wellbore.

An exemplary electric submersible pump (ESP) assemblymay be deployed downhole in a well within the casingand may comprise an optional sensor unit, an electric motorwhich may include a motor head, a seal unit, an electric power cable, a pump intake, a centrifugal pump, and a pump outletthat couples the centrifugal pumpto a production tubing. The centrifugal pumpmay be operatively coupled to the motorby a shaft. In an embodiment, the ESP assemblymay employ radial and thrust bearings in several places, for example in the electric motor, in the seal unit, and/or in the centrifugal pump. In an embodiment, the ESP assemblycan comprise a gas separator that may employ one or more thrust bearings. The motor headmay couple the electric motorto the seal unit. The electric power cablemay connect to a source of electric power at the surfaceand to the electric motor, for example being configured to provide power from the source of electric power at the surfaceto the electric motor.

In operation, the casingis pierced by perforations, and reservoir fluidflows through the perforationsinto the wellbore. The fluidflows downstream in an annulus formed between the casingand the ESP assembly, is drawn into the pump intake, is pumped by the centrifugal pump, and is lifted through the production tubingto the wellheadto be produced at the surface. The fluidmay comprise hydrocarbons such as oil and/or gas, water, or both hydrocarbons and water.

While the example illustrated inrelates to land-based subterranean wells, similar ESP systems can be used in a subsea environment and/or may be used in subterranean environments located on offshore platforms, drill ships, semi-submersibles, drilling barges, etc. And while the wellbore is shown inas being approximately vertical, in other embodiments, the wellbore may be horizontal, deviated, or any other type of well. Also, while the pump of the ESP is described with respect toas a centrifugal pump, other types of pumps (such as a rod pump, a progressive cavity pump, any other type of pump suitable for the system, or combinations thereof) may be used instead.

As shown in, an exemplary motorof the ESP assembly includes a housing, a stator, a rotor, and a drive shaft. The housingmay comprise a hollow cylinder or tube and is configured to protect the internal components of the motorfrom the external environment. The statormay also comprise a hollow cylinder and is secured to the housing(e.g. to the inner surface of the housing) so as to be stationary within the housing. The statormay comprise a plurality of laminations, which may be thin sheets of steel, iron, or bronze, wrapped by a plurality of electrically conductive windings. When energized, the windings generate a rotating magnetic field for interaction with the rotorto induce rotation of the rotor. The rotormay also comprise a hollow cylinder and is concentrically arranged between the statorand the drive shaft, for example with the drive shafttypically extending longitudinally along the centerline of the motor, the rotordisposed around the drive shaft, and the statordisposed around the rotor, within the housing. The rotormay be rotatable within the statorand secured to the drive shaft, such that rotation of the rotordrives the drive shaft. In embodiments, the motormay be a two or more pole motor, a three-phase squirrel cage induction motor, a permanent magnet motor (PMM), a hybrid PMM, or other motor configuration.

Depending on the power requirements of the motor, the rotorcan be an assembly which typically includes a number of rotor modules, which together jointly form the rotor assembly, with each rotor module secured to the drive shaft. The rotational magnetic field of the statorwhen energized can induce rotation of the rotor, and thereby the drive shaft, with the drive shafttransmitting rotational torque from the motorto the pump. As shown in, the rotor modules(jointly forming the rotor) can be spaced apart from each other along the drive shaft, with a rotor bearing assemblylocated between adjacent rotor modules. Rotor bearing assembliescan also be located at the top of the uppermost rotor moduleand/or the bottom of the lowermost rotor module(e.g. at the top and bottom of the rotor). In some embodiments, the rotor bearing assemblycan be a hydrodynamic rotor bearing assembly. Typically, each rotor bearing assemblyis configured to support the rotorat predefined axial positions to maintain correct radial alignment of the drive shaftduring motor operation.

As discussed in more detail below with respect to specific embodiments, rotor bearing assembliescan comprise a journal sleeve and a bushing assembly. The journal sleeve may be concentrically disposed around and secured to the drive shaftto rotate with the drive shaft. In embodiments, the inner journal sleeves can be configured to space each rotor moduleevenly on the drive shaft. The outer bushing assembly may be concentrically located around the inner journal sleeve, and the bushing assembly may fixedly engage into the stator lamination (e.g. the bushing assembly is configured to engage the inner surface of the statorto prevent rotation therein). The engagement into the stator lamination is required to ensure that the bushing assembly does not spin during operation, but instead provides a stationary surface within which the inner journal sleeve can rotate, to produce a hydrodynamic lubricating film.

During start-up and in operation, the rotormay be heated, for example due to friction, and thereby expands radially and axially. Since materials with different coefficient of thermal expansion (CTE) may be used in rotor construction, the components of the rotor(e.g. with different CTE) can expand at different rates. Further, the expansion between the drive shaftand one or more of the components of the rotorcan vary.

A snap ring or similar end support structure can be installed at one end of the shaft to support the mass of the rotor assemblycomponents (e.g. with respect to gravity). The mass of each rotor modulecan be transferred to the next (e.g. lower) rotor module(e.g. through the rotor bearing assembliesdisposed between adjacent rotor modules). The components of the last (e.g. lowest/bottom) rotor module, such as the last thrust washer, may be subjected to the weight of all components above. The strength of this polymeric thrust washer, for example, could be the limiting factor for the number of rotor modulesthat can be used in a rotor assembly.

Another snap ring can be installed at the opposite end of the shaft, at a pre-defined distance from the first/upper most rotor moduleto ensure that there is enough expansion length (e.g. for thermal expansion). In other embodiments a spring loaded mechanism can fill the gap between the snap ring and rotor module. The rotor modulescan be (axially) loose on the shaft, and they can be operable to shift axially during installation into the statorand/or during operation of the motor. The statormay require allowance for the rotorthermal growth, to ensure that the rotor end bearings cannot extend out from its support in the stator lamination stack.

In embodiments, various loads can be applied to one or more component of a rotor assembly, which can in some instances negatively impact the rotor assembly. For example, ESPs with certain types of motors (for example, permanent magnet motors) can exert a considerable load on the bearing due to the magnetic attraction to the stator. This can magnify the bearing load by two to ten times the gravitational load from the rotor mass. This force can create a large axially disposed frictional sliding force in the axial direction. A reaction load must be applied above this sliding force in order to move the bearing axially. In other words, the thrust capacity of the end of the bearing needs to be higher than the reaction load. In vertical operation of the motor, the gravitational weight of the outer bearing sleeve may bear down onto the thrust washer face. In other words, the outer bearing sleeve typically should have enough capacity to support this weight. In all orientations of the motor, the components may thermally expand to different degrees. This can lead to situations (due to the long lengths of the downhole motors) where the stationary outer bearing sleeve comes into axial contact with the rotor axial face due to the different relative rotor thermal growths. If the rotor thermal growth is larger than the axial gaps, high loads will be generated in the case in which outer bearing sleeve does not move. This load may climb until the applied “thermal growth” reaction force exceeds the sliding force.

The axial face of the conventional bearing may have insufficient load capacity to carry such loads and contact may occur between the rotating rotor face and the static bearing face. A thrust washer of the bearing may start to wear. Additionally, contact can generate heat that can cause the material to indent as its strength becomes too weak to resist the applied force. As the failure progresses, the static sleeve may dig into the washer, which may eventually cause the thrust washer to fail. The digging in also may also lead to increased radial load on the bearing, which can ultimately lead to a radial bearing failure. The eventual consequence of the bearing failures may be motor failure and ultimate failure of the ESP.

Turning now to the figures in detail for more specific examples,illustrates a typical rotor assemblyof an electric motor(for example, of an ESP assembly). In embodiments, the electric motorcan be a permanent magnet motor. Typically, the rotor assembliesshown in the figures belong to such a permanent magnet motor (PMM). However, alternate embodiments may include an electric motor of any conventional type, i.e. an induction motor or a hybrid PMM containing elements of both permanent magnet and induction motors. The rotor assemblyof the PMM utilizes permanent magnets to generate the electromagnetic field, compared to induction motors where the magnetic field is generated by inducing a current in rotor interconnected bars made from copper.

A rotor assemblyembodiment can comprise a single drive shaft, a plurality of magnetic rotor modules, and a plurality of rotor bearing assemblies(e.g. typically radial hydrodynamic rotor bearing assemblies). Typically, all rotor modulesand/or all rotor bearing assembliesof a rotor assemblycan be substantially identical. A rotor bearing assemblycan be disposed between adjacent rotor modules. In some embodiments, the rotor assemblycan also include a pre-loading mechanism(as shown infor example), which can provide thermal expansion compensation for the rotor assembly. In the embodiment shown in, the pre-loading mechanismis disposed at the non-drive end (e.g. the motor base) of the rotor assembly, and it can be configured to act against the gravitational loadcreated by all the rotor modulesand journal rotor bearing assembliesinstalled on the shaft(as well as addressing differential thermal expansion, for example). Alternatively, or in conjunction, the pre-loading mechanismcan be positioned at the drive end (e.g. the motor head) of the shaft, according to other embodiments and/or distributed throughout the assembly (e.g. with springs and/or snap rings at various locations along the length).

illustrate schematically alternate stacking embodiment options for components of a rotor assembly. In the embodiment of, a journal sleeveof a rotor bearing assemblyis installed between each adjacent pair of rotor modules. The journal sleevemay be installed directly onto the drive shaft(e.g. concentric with the drive shaft) and may axially contact any adjacent rotor modules(which are also concentrically disposed on the drive shaft). This method of stacking the rotor modulesand journal sleevesonto the shaftmay have all rotor modulecomponents compressed between two adjacent journal sleeveslocated on both sides of the rotor module. A thrust washermay be trapped between the bearing and the rotor module.

An alternate stacking method is shown in. For example, the cage rings, rotor bars, and the thrust washerscan be disconnected from (e.g. moved out of) the axial stack of supporting components of the rotor assembly. Each rotor module(e.g. comprised here with respect to axial force transmission of only the lamination stackand the end laminations, both made from steel) can be spaced by a steel support sleeve(as will be discussed in more detail below with respect to specific embodiments). While the support sleevemay be steel in some embodiments, in other embodiments, the support sleeve can be formed of other materials with CTE similar to that of the lamination stack, end laminations, and/or drive shaft. In embodiments, the bearing assembly can be disposed on the support sleeve, as discussed in more detail below. In some embodiments, the thrust washersmay be connected to the support sleeveto prevent them moving axially as shown in later embodiments.

The thrust washer does not necessarily have to be a separate component. In some embodiments, the thrust washer can be absent, and instead the end face of the rotor module, case ring, bearing spacer, or any other suitable element may have a face that acts as the face of the thrust washer. This end face may have any of the features (e.g., concavities, grooves, etc.) discussed herein with respect to the thrust washer.

depicts a longitudinal cross-section of an exemplary rotor assemblyembodiment, illustrating the exemplary rotor assemblyembodiment in greater detail, showing the overall rotor assemblyconstruction.,, andillustrate in more detail portions of the rotor assemblyof. For example,illustrates an exemplary rotor module, illustrating interaction with other components based on the proposed stacking method shown in.focuses on the proposed exemplary stacking method (e.g. using the support sleeve) which can be used between any two adjacent (e.g. magnetic) rotor moduleson the shaft.focuses on the exemplary retention and stacking method at the drive end (e.g. at the motor head) of the shaft.

The magnetic rotor moduleshown inmay include the lamination stack, the end laminations, the plurality of cage bars, and the plurality of cage rings. The lamination stack, plurality of cage barsas a whole, and each cage ringmay be concentrically disposed about the drive shaft. The lamination stackcan be made from a plurality of stamped thin sheets of electrical steel, which may be assembled together by bonding, by clinching, or by use of interference fit, etc. to another component (e.g. the drive shaft). In embodiments, the lamination stackcan include the desired geometry (e.g. pockets) to accept a plurality of permanent magnets, which may be made from rare earth such as Samarium Cobalt or Neodymium Iron Boron. The end laminationscan be disposed on each end of the lamination stack, for example to trap the magnets in the lamination stack pockets. The end laminationsmay be thicker steel than the lamination stack. The plurality of electrically conductive (e.g. copper) cage barscan be installed inside a plurality of longitudinally extending holes in the lamination stack(e.g. with the longitudinally extending holes disposed around the drive shaft), and may protrude from each end of the lamination stack. The electrically conductive (e.g. brass) cage rings, can be disposed on each end of the lamination stack, for example connected to the plurality of cage barsby interference fit or soldering to create a squirrel cage (e.g. similar to an induction motor). In other embodiments, the permanent magnetscan be omitted, making the rotor modulea standard induction rotor module.

shows a rotor bearing assembly, which may support the rotor at predefined axial positions to maintain radial alignment of the shaftduring the motor operation. The rotor bearing assemblycan comprise an inner journal sleeveand an outer bushing assembly, for example with the bushingconfigured to be disposed concentrically about the journal sleeve. In some embodiments, the inner journal sleevecan be secured to the shaftthrough a support sleeve(which typically may be steel or some other material with CTE similar to the lamination stack, the end laminations, and/or the drive shaft). For example, anti-rotation elements(e.g. helical springs or elastomeric rings) may rotationally fix the journal sleeveto the support sleeve, so that the journal sleeverotates with the support sleeve(and thereby the shaft). The support sleevemay be concentrically disposed about the drive shaft(e.g. between two adjacent rotor modules) and can be configured to rotate with the drive shaftwhile being able to slide axially with respect to the shaft. For example, the support sleevecan be keyed to the shaft(e.g. with one or more keys in corresponding longitudinally extending key slots in the shaft) so as to be allowed to slide along the shaftaxially while rotating with the shaft. In other embodiments the inner journal sleevemay be directly mounted and keyed to the shaft. A thrust washermay be trapped between the bearing and the rotor module.

The anti-rotation element'ssecondary function can be to axially center the inner journal sleevebetween the two adjacent rotor modules. The outer bushing assemblymay be concentrically located around the journal sleeveand may engage into the stator lamination. The engagement into the stator lamination may ensure that the bushing assemblydoes not spin during operation. Rather, the bushing assemblycan provide a stationary surface for journal sleeveto rotate in, which may allow it to produce hydrodynamic lubricating film. The support sleevealso can space each rotor moduleevenly on the shaft. The support sleeveinis configured to provide axial support to the lamination stackof adjacent rotor modulesthrough the end laminations, for example touching/abutting the adjacent end laminationon both adjacent magnetic rotor modules(e.g. on either side) at the contact surface. The adjacent cage ringsof the magnetic rotor modulesofmay be concentrically disposed around the steel support sleeve, having a radial clearance round the steel support sleeve. In this embodiment, the thrust washerscan be mounted onto the support sleeve, on both ends (e.g. with the rotor bearing assemblydisposed therebetween). For example, a thrust washermay be disposed between the rotor bearing assemblyand the adjacent rotor module. In embodiments, the thrust washerscan be mounted on the support sleeveby an interference fit method, although other methods of assembly can be implemented, such as anti-rotation keys/tabs and axial retaining shoulders/spigots. The design of the support sleevecan create defined axial clearancesandbetween the thrust washerand the rotor bearing assemblyand the cage ringof the magnetic rotor module, respectively. Clearancemay allow the thrust washersto not contact the bushing assemblyduring the motor operation (e.g. when the rotor assemblyis rotating inside the stator assembly). In other embodiments this gap may close and result in thrust force on the thrust washer.

The end arrangement depicted incan comprise a snap ringlocated in a corresponding groove (e.g. in the exterior of the shaft) at a predefined distance from the shaft end on the shaft, and a spacer ring(e.g. axially abutting the snap ring) which may be designed to correspond to the profile of the cage ringof the magnetic rotor module. The spacer ringcan be installed concentrically with the steel supportwith a radial clearancearound the steel support sleeve. The spacer ringcan touch/abut the support sleeveaxially at the contact area. Other embodiments may include a spring loading mechanism. Clearancemay allow the thrust washersto not contact the bushing assemblyduring the motor operation (e.g. when the rotor assemblyis rotating inside the stator assembly). In other embodiments this gap may close and result in thrust force on the thrust washer.

An exemplary outer bushing assembly, of the sort which might be used in an ESP motor for use downhole in a well as part of an ESP, is shown in. The outer bushing assemblycan comprise a bushing, one or more anti-rotation tabs, one or more biasing elements, and one or two retention rings. Althoughillustrates an exemplary embodiment having a plurality of anti-rotation tabs, with a corresponding plurality of biasing elements, the disclosure is not so limited. The bushingmay comprise one or more spring recessextending inward from an outer surface of the bushing, one or more axial sloton the outer surface of the bushing(e.g. extending axially, such as approximately parallel to the longitudinal axis of the bushing), and one or more slotsof the outer surface having a smaller outer diameter than a main body portion of the bushing(e.g. an inwardly/inset stepped portion). Each axial slotmay intersect the corresponding spring recessand axial face. The bushingmay have additional circular cut outs (e.g. channels) to allow oil to bypass the bearing. In embodiments, the bushingis substantially cylindrical about a longitudinal axis.

illustrates a longitudinal cross-section of an exemplary rotor assemblyof an alternate embodiment (e.g. configured for intermediate pre-compression), showing the overall rotor assemblyconstruction. A detailed view of a portion ofis further illustrated in, which focuses on the proposed stacking system ofbetween any two adjacent magnetic rotor moduleson the shaft(e.g. with bearing assemblydisposed therebetween on a support sleeve).

Referring to, a rotor bearing assemblyfor an ESP may include a drive shaft; a journal sleeveconcentrically disposed about and rotationally fixed to the drive shaft; a bushingconcentrically disposed about and configured to rotate with respect to the journal sleeve; and a thrust washerencircling the drive shaft. In some embodiments, concavitiesmay be formed in an axial faceof the bushingand/or an axial faceof the thrust washer. The axial faceof the bushingmay be disposed proximate to the axial faceof the thrust washer, with the gap or open space of the concavitiesdisposed therebetween. The concavitiesmay be configured to influence flow of lubrication fluid (e.g., oil) between the bushingand the thrust washerto create a hydrodynamic force against the bushingand the thrust washerwhen the drive shaftrotates. The hydrodynamic force may repel the bushingfrom the washer(e.g., the bushingmay experience force in an axial direction away from the washerand the washermay experience force in an axial direction away from the bushing). This may prevent the bushingand the washerfrom touching, and thus wear on the washermay be greatly reduced or eliminated. Essentially, the washermay ride on an oil film configured to act as a hydrodynamic bearing.

Groovesmay be formed in the axial faceof the bushing or the axial faceof the thrust washer. The groovesmay be on whichever surface the concavitiesare on. The groovesmay be configured to guide lubrication fluid radially outward particularly when the clearanceas shown inis closed when thrust washeris in contact with bushing. Centrifugal force may carry the fluid through the groovesfrom an area proximate the inner circumferential surfaceof the bushingto the outer circumferential surfaceof the bushingor from the inner circumferential surfaceof the thrust washerto the outer circumferential surfaceof the thrust washer. The axial faceof the bushingmay be approximately parallel to the axial faceof the thrust washer. The concavitiesmay include a converging wedge shape. The converging wedge shape may act as a ramp for the fluid so that the fluid will be forced into a small space between the bushingand the washerand thus cause a pressure increase and thus force. This hydrodynamic force may prevent contact between the bushingand the thrust washerwhen the drive shaftrotates. The groovesmay extend deeper than the concavities. In some embodiments, groovesmay be formed in the concavities. In some embodiments, groovesmay be disposed between the concavities. In some embodiments, groovesmay be formed both in the concavitiesand between the concavities.

In the embodiment of, the thrust washer is disposed on a thrust washer support(e.g. with the thrust washer supportconcentrically disposed on the shaftand the thrust washerconcentrically disposed (e.g. seated) on the thrust washer support). Axially, the thrust washer supportcan be disposed between the end laminationand the support sleeve. The thrust washer supportscan contact the steel support sleeveat contact areas each side of the steel support sleeve. The thrust washercan be disposed concentrically around the thrust washer support(e.g. with the thrust washer supportdisposed radially between the thrust washerand the drive shaft), and in some embodiments can be trapped between the steel support sleeveand a portion of the thrust washer support(e.g. as shown in), creating the axial clearancesand. Clearance(e.g. the bearing gap) can be configured with the goal of the thrust washersnot contacting the bearing bushing assemblyduring the motor operation (e.g. when rotor assemblyis rotating inside the stator assembly). In embodiments, the clearance(e.g. the module gap) can be configured to accommodate the differential thermal expansion of the cage ringsand cage barsin the axial direction with respect to the steel lamination stackof the magnetic rotor module.

In embodiments, the concavities may each comprise a shallow, converging wedge shape, for example in which the span of the concavity is significantly greater (e.g. for example 500-10,000; 500-5,000, 5,000-10,000; 1,000-10,000; 1,000-5,000; 3,000-10,000; 3,000-5,000; 5,000-7,000; 7,000-10,000, 500-1,000; 500-3,000; 1,000-3,000, or 3,000-10,000) than its depth and/or with the depth narrowing towards one or more edges. In some embodiments, the concavities may have a curvature/arc with a radius which is orders of magnitude greater than its depth (e.g., arc multiple), for example 500-10,000; 500-5,000, 5,000-10,000; 1,000-10,000; 1,000-5,000; 3,000-10,000; 3,000-5,000; 5,000-7,000; 7,000-10,000, 500-1,000; 500-3,000; 1,000-3,000, or 3,000-10,000 times its depth. For example, the radius of curvature for the concavities may be greater than or approximately 200 mm (e.g. 100-1000 mm) while the depth of the concavities may be approximately 0.01-0.5 mm, 0.05-0.4 mm, 0.05-0.25 mm, 0.05-0.1 mm, 0.1-0.5 mm, or 0.1-0.25 mm.

Referring to, the concavitymay have an arcuate profile in which an angle between the arcuate profile and the axial faceof the bushing(or the axial faceof the thrust washer) decreases moving towards the center of the concavity. The shape may a segment of a circle, a segment of an oval, a parabola, or an irregular shape, and/or may form a scallop. In some embodiments, the profile is symmetrical, which may have the advantage of allowing the bushingto rotate clockwise or counterclockwise with no change in the hydrodynamic effect of the concavities. In some embodiments, the profile may be asymmetrical (for example, similar to half of the concavity shown in). The groove, if formed in the concavity, may be formed at the center of the arcuate profile or offset with respect to the center of the arcuate profile. In, the solid line represents the profile of the concavitywith the optional grooveand the dashed lineA represents the profile of the concavitywithout the optional groove.

Referring to, the concavity may alternatively have a V-shaped profile. That is, a depth of the concavitymay increase or decrease in a linear fashion moving from one side of the concavityto the other, or the depth of the concavitymay decrease moving from a center of the concavityto an end of the concavity. For example, the concavities may each comprise one or more chamfer, having a very shallow angle (e.g. 0.005-0.05 degrees, 0.01-5 degrees, 0.01-0.1 degrees, 0.01-2.5 degrees, 0.1-2.5 degrees, 0.01-1 degrees, 0.1-10 degrees, or 0.05-0.1 degrees). The dashed line shows an embodiment where in the absence of the groovethe profile levels out towards the center, but in other embodiments the profile comes together at an angle (e.g., sharp or rounded). In some embodiments, the leveled-out portion could be relatively longer or shorter than what is shown in. The groovemay be formed at the center of the V-shaped profile. The grooveis shown inas having an arcuate profile but in other embodiments, the groovecould have a square, triangular, or irregularly shaped profile. An exemplary rectangular embodiment is denoted with reference numeralA.

Referring to, the concavitymay have an actuate profile in which an angle between the arcuate profile and the axial faceof the bushing(or the axial faceof the thrust washer) increases moving towards a center of the concavity. In embodiments, such concavities may be similar in shape to the chamfer of, but with a radius of curvature (e.g. fillet radius) in place of a linear angled surface. The groovemay be formed at the center of the actuate profile, at another location within the arcuate profile, or be absent from the concavityaltogether. In the embodiment shown inwhere there is a groove, the groovemay start at or be disposed between inflection points of the curve defining the concavity. In embodiments where there is no groovein the concavity, the profile of the concavitymay have a flat portion (e.g., in the middle of the concavity) or may have a U-shaped curvature in the middle or at another location on the concavity.

In view of the various profiles shown in, it can be seen that fluid may enter the concavityfrom one direction, be drawn into the concavity, and then be expelled out of the concavity on the other side. When the fluid is expelled, it may be forced into a small gap between the bushingand the thrust washer(e.g. formed by a converging wedge portion of the concavity and/or narrowing of the depth of the concavity, for example with the volume of fluid being forced into a progressively shallower gap) and thus maintain separation of the thrust washerand the bushingwhile the shaftturns. That is, the fluid dynamics caused by the concavity may repel the bushingfrom the thrust washerso that they do not touch when the shaftrotates. The configuration/shape of the concavities may be selected to provide the hydrodynamic force for separating the busingand thrust washerdue to fluid dynamics, effectively providing a hydrodynamic bearing between the busingand the thrust washer. Although the exemplary embodiments ofshows that the concavityand the optionally the grooveare formed on the bushingand the thrust washeris flat, in some embodiments, the concavityand optionally the grooveare formed on the thrust washerand the bushingis flat. Regardless, the opening/gap formed by the concavitiesmay be disposed between the axial faces of the bushingand the thrust washer. In some embodiments, the width of the grooveis one quarter or less the width of the concavity. In some embodiments, the concavitiesare equally spaced around the bushingor the thrust washer(e.g., they are spaced apart by a constant interval). In some embodiments, the number of concavitiesis ten, but any number greater than one is within the scope of the present disclosure (e.g. 2-10, 3-10, 4-10, 6-10, 8-10, 4-8, or 6-8 concavities may be spaced around the bushingor thrust washer). In some embodiments, the number of groovesis eight to twelve, but any number greater than one is within the scope of the present disclosure. In some embodiments, the number of groovesmay equal the number of concavities(for example, with each concavityhaving a corresponding groovetherein).

It should be noted thatare not to scale, but purposefully exaggerate the depth of the concavity (e.g. with respect to the radius of curvature) for ease of viewing various elements thereof.

Referring again to, the concavitiesand the groovesmay be formed in the axial faceof the bushing. Channelsmay be formed in an outer circumferential surfaceof the bushingand/or extend from the axial faceof the bushingto another axial faceof the bushing. The channelsmay be approximately parallel to each other. The concavitiesand/or the groovesmay extend from the inner circumferential surfaceof the bushing towards the outer circumferential surfaceof the bushingsuch that the concavitiesand/or the groovesspan across the entire axial faceof the bushing. The concavitiesand/or the groovesmay have radial symmetry. In the embodiment of, the groovesmay be angularly aligned with the channelsand/or the concavitiesmay be angularly aligned with the channels. In the embodiment of, the groovesmay be angularly offset from the channelsand/or the concavitiesmay be angularly offset from the channels. In some embodiments, edges of the concavitiesdo not overlap with the channels. The location of the concavitiescan be arbitrarily selected to maximize the axial force.

In some embodiments, such as the embodiment of, additional groovesmay be disposed between the concavitieswhich may also have grooves. The groovesdisposed between the cavitiesmay be wider and/or deeper than the groovesdisposed in the concavities. Any suitable combination or arrangement of stand-alone concavities, stand-alone grooves, and/or groovesformed in concavitiesis within the scope of the present disclosure.

Referring to, the axial faceof the bushingmay be substantially flat (i.e., there may be no concavitiesnor grooveson the axial faceof the bushing) in some embodiments. In embodiments, the outer circumferential surfaceof the bushingmay also be unbroken (i.e., there may be no channelsformed in the outer circumferential surface). Instead, channelsmay be formed in an outer circumferential surfaceof the thrust washer(e.g., extending from the axial faceof the thrust washerto another axial faceof the thrust washer). The concavitiesand the groovesmay extend from an inner circumferential surfaceof the thrust washertowards an outer circumferential surfaceof the thrust washersuch that the concavitiesand the groovesspan across the entire axial surfaceof the thrust washer. Any configuration of concavities, groovesand/or channelsdisclosed herein as being applied to the bushingmay also be applied to the thrust washeror the end face of the rotor module, case ring, spacer ring, or any other suitable element.

Referring again to, the thrust washermay be concentrically disposed about the drive shaft. The journal sleevemay be disposed between the drive shaftand the bushing. An outer diameter of the thrust washermay be greater than or equal to an inner diameter of the bushing. In some embodiments, the outer diameter of the thrust washermay extend to be adjacent to at least half of the axial face of the bushing. In some embodiments, an outer diameter of the thrust washermay be approximately equal to an outer diameter of the bushingor may be greater than the outer diameter of the bushing. In some embodiments, the thrust washermay extend radially outward at least as far as the inner diameter of the bushingbut no more than the outer diameter of the bushing. There may be two thrust washers(i.e., a washerand another washer), and the bushingmay be disposed between the two thrust washers. The length of the bushingmay be approximately the same as the length of the inner journal sleeve. The bushingand/or the inner journal sleevemay be disposed entirely within a plane defined by an inner axial faceof the thrust washerand an inner axial faceof the other thrust washer. The axial faces of the inner journal sleevemay be proximate to the inner axial facesof the washerand may be coplanar with the axial facesof the bushing. The axial facesof the bushingmay be approximately parallel to the inner axial facesof the thrust washers. Based on this disclosure, persons of skill will understand various embodiments relating to concavitiesthat may be configured to influence flow of lubrication fluid (e.g., oil) between the bushingand the thrust washerto create (e.g. axial) hydrodynamic force against the bushingand the thrust washerwhen the drive shaftrotates, and this disclosure is not limited to the specific examples illustrated herein.

In typical ESP motor designs, the bearing assemblies can be allowed to slide within the stator bore. However, to do this they need to overcome friction. In permanent magnet motors, the side forces on the rotor can be especially high, which means the frictional slide forces can also be high. Such a slide force can react axially on to the thrust washer, and typically may be high enough (e.g. sufficiently radially outward) that the thrust washer will deform to form a dish shape. Excessive dishing can lead to contact of the thrust washer with other rotor assembly components and/or damage to the thrust washer and/or other rotor assembly components. In extreme cases, dishing may lead to failure of the thrust washer, another rotor assembly component, the rotor assembly as a whole, and/or the motor.

Additionally, axial forces can be generated on the thrust washer due to thermal growth, which may contribute to dishing of the thrust washer. In a typical thermal growth scenario (e.g. as discussed above), the bushing assembly can be initially fixed in position (e.g. axially), for example in the motor's stator inside the motor's housing. However, the rotating rotor assembly is typically free to move axially due to the low frictional coefficients of an operating fluid film bearing. For example, axial movement can be created by either the rotor assembly having a different temperature than the stator and/or housing, or by the rotor assembly materials having dissimilar thermal growth coefficients (e.g. CTE) to the stator and/or housing materials. In embodiments, the rotor assembly can be prevented from moving at the head end by a thrust bearing, which can result in thermal growth of the rotor assembly relative to the stator being directed to the base end of the motor (although in other embodiments the thrust bearing could be located at the base end of the motor and/or thermal growth could be towards the head end). As motors can be very long, this thermal growth can be substantial and can typically exceed the bearing gap (e.g. the gap between the thrust washer and the bearing assembly), resulting in contact between the thrust washer and the bearing assembly (e.g. its bushing). If the bearing assembly (e.g. bushing) does not slide, further thermal growth can lead to increasingly high axial forces on the axial faces of the thrust washers (which may cause dishing).

Thrust washers are typically constructed of polymeric material, for example having an elastic modulus that is significantly lower than the metal or ceramic materials from which the other components of the motor are typically constructed (and thus can be more susceptible to dishing and/or damage). The bearing assembly can also be subjected to a high radial load, for example caused by the gravitational weight of the rotor assembly along with the radial magnetic pull of the rotor modules (e.g. in a PMM rotor) (e.g. and hence the rotor assembly towards the stator.) As a consequence, the axial load required to slide the bearing can also be high (for example with the axial force given by the radial force multiplied by a friction coefficient), and by extension, the thrust washers can be required to carry a significant axial load. In embodiments, application of a high axial load (e.g. radially outward from the base of the thrust washer) to the thrust washer at a force radius well above an exemplary thrust support sleeve's outer diameter can cause the thrust washer to significantly dish (e.g. form a conical form), for example by up to 0.5 mm.

Additional axial forces on the thrust washer can be generated in rotor assembly embodiments using bearing assemblies and/or thrust washers forming axial concavities (e.g. similar to). For example, rotor assembly embodiments can include a set of hydrodynamic bearing features (e.g. concavities) on the axial end/face of the bearing assembly and/or thrust washer. These features typically operate with very narrow film thicknesses (e.g. approximately 20 μm) and/or can generate axial forces between the bearing assembly and the adjacent thrust washer. A significant dish of 0.5 mm could severely limit the effectiveness of these features. And even without these features, a significantly dish of the thrust washer could contact the flat axial end of the bearing assembly (e.g. bushing), which may result in significant stress to and/or cutting into the thrust washer. Over time this issue could lead to failure of the thrust washer, and additional loads could result in failed bearings.