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The clearance flow of pump-turbine has significant influence on hydraulic forces of the runner, which is related to safety of the unit. To clarify the influence factors, clearance flowrate and clearance hydraulic axial force of a prototype pump-turbine were analyzed by 3D CFD simulations. The results show that the rotational speed, and the smallest radial sizes of clearance inlet, outlet, and the seal ring sizes are the determinant factors for clearance leakage flowrate, while the rotational speed and the radial size at clearance inlet are the major factors for clearance axial force. The rotational speed of rotating surfaces mainly affects the strength of rotating shear flow, while geometric sizes mainly affect the hydraulic loss of leakage flow. By assuming that the clearance region as several ring pipes, we obtained the simplified calculation formulas for estimating clearance leakage flowrate and clearance axial force. The flowrate can be expressed as a function of the water head difference across the clearance region, the rotational speed, and the sizes of clearance inlet, outlet and sealing ring, while the clearance axial force is a function of the inlet pressure and the square of both radius and rotational speed. The formula calculations agree with the numerical simulations well. This paper can provide a reference for runner clearance size design.

This paper focuses on the effects of the off-design operation of CAES on the dynamic characteristics of the triple-gear-rotor system. A finite element model of the system is set up with unbalanced excitations, torque load excitations, and backlash which lead to variations of tooth contact status. An experiment is carried out to verify the accuracy of the mathematical model. The results show that when the system is subjected to large-scale torque load lifting at a high rotating speed, it has two stages of relatively strong periodicity when the torque load is light, and of chaotic when the torque load is heavy, with the transition between the two states being relatively quick and violent. The analysis of the three-dimensional acceleration spectrum and the meshing force shows that the variation in the meshing state and the fluctuation of the meshing force is the basic reasons for the variation in the system response with the torque load. In addition, the three rotors in the triple-gear-rotor system studied show a strong similarity in the meshing states and meshing force fluctuations, which result in the similarity in the dynamic responses of the three rotors.

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Abstract. The tooth surface friction effects and the resulting tooth surface contact temperature are important factors for the dynamic characteristics of a gear-rotor system in compressed air energy storage (CAES). Therefore, a 3∘ of freedom finite-element model of the system is set up in which the lubrication state of the gear pair, tooth surface friction, contact temperature of the tooth surface, backlash and unbalanced excitation are considered. The friction coefficient is calculated according to the variation of the lubrication state, and the tooth surface contact temperature is derived based on the friction coefficient. The tooth profile deformation caused by the change in the contact temperature is calculated, and the resulting effects on backlash and comprehensive meshing stiffness are considered. The influence of rotating speed, torque load and viscosity of lubricating oil on the system response is studied, and the variation of the friction coefficient, flash temperature of the tooth surface, pressure of the tooth surface and so on are discussed in detail. The results indicate that when the friction coefficient is derived according to the variation of the lubrication state, the variation of the contact temperature of the tooth surface with rotating speed is quite different from that calculated based on a friction coefficient which is set artificially. This leads to a new variation of the dynamic response of the gear-rotor system, and the method of stabilizing the operation of the system is put forward based on the optimization curve for the operation of the system. The results obtained in this paper will provide a reference for the study and design of a gear-rotor system in CAES.