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Magnetic Bearings': Under The Guidence of
Magnetic Bearings': Under The Guidence of
com
A SEMINAR ON
MAGNETIC BEARINGS
SUBMITTED BY:
DIGVIJAY ARUN SHELAR
T.E (MECHANICAL)
ROLL NO.:-T6039
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CERTIFICATE
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ACKNOWLEDGEMENT
I will fail in my duty if I Wont acknowledge a great sense of gratitude to our Head of
the Department Dr Vikram Singh.
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CONTENTS
CHAPTER TITLE PAGE
* List of figures 4
* List of tables 5
* Abstract 5
01 Introduction 6
02 History 7
03 Construction of Magnetic Bearings 10
04 Working of Magnetic Bearings 11
05 Types of Magnetic Bearings 12
06 Load 14
07 Speed 19
08 Losses 22
09 Advantages 23
10 Disadvantages 24
11 Application 24
12 Conclusion 24
13 Reference 25
LIST OF FIGURES
FIGURE DESCRIPTION PAGE
FIGURE 1 A Magnetic Bearing 6
FIGURE 2 Construction of Magnetic Bearings 10
FIGURE 3 Magnetic bearing working 11
FIGURE 4 Passive Magnetic Bearing 12
FIGURE 5 Active Magnetic Bearing 13
Basic set-up of an active magnetic bearing
FIGURE 6 14
carrying a rotor load
B-H Diagram, Hysteresis loop and
FIGURE 7 15
Saturation
Force on Magnet and Geometry of Radial
FIGURE 8 16
bearing
Centrifugal loads acting on the volume
FIGURE 9 20
element of a rotor
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LIST OF TABLES
TABLE DESCRIPTION PAGE
TABLE 1 Early U.S. Patents in AMB 9
Achievable circumferential
TABLE 2 speed for a full disc
21
ABSTRACT
A bearing is a machine element, which supports another moving machine element. It
permits relative motion between the contact surfaces of the members, while carrying
load.
Due to relative motion, friction occurs and rubbing surface wears rapidly. To prevent
this a lubricant may be used.
physical contact so that there is no wear. Is there a force, which can exerted even if
there is no contact between two-surfaces. Magnetic force allows such property and
thus the idea of magnetic bearing was visualized.
Already in 1842 Earnshaw had demonstrated that passive (permanent) could made but
it cannot stable in all spatial direction. For successful operation the unstable direction
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1. INTRODUCTION
A magnetic bearing is a
bearing which supports a load
using magnetic levitation.
Two sorts of instabilities are very typically present with magnetic bearings.
Firstly, attractive magnets give an unstable static force that decreases with greater
distance and increases at close distances. Secondly since magnetism is a conservative
force, in and of itself it gives little if any damping and oscillations may cause loss of
successful suspension if any driving forces are present, which they very typically are.
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control systems by using Halbach Arrays and simple closed loop coils. These systems
gain in simplicity, but are less advantageous when it comes to eddy current losses. For
rotating systems it is possible to use homopolar magnet designs instead of multipole
halbach structures, which reduces losses considerably.
2. HISTORY
The evolution of active magnetic bearings may be traced through the patents
issued in this field. The table below lists several early patents for active magnetic
bearings. Earlier patents for magnetic suspensions can be found but are excluded here
because they consist of assemblies of permanent magnets of problematic stability per
Earnshaw's Theorem.
Early active magnetic bearing patents were assigned to Jesse Beams at the
University of Virginia during World War II and are concerned with ultracentrifuges
for purification of the isotopes of various elements for the manufacture of the first
nuclear bombs, but the technology did not mature until the advances of solid-state
electronics and modern computer-based control technology with the work of
Haberrnann and Schweitzer. Extensive modern work in magnetic bearings has
continued at the University of Virginia in the Rotating Machinery and Controls
Industrial Research Program. The first international symposium for active magnetic
bearing technology was held in 1988 with the founding of the International Society of
Magnetic Bearings by Prof. Schweitzer (ETHZ), Prof. Allaire (University of
Virginia), and Prof. Okada (Ibarak:i University). In 1987 further improved AMB
designs were created in Australia by E.Croot (see reference below as well) but these
designs were not manufactured due to expensive costs of production. However, some
of those designs have since been used by Japanese electronics companies, they remain
a specialty item: where extremely high RPM is required.
Since then there have been nine succeeding symposia. Kasarda reviews the
history of AMB in depth. She notes that the first commercial application of AMBs
was with turbo machinery. The AMB allowed the elimination of oil reservoirs on
compressors for the NOVA Gas Transmission Ltd. (NGTL) gas pipelines in Alberta,
Canada. This reduced the fire hazard allowing a substantial reduction in insurance
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costs. The success of these magnetic bearing installations led NGTL to pioneer the
research and development of a digital magnetic bearing control system as a
replacement for the analog control systems supplied by the American company
Magnetic Bearings Inc. (MBI). In 1992, NGTLs magnetic bearing research group
formed the company Revolve Technologies Inc. to commercialize the digital
magnetic bearing technology. This firm was later purchased by SKF of Sweden. The
French company S2M, founded in 1976, was the first to commercially market
AMBs. Extensive research on magnetic bearings continues at the University of
Virginia in the Rotating Machinery and Controls Industrial Research Program.
Starting from 1996 the Dutch oil and gas company NAM installed over a period of 10
years 20 large E-motor driven (with variable speed drive) gas compressors of 23 MW
fully equipped with AMBs on both the E-motor and the compressor. These
compressors are used in the Groningen gas field to deplete the remaining gas from
this large gas field and to increase the field capacity. The motor - compressor design
is done by Siemens and the AMB are delivered by Waukesha (owned by Dover).
(Originally these bearings were designed by Glacier, this company is later on taken
over by Federal Mogul and now part of Waukesha)
By using AMB's and a direct drive between motor and compressor (so no the gearbox
in between) and applying dry gas seals a full so called dry-dry system (=fully oil free)
has been installed. A few of the main advantages by applying AMB's in the driver as
well as in the compressor (compared to the traditional configuration with a gearbox,
plain bearings and a gasturbine-driver) is a relative simple system with a very wide
operating envelope, high efficiencies (particularly at partial load) and also, as done in
the Groningen field, to install the full installation outdoors (no large compressor
building needed).
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The active magnetic bearing comprises two parts the mechanical and
electronic. The mechanical parts are similar to electrical motor with a rotor and stator.
A core on the stator is wound with the coil through which the electric current that
induces the magnetic field.
This generates the force that supports the shaft. The electronic part of the
active magnetic even slightest deviation from the desire position will trigger in
electronic system to adjust the current flowing through the electromagnets that
determines the strength of the magnetic.
The current are adjust so that desired rotor position is maintained even under
varying load conditions. The magnetic field is dependent on the current flowing
through the coils. The larger the current, the stronger the magnetic field and the load it
is able to support. The load an active magnetic bearing is able to support is very high.
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electromagnets. A controller works with the position sensors which provide feedback
to control the position of the rotor within the gap.
The position sensor registers a change in position of the shaft (rotor). This
change in position is communicated back to the processor where the signal is
processed and the controller decides what the necessary response should be, then
initiates a response to the amplifier. This response should then increase the magnetic
force in the corresponding electromagnet in order to bring the shaft back to center. In
a typical system, the radial clearance can range from 0.5 to 1 mm.
This process repeats itself over and over again. For most applications, the
sample rate is 10,000 times per second, or 10 kHz. The sample rate is high because
the loop is inherently unstable. As the rotor gets closer to the magnet, the force
increases. The system needs to continuously adjust the magnetic strength coming
from the electromagnets in order to hold the rotor in the desired position.
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Two basic types of magnetic bearing technologies are present and in use today:
Active and Passive.
Passive bearings are similar to mechanical bearings in that no active control necessary
for operation.
These forces act to cause the rotor to remain in the desired position. This type of
bearing system is suited for very lightly loaded systems, or ones with any significant
load in only one axis and very 1in1ited response necessary from the remaining axes.
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AMBs are a very promising technology and are now being employed for a
variety of industrial rotating machinery applications. These non-contacting bearings
use magnetic forces to firmly hold the rotor and maintain separation between it and
machines stationary components
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6. LOAD
The term load already, as simple as it seems, touches upon basic properties of
magnetic bearings. The load capacity depends on the arrangement and geometry of
the electromagnets, the magnetic properties of the material, of the power electronics,
and of the control laws - a set-up with main elements is shown in Figure 6.
Furthermore, carrying a load is not just a static behaviour usually it has strong
dynamic requirements. Subsequently, first the static properties of an AMB and the
generation of magnetic forces will be briefly outlined.
..... (1)
This means that the magnitude of the magnetic field in Figure 7a is H = i/2 nr. The
magnetic field is independent of the material around the conductor. If the integration
path encompasses several current loops, as is the case with the air coil in Figure 7b,
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visualized by magnetic field lines. Each field line is always closed. The density of
these lines represents the flux density B. The magnetic field H is linked to the flux
B = 0 r H
..(2)
-
Here, 0 = 4 10 7 Vs/Am stands for the magnetic field constant of the vacuum, and
r is the relative permeability depending on the medium the magnetic field acts upon.
r equals 1 in a vacuum.
flux density B does not increase much more beyond Bsat even when the magnetic
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field H and the generating current i is further increased. The current, corresponding to
For deriving the force in an AMB let us consider Figure 8. It shows a single two-pole
magnetic bearing element, as part of a complete bearing ring of Figure 6, indicating
the path of the magnetic flux ()
The usual assumptions hold, i.e. that the iron part lfe in the magnetic loop is
neglected, that the relations for static fields hold as the frequencies for the alternating
current are not too high, that the flux CD is homogeneous in the iron core and the
air gap, and that the cross- sectional areas are the same Afe = Aa. Then, the
induction B = Ba is the same along the magnetic loop. It is proportional to the current
i until the saturation induction Bsat is reached. A further increase of the current
beyond isat does not increase the induction much further beyond Bsat. The force f
exerted can be derived by considering the energy Wa stored in the air gap between
rotor and magnet
_ ......(3)
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The force acting on the ferromagnetic body is generated by a charge of the field
energy in the air gap, as function of the body position. For small displacements ds the
magnetic flux BaAa remains constant. When the air gap increases by ds the Volume
Va = 2sAa increases, and the energy Wa in the field increases by dW. This energy
(4)
In the range, where the induction Ba is proportional to the magnetic field Ha and the
currrent i, i.e. below saturation, the force as a function of coil current i and air gap s
for the arrangement of fig 8(a) is
(5)
Equation (1) shows the quadratic dependence of the force on the current and
the inversely quadratic dependence on the air gap. In the case of a real radial bearing
magnet, the force of both magnetic poles affect the rotor with an angle on
(figure 4b), as opposed to the model of the U-shaped magnet of Figure 4a. In the case
of a radial bearing with four pole pairs equals for instance 22.5 , with cos () = 0.92.
(6)
The force increases with the maximum admissible magnetomotive force nimax,
i.e. the product of the maximum current imax and winding number n. This value is
subject to design limitations. As a consequence, the maximum value for the force
depends on the winding cross section, the mean winding length and the possible heat
dissipation, or the available amount of cooling, respectively. Therefore, one
lin1itation for a high static load is the adequate dissipation of the heat generated by
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the coil current due to the Ohm resistance of the windings. This soft limitation can
be overcome by a suitable design.
Assuming that this problem has been adequately considered, then the current
imax will eventually reach a value where the flux generated will cause saturation,
and then imax =iSat;, and the carrying force has reached its maximal value fmax. Any
overload beyond that physically motivated hard limitation of the carrying force
fmax will cause the rotor to break away from its centre position and touch down on its
retainer bearings.
carrying force is related to the size of the bearing, or more precisely, to the projection
of the bearing area db (Figure 5), leading to the specific carrying force. Let us assume
that the pole shoe Width p equals the leg Width c. On the bearing diameter d we have
one eighth of the circumference per pole at our disposal. Using half of that for the
pole shoe Widthp, the pole shoe surface is given by
Aa = d 0.5 b
.(7)
With actually available Si-alloyed transformer sheets, which are used for hearing
magnets, a maximum flux density Bmax ~ 1.5 Tesla < Bsat is recommended.
.(8)
Inserting this value for Ba in equation (3), and considering that the forces of both
poles do not act perpendicularly, but at an angle of 11/8, we obtain with Aa from
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equations (7) and (3) the specific carrying force Based on this result, an estimation of
the carrying force fmax can be determined from Figure 6. The specific load of
32 N/cm2 (or 0.32 MPa) is considerably lower than that for oil lubricated bearings,
7. SPEED
realized in physical experiments for testing the material strength of small steel balls
requirements for power generation and adequate heat dissipation if the rotor runs in
vacuum.
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Figure 10 : tangential stress distributions for a disc with and without hole in the centre
The tangential stress, as the most critical one, is shown in Figure 10. Highest stress
values occur at the inner boundaries of a rotor disc. As the rotor partially consists of
laminated soft iron sheets, which have to be shrink-fit to the rotor shaft, the tangential
stress at the inner rim is still further increased. Numerous lab experiments have
been performed. Rotor speeds of up to 340 m/s in the bearing area can be reached
with iron sheets from amorphous metal (metallic glass), having good magnetic and
mechanical properties [4]. The theoretical value for the achievable speed Vmax lies
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is the density of the material), and the according values for some materials are given
in Table
In industrial applications the speed usually is limited not by the bearings themselves,
but by the mechanical design of the motor drive. Figure 12 shows the example of a
broken rotor. Figure 13 gives a survey on various AMB applications that
have been realized conventionally. For high speeds permanent magnet synchronous
drives are used where the rotor is wound with carbon fibers, allowing speeds of about
280 m/s.
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operational rotation speed. In classical rotor dynamics this task is difficult to achieve.
8. LOSSES
With contact-free rotors there is no friction in the magnetic bearings. The
operation of active magnetic bearings causes much less losses than operating
conventional ball or journal bearings, but, nevertheless, the losses have to be taken
into account, and sometimes they lead to lin1itations. Losses can be grouped into
losses arising in the stationary parts, in the rotor itself, and losses related to the design
of the control.
Losses in the stationary parts of the bearing come mainly from copper losses
in the windings of the stator and from losses in the amplifiers. The copper losses are a
heat source, and, if no sufficient cooling is provided, can limit the control current and
hence the maximal achievable carrying force, as described in section 2.
Losses in the rotor part are more complex and lead to more severe lin1itations. These
losses comprise iron losses caused by hysteresis and eddy currents, and air drag
losses. The losses heat up the rotor, cause a breaking torque on the rotor, and have to
be compensated by the drive power of the motor.
The iron losses depend on the rotor speed, the material used for the bearing bushes,
and the distribution of flux density B over the circumference of the bushes. The
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The iron losses in the rotor can limit operations, as, in particular in vacuum
applications; it can be difficult to dissipate the generated heat.
Wh = Vfe ABH.
Here, ABH stands for the area of the hysteresis loop, and Vfe for the volume of the
iron.
The area of the hysteresis loop depends on the material of the magnet and on the
amplitude of the flux density variation. For iron and flux densities between 0.2 and
1.5 Tesla the classical relation
9. ADVANTAGES
Contact-free
No lubricant
No maintenance
Tolerable against heat, cold, vacuum, chemicals
Low losses
Capacity to operate within a wide temperature range
Environmentally friendly workplace
Very high rotational speeds
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10. DISADVANTAGES
1. Larger Bearings.
11. APPLICATIONS
Magnetic bearing advantages include very low and predictable friction, ability
to run without lubrication and in a vacuum. Magnetic bearings are increasingly used
in industrial machines such as compressors, turbines, pumps, motors and generators.
Magnetic bearings are commonly used in watt-hour meters by electric utilities to
measure home power consumption. Magnetic bearings are also used in high-precision
instruments and to support equipment in a vacuum, for example in flywheel energy
storage systems. A flywheel in a vacuum has very low windage losses, but
conventional bearings usually fail quickly in a vacuum due to poor lubrication.
Magnetic bearings are also used to support maglev trains in order to get low noise and
smooth ride by eliminating physical contact surfaces.
A new application of magnetic bearings is their use in artificial hearts. The use of
magnetic suspension in ventricular assist devices was pioneered by Prof. Paul Allaire
and Prof. Houston Wood at the University of Virginia culminating in the first
magnetically suspended ventricular assist centrifugal pump (VAD) in 1999.
12. CONCLUSION
Limitations in Active Magnetic Bearings arise from two reasons: the state of the
actual technology in design and material, and from basic physical relations. The paper
has given a survey on such limitations, giving a brief theoretical background, showing
examples and pointing to actual data. Further research appears to be indicated in
developing insight and outlook at the boundaries of the field of magnetic bearings. A
systematic comparison of AMB performance with that of classical bearings needs
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consistent data. The joint operation of a magnetic bearing with a roller bearing under
emergency situations, in load sharing or in touch down contacts, needs further
experiments and design efforts. The operation at supercritical speeds, passing many
elastic rotor and structure frequencies needs more research on the control design. The
advanced information processing within the bearing system, extending the smartness
of the rotating machinery will be a promising research area.
13. REFRENCES
1. Application and Research Topics for Active Magnetic Bearings;
a Materials and Devices Research Center, HDD Program Team, Samsung Advanced
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5. Optimal control of the magnetic bearings for a flywheel energy storage system
7. Wikipedia
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