FRICTIONLESS COMPRESSOR 2018-2019

FRICTIONLESS COMPRESSOR

Abstract
Magnetic bearing centrifugal compressor eliminates the efficiency-robbing friction inherent
in traditional centrifugal chiller. Integrated VFD optimized part load efficiency, a key
performance feature since most chillers operate at part load 99% of their life. Sustainable
performance assured for the operating life of the chiller.
The positive pressure, oil-free design eliminates performance degradation due to non-
condensable and oil contamination of the refrigerant. Easy integration with our open choices
feature using BACnet, Lon Works or Modbus communications without an expensive
panel.R-134a refrigerant has no depletion potential and no phase=out schedule. Reduced
maintenance costs due to elimination of oil.
Oil system, purge system, and shaft seals found in order technology chillers. Small unit
footprint helps the magnitude chiller fit in place where space is limited, making it ideal for
retrofit projects. Unmatched unloading with the integrated VFDs since the on-board digital
control reduces compressor speed to match the load. Low inrush current at start-up is ideal
for operation with backup or emergency power systems. Touch screen operator panel is
graphically intuitive and easy o use for enhanced operator productivity. Important status and
control information is available at a glance or a touch.

Introduction:
Traditional centrifugal compressors use roller bearings and hydrodynamic bearings, both of
which consume power and require oil and lubrication system. This can be overcome by the
introduction of new compressor technology called frictionless compressor technology.
The frictionless compressor technology is compressor with the application of magnetic
bearings and permanent magnet synchronous motor. In frictionless compressor instead of
roller bearings and hydrodynamic bearings, magnetic bearings are used. Magnetic bearings
consume less power and there is no need for oil and lubrication systems. Permanent magnet
brushless synchronous motor has permanent magnet instead of copper windings.
After 10 years of development, magnetic bearing compressors offer economic, energy, and
environmental benefits. Chief among them are increased energy efficiency, the elimination of
oil and oil management and considerable less weight, noise, and vibration. This is initial mid-
range package offers centrifugal compression efficiencies previously reserved for large
tonnage systems only.
This compressor has high reliability, efficiency, less maintenance cost and staff. With the
help of digital control system the controlling and monitoring of work is very easy. The
frictionless compressor technology makes new revolutions in the field of air conditioning,
refrigeration etc. Frictionless Compressor Technology is one of the fast growing Technology
in the engineering field.
FRICTIONLESS COMPRESSOR 2018-2019

The Frictionless compressor is also the world’s first totally Oil-Free compressor specifically
designed for the Heating, Ventilation, Air Conditioning and Refrigeration (HVACR)
industry. The variable-speed centrifugal compression and digital electronic technologies
enables the frictionless compressors (nominal 60-150 ton capacity range) to achieve the
highest compressor efficiencies, cost effectively, for middle-market, water-cooled,
evaporative cooled and air-cooled HVACR applications. The well-proven energy
performance advantages of variable-speed centrifugal
Compressors are now brought to mainstream middle-market applications through the use of
High-speed, two- stage centrifugal compression with integral variable-speed drive.
Compressor speed is reduced as the condensing temperature and/or heat load reduces,
Optimizing energy performance through the entire operating range from 100% to 20% or
below of rated capacity.
Operations to near zero loads are achievable via an optional, digitally controlled, load
balancing valve. Centrifugal compressors tend to be more efficient than screw or scroll
Compressors, and take advantage of speed control more effectively, but they are usually only
available in larger sizes. By using the smaller shaft, they are able to take advantage of the
centrifugal compressor technology in a smaller size than is normally available.

The bearing
Traditional centrifugal bearing uses roller bearings and Hydro-dynamic bearings, both of
which requires oil and lubrication system .Recently, ceramic roller bearing , which avoid
issues related to oil and reduce power consumption , were introduced to the HVAC Industry
The lubrication of these bearing is provided by the refrigerant itself
Magnetic bearing technology is significantly different. A digitally controlled magnetic-
bearing system; consist of permanent magnet and electro-magnets, replaces conventional
lubricated bearings. The frictionless compressor shaft is the compressors only moving
component. It rotates on levitated magnetic cushion .Magnetic bearings—Two radial and one
axial-holds the shaft in position.
FRICTIONLESS COMPRESSOR 2018-2019

Y- Y-
axi Chann Channels
els axis 2- 4
s Channel
pos 0-1 positi 3
itio on
n X-axis sens
X-axis
sen or
position position
sor sensor sensor
Impellers
Target Mot Sens Re Axial
sleeve Z-axis Sensor
sensor or orar bearing
Front position ring radial rin
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earing
When the magnetic bearing energized,beari
ngthe motor
and the impellor which are keyed directly to
the magnetic shaft levitate. Permanent magnetic bearings do the primary work, while digitally
controlled electromagnets provide the fine positioning. Four positioning signals per bearing
holds the levitated assembly to a tolerance of 0.00002 in. As levitated assembly moves from
the center point, to correct the position .These adjustments occur 6 million times a minute the
software has been designed to automatically compensate for any of the balance condition in
the levitated assembly
When the compressor is not running, the shaft assembly rests on graphite-lined, radially
located touchdown bearings. The magnetic bearings normally position the rotor in the proper
location, preventing contact between the rotor and other metallic surfaces. If the magnetic
bearings fail, the touchdown bearings (also known as backup bearings) are used to prevent a
compressor failure. The compressor uses capacitors to smooth ripples in the DC link in the
motor drive. Instantaneously after a power failure, the motor becomes a “generator,” using its
angular momentum to create electricity (sometimes known as back EMF) and keeping the
capacitors charged during the brief coast down period.
The capacitors, in turn, provide enough power to maintain levitation during coast down;
allowing the motor rotor to stop and DE levitate. This feature allows the compressor to see a
power outage as a normal shutdown.In case of power failure, within 0.5 micro-seconds, the
motor acts as a generator for the magnetic bearings and the compressor comes gradually to a
complete stop; the rotor de-levitates normally unto backup bearings.

What is magnetic bearing

A magnetic bearing is a type of bearing that supports a load using magnetic levitation.
Magnetic bearings support moving parts without physical contact. For instance, they are able
to levitate a rotating shaft and permit relative motion with very low friction and no
mechanical wear. Magnetic bearings support the highest speeds of all kinds of bearing and
have no maximum relative speed.
Active bearings have several advantages: they do not suffer from wear, have low friction, and
can often accommodate irregularities in the mass distribution automatically, allowing rotors
to spin around their center of mass with very low vibration.
Passive magnetic bearings use permanent magnets and, therefore, do not require any input
power but are difficult to design due to the limitations described by Earnshaw's theorem.
Techniques using diamagnetic materials are relatively undeveloped and strongly depend on
material characteristics. As a result, most magnetic bearings are active magnetic bearings,
using electromagnets which require continuous power input and an active control system to
keep the load stable. In a combined design, permanent magnets are often used to carry the
static load and the active magnetic bearing is used when the levitated object deviates from its
FRICTIONLESS COMPRESSOR 2018-2019

optimum position. Magnetic bearings typically require a back-up bearing in the case of power
or control system failure.
Magnetic bearings are used in several industrial applications such as electrical power
generation, petroleum refinement, machine tool operation and natural gas handling. They are
also used in the Zippe-type centrifuge, for uranium enrichment and in turbomolecular
pumps, where oil-lubricated bearings would be a source of contamination.

Design

An active magnetic bearing works on the principle of electromagnetic suspension based on

the induction of in a rotating conductor. When an electrically conducting material is moving
in a magnetic field, a current will be generated in the material that counters the change in the
magnetic field (known as Lenz's Law). This generates a current that will result in a magnetic
field that is oriented opposite to the one from the magnet. The electrically conducting
material is thus acting as a magnetic mirror
The hardware consists of an electromagnet assembly, a set of power amplifiers which supply
current to the electromagnets, a controller, and gap sensors with associated electronics to
provide the feedback required to control the position of the rotor within the gap. The power
amplifier supplies equal bias current to two pairs of electromagnets on opposite sides of a
rotor. This constant tug-of-war is mediated by the controller, which offsets the bias current by
equal and opposite perturbations of current as the rotor deviates from its center position.
The gap sensors are usually inductive in nature and sense in a differential mode. The power
amplifiers in a modern commercial application are solid state devices which operate in
a pulse width modulation configuration. The controller is usually a microprocessor or digital
signal processor.
Two types of instabilities are typically present in magnetic bearings. Attractive magnets
produce an unstable static force that decreases with increasing distance and increases at
decreasing distances. This can cause the bearing to become unbalanced. Secondly, because
magnetism is a conservative force, it provides little damping; oscillations may cause loss of
successful suspension if any driving forces are present.
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THE MOTOR
Most hermetic compressor uses induction motors cooled by either liquid or suction-gas
refrigerant. Induction motors have copper windings that, when alternating current is run
through them, create the magnetic fields that cause the motor to turn. These copper windings are
bulky, adding size and weight to the motor
Two-pole, 60-Hz induction motors operate at approximately 3,600 rpm. A higher number of
revolutions per minute can be obtained by increasing the frequency. Compressors that require
Higher shaft speeds tends to use gears . While gears are a proven technology , they create
noise and vibration ,consume power ,and required lubrication
The magnetic bearing compressor features a synchronous permanent magnet brushless DC
motor with a completely integrated variable frequency drive .The stator windings found on
conventional induction motors are replaced with a permanent magnet rotor .Alternating
current from the inverter energizes the armature windings .The stator and the rotor change
places.
The motor and key electronic components are internally re-freginated, So no special cooling
is required for the VFD or the motor.
The use of permanent magnet instead of rotor windings makes the motor small and lighter
than induction motor .Using magnetic bearing technology, a 75-ton Compressor weighs 265
lb about one-fifth the weight of a conventional compressor
A variable-speed drive (VSD) is required for the motor to operate. The VSD varies the
frequency between 300 and 800 Hz, which provides a compressor-speed range from 18,000 to
48,000 rpm. This avoids a gear set. The VSD is integrated into the compressor housing,
avoiding long leads and allowing key electronic components to be refrigerant-cooled. The
VSD also acts as a soft starter; as a result, the compressor has an extremely low startup in-
rush current: less than 2 amps, compared with 500 to 600 amps for a traditional 75-ton, 460-
v screw compressor with a cross-the-line starter.With the integration of the motor, VSD, and
magnetic-bearing system, the capacitors required for the motor and drive can be used as
a backup power source for the bearings in the event of a power outage or emergency
shutdown.

OIL-FREE DESIGN
Oil management, particularly as it pertains to the lubrication of compressor Bearings, is a
critical issue in refrigeration- system design. But with magnetic bearings, this issue is avoided.
Only a very small amount of oil is required to lubricate other system components, such as
Seals and valve; often, however experience shows that even this small amount of oil is not
needed. Avoiding oil-management systems means avoiding the capital cost of oil pumps, sumps,
heaters, coolers, and oil separators, as well as the labor and time required to perform oil- related
services. Reports indicate that For many installations, compressor maintance costs have
been cut by more than 50 percent
Most air cooled products uses DX evaporators. Most DX system allow oil to travel through the
refrigeration circuit and back to the compressor oil sump. Great care must be taken during design to
provide oil return, particularly at part load, when refrigerant flow rates are reduced
FRICTIONLESS COMPRESSOR 2018-2019

Water-cooled chillers often use flooded evaporators. In a flooded evaporator, even small
amounts of oil can coat evaporator tubes and significantly diminish chiller performance. This can
lead to an elaborate oil-recovery system. Magnetic bearings eliminate the need for these
systems and oil management in general. In fact, the only required regular maintenance of the
compressor is the quarterly tightening of the terminal screws, the annual blowing off of dust
and cleaning of the boards, and the changing of the capacitors every five years .complete
service agreements and extended mainatnce contracts can be provided by the manufacturer

Mechanical components of frictionless compressor:

Touchdown
Bearings Mi
Permanent-magnet Synchronous Motor
Shaft and Impellers
Compressor Cooling
Magnetic Bearings and Bearing Sensors
Inlet Guide Vane Assembly

CONTROLS
The new compressor effectively is a computer. It provides diagnostic and performance information
through Mod- bus to the refrigeration system, which then communicates to the building automation
system through Modbus, LonWorks, or BACnet.

CAPACITY AND EFFICIENCY

Among the key parameters affecting performance are capacity (tons) and efficiency (kilowatts per
ton). The compressor’s capacity ranges from 60 to 90 tons, depending on the operating conditions.
Plans call for that range to be extended to 150 tons water-cooled and 115 tons air-cooled by the
end of 2004 with the use of R-134a refrigerant. An R-22 version is planned for retrofit
applications.
Efficiency improvements stem from a combination of the centrifugal compressor, permanent-
magnet motor, and magnetic bearings. Within the compressor, efficiency is affected by the
Compressor isentropic efficiency (the efficiency of the wheels), the motor, and the bearings.
Traditional induction motors of this size typically are in the 92-percent efficiency range. This
compressor’s permanent-magnet motor has an efficiency of 96 to 97 percent. Efficiency is further
enhanced with the use of magnetic bearings, which avoid the friction of rubbing parts associated
with traditional oiled bearings. Conventional bearings can use as much as 10,000 w, while magnetic
bearings re- quire only 180 w. That amounts to 500 times less friction loss. Current development projects
are expanding the range and duty of the compressor wheels and promise to offer even greater
efficiency for water-cooled and air-cooled duties and different capacities.
FRICTIONLESS COMPRESSOR 2018-2019

SHUTDOWNS AND POWER FAILURES

When the compressor is not running, the shaft assembly rests on graphite-lined, radially located
touchdown bearings. The magnetic bearings normally position the rotor in the proper location,
preventing contact between the rotor and other Metallic surfaces. If the magnetic bearings

fail, the touchdown bearings (also known as backup bearings) are used to prevent a compressor
failure. The compressor uses capacitors to smooth ripples in the DC link in the motor
drive. Instantaneously after a power failure, the motor becomes a “generator,” using its
angular momentum to create electricity (sometimes known as back EMF) and keeping the
capacitors charged during the brief coast down period. The capacitors, in turn, provide
enough power to maintain levitation during coast down, allowing the motor rotor to stop and
delevitate. This feature allows the compressor to see a power outage as a normal shutdown.

SOUND AND VIBRATION

Because of the rotating assembly levitates, there essentially is no structure-borne Vibration
the magnetic bearings create an air buffer that prevents the only major moving part—the motor
rotor from transmitting vibration to the structure.
Similarly , sound levels are extremely low, because of refrigerant gas movement through the
compressor and the rest of the refrigeration system. There are no tonal issues, such as those
found with some screw compressors, and the noise occurs in the higher octave bands, where it
is easier to attenuate. When two magnetic-bearing compressors were integrated into a chiller,
the sound pressure was 77 dBA at 3.3 ft under ARI Standard 575-94, Method of measuring
machinery sound within an equipment space

SUMMARY
After 10 years of development, magnetic bearing compressors offer economic, energy, and
environmental benefits. Chief among them are increased energy efficiency, the elimination of oil
and oil management, and considerably less weight, noise, and vibration. This initial mid range
package offers centrifugal compressor efficiencies previously reversed for large tonnage system
only
FRICTIONLESS COMPRESSOR 2018-2019

REFERENCE
1) Ivanovich, M.G. (2002, June). The market for chillers: drives, controls,Simplicity.
HPAC Engineering ,
2) W. Chomczyk, Multi-chamber Sucking-forcing-out Working Machine, Bialystok University
of Technology, Białystok, (to be pub- lished), (in Polish).
3) V. Chlumsky, Piston compressors, PWT, Warszawa, 1961, (in Polish).
4) W. Chomczyk, Multi-chamber Working Machine with a Vaned Piston, Especially as a
Compressor, Pump, Engine, Patent No. 68220, 1973, (in Polish).
5) W. Chomczyk, W. Ostapski, and J. Piotrowski, Frictionless and Oilless Compressor with a
Rotating Piston and Cylinder, Patent No. P385734, 2008, (in Polish).
6) W. Chomczyk, W. Ostapski, and J. Piotrowski, Frictionless and Oilless Compressor with a
Fixed Piston and Rotating Cylinder, Patent No. P385733, 2008, (in Polish).
7) W. Ostapski and J. Piotrowski, Construction of an Unloaded Piston for Uplift Machines,
Patent No. P394072, 2011.
8) M. Hać, J. Łazęcki, and W. Ostapski, “Modeling of driving mechanism of oscillatory air–
compressor”, Machine Dynamics Problems