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New designs of unipolar magnetic bearings in electrical industrial machines are optimized by means of genetic algorithms. As a result, the optimal geometric dimensions are determined. On that basis, a design is developed for an electric motor with a unipolar active magnetic bearing.
Research activities concerning high efficiency permanent magnet plus electromagnet (PM/EM) pancake magnetic bearings at the University of Maryland are reported. A description of the construction and working of the magnetic bearing is provided. Next, parameters needed to describe the bearing are explained. Then, methods developed for the design and testing of magnetic bearings are summarized. Finally, a new magnetic bearing which allows active torque control in the off axes directions is discussed.
Magnetic bearings have existed for many years, at least in theory. Earnshaw's theorem, formulated in 1842, concerns stability of magnetic suspensions, and states that not all axes of a bearing can be stable without some means of active control. In Beam's widely referenced experiments, a tiny (1/64 in diameter) rotor was rotated to the astonishing speed of 800,000 rps while it was suspended in a magnetic field. Despite a long history, magnetic bearings have only begun to see practical application since about 1980. The development that finally made magnetic bearings practical was solid state electronics, enabling power supplies and controls to be reduced in size to where they are now comparable in volume to the bearings themselves. An attempt is made to document the current (1991) state of the art of magnetic bearings. The referenced papers are large drawn from two conferences publications published in 1988 and 1990 respectively.
Application of magnetic bearings to boiler feed pumps presents various attractive features, such as longer bearing life, lower maintenance costs, and improved operability through control of the rotordynamics. Magnetic bearings were fitted to an eight-stage, 600 hp boiler feed pump, which generates 2600 ft of heat at 680 gpm and 3560 rpm. In addition to the varied and severe operating environment in steady state operation of this pump in a power plant, it is also subjected to transient loads during frequent starts and stops. These loads can now be measured by the in-built instrumentation of the magnetic bearings. Following site installation, a follow-up bearing tune-up was performed, and pump transient response testing was conducted. The bearing response was completely satisfactory, ensuring trouble-free pump operation even in the range of reduced load. The experience gained so far through design and testing proves feasibility of magnetic bearings for boiler feed pumps, which sets the stage for application of even higher energy centrifugal pumps equipped with magnetic bearings.
Magnetic bearings are the subject of a new NASA Lewis Research Center and U.S. Army thrust with significant industry participation, and cooperation with other Government agencies. The NASA/Army emphasis is on high-temperature applications for future gas turbine engines. Magnetic bearings could increase the reliability and reduce the weight of these engines by eliminating the lubrication system. They could also increase the DN (diameter of bearing times the rpm) limit on engine speed and allow active vibration cancellation systems to be used, resulting in a more efficient, "more electric" engine. Finally, the Integrated High Performance Turbine Engine Technology (IHPTET) program, a joint Department of Defense/industry program, identified a need for a high-temperature (1200 F) magnetic bearing that could be demonstrated in their Phase III engine. This magnetic bearing is similar to an electric motor. It has a laminated rotor and stator made of cobalt steel. Wound around the stator's circumference are a series of electrical wire coils which form a series of electric magnets that exert a force on the rotor. A probe senses the position of the rotor, and a feedback controller keeps it centered in the cavity. The engine rotor, bearings, and casing form a flexible structure with many modes. The bearing feedback controller, which could cause some of these modes to become unstable, could be adapted to varying flight conditions to minimize seal clearances and monitor the health of the system.
Magnetic bearings are just beginning to be flown in spacecraft systems, but their development spans more than 50 years. The promise of completely noncontacting, unlubricated rotating systems operating at speeds substantially beyond the range of conventional bearings, and with no wear and virtually no vibration, has provided the incentive to develop magnetic bearing technology for many diverse applications. Earnshaw theorized in 1842 that stable magnetic suspension is not possible in all three spatial directions unless the magnetic field is actively controlled. Since that time, researchers have attempted to successfully support spinning rotors in a stable manner. Development of magnetic suspension systems over the past fifty years has included progress on both passive (permanent magnet) and active (electromagnet) systems. The improvements in bearing load capacity, stiffness, and damping characteristics are traced. The trends in rotor size, rotational kinetic energy, and improvements in active control systems capabilities are also reviewed. Implications of superconductivity on suspension system design and performance are discussed.
An advanced thrust-measurement system utilizes active magnetic bearings to both (1) levitate a floating frame in all six degrees of freedom and (2) measure the levitation forces between the floating frame and a grounded frame. This system was developed for original use in measuring the thrust exerted by a rocket engine mounted on the floating frame, but can just as well be used in other force-measurement applications. This system offers several advantages over prior thrust-measurement systems based on mechanical support by flexures and/or load cells: The system includes multiple active magnetic bearings for each degree of freedom, so that by selective use of one, some, or all of these bearings, it is possible to test a given article over a wide force range in the same fixture, eliminating the need to transfer the article to different test fixtures to obtain the benefit of full-scale accuracy of different force-measurement devices for different force ranges. Like other active magnetic bearings, the active magnetic bearings of this system include closed-loop control subsystems, through which the stiffness and damping characteristics of the magnetic bearings can be modified electronically. The design of the system minimizes or eliminates cross-axis force-measurement errors. The active magnetic bearings are configured to provide support against movement along all three orthogonal Cartesian axes, and such that the support along a given axis does not produce force along any other axis. Moreover, by eliminating the need for such mechanical connections as flexures used in prior thrust-measurement systems, magnetic levitation of the floating frame eliminates what would otherwise be major sources of cross-axis forces and the associated measurement errors. Overall, relative to prior mechanical-support thrust-measurement systems, this system offers greater versatility for adaptation to a variety of test conditions and requirements. The basic idea of most prior active-magnetic-bearing force-measurement systems is to calculate levitation forces on the basis of simple proportionalities between changes in those forces and changes in feedback-controlled currents applied to levitating electromagnetic coils. In the prior systems, the effects of gap lengths on fringing magnetic fields and the concomitant effects on magnetic forces were neglected. In the present system, the control subsystems of the active magnetic bearings are coupled with a computer-based automatic calibration system running special-purpose software wherein gap-length-dependent fringing factors are applied to current and magnetic-flux-based force equations and combined with a multipoint calibration method to obtain greater accuracy.
An optical disk buffer concept can provide gigabit-per-second data rates and terabit capacity through the use of arrays of solid state lasers applied to a stack of erasable/reusable optical disks. The RCA optical disk buffer has evoked interest by NASA for space applications. The porous graphite air bearings in the rotary spindle as well as those used in the linear translation of the read/write head would be replaced by magnetic bearings or mechanical (ball or roller) bearings. Based upon past experience, roller or ball bearings for the translation stages are not feasible. Unsatisfactory, although limited experience exists with ball bearing spindles also. Magnetic bearings, however, appear ideally suited for both applications. The use of magnetic bearings is advantageous in the optical disk buffer because of the absence of physical contact between the rotating and stationary members. This frictionless operation leads to extended life and reduced drag. The manufacturing tolerances that are required to fabricate magnetic bearings would also be relaxed from those required for precision ball and gas bearings. Since magnetic bearings require no lubricant, they are inherently compatible with a space (vacuum) environment. Magnetic bearings also allow the dynamics of the rotor/bearing system to be altered through the use of active control. This provides the potential for reduced vibration, extended regions of stable operation, and more precise control of position.
A 100 percent passive magnetic bearing flywheel rig employing no active control components was designed, constructed, and tested. The suspension clothe rotor was provided by two sets of radial permanent magnetic bearings operating in the repulsive mode. The axial support was provided by jewel bearings on both ends of the rotor. The rig was successfully operated to speeds of 5500 rpm, which is 65 percent above the first critical speed of 3336 rpm. Operation was not continued beyond this point because of the excessive noise generated by the air impeller and because of inadequate containment in case of failure. Radial and axial stiffnesses of the permanent magnetic bearings were experimentally measured and then compared to finite element results. The natural damping of the rotor was measured and a damping coefficient was calculated.
Passive levitation by superconducting magnetic bearings can be utilized in flywheels for energy storage. Basic design criteria of such a bearing are high levitation force, sufficient vertical and horizontal stability and low friction. A test facility was built for the measurement and evaluation of friction in a superconducting magnetic bearing as a function of operating temperature and pressure in the vacuum vessel. The bearing consists of a commercial disk shaped magnet levitated above single grain, melt-textured YBCO high-temperature superconductor material. The superconductor was conduction cooled by an integrated AEG tactical cryocooler. The temperature could be varied from 50 K to 80 K. The pressure in the vacuum chamber was varied from 1 bar to 10(exp -5) mbar. At the lowest pressure setting, the drag torque shows a linear frequency dependence over the entire range investigated (0 less than f less than 40 Hz). Magnetic friction, the frequency independent contribution, is very low. The frequency dependent drag torque is generated by molecular friction from molecule-surface collisions and by eddy currents. Given the specific geometry of the set-up and gas pressure, the molecular drag torque can be estimated. At a speed of 40 Hz, the coefficient of friction (drag-to-lift ratio) was measured to be mu = 1.6 x 10(exp -7) at 10(exp -5) mbar and T = 60 K. This is equivalent to a drag torque of 7.6 x 10(exp -10) Nm. Magnetic friction causes approx. 1% of the total losses. Molecular friction accounts for about 13% of the frequency dependent drag torque, the remaining 87% being due to eddy currents and losses from rotor unbalance. The specific energy loss is only 0.3% per hour.
Classical design methods involved in magnetic bearings and magnetic suspension systems have always had their limitations. Because of this, the overall effectiveness of a design has always relied heavily on the skill and experience of the individual designer. This paper combines two approaches that have been developed to aid the accuracy and efficiency of magnetostatic design. The first approach integrates classical magnetic circuit theory with modern optimization theory to increase design efficiency. The second approach uses loss factors to increase the accuracy of classical magnetic circuit theory. As an example, an axial magnetic thrust bearing is designed for minimum power.
A description of a microcomputer controlled magnetic bearing test fixture is presented. Parameters which are controlled are magnetic bearing current and gaps. Parameters which are measured are magnetic bearing gaps, magnetic flux in the bearing gaps, and bearing forces. The test fixture is configured for bearing elements similar to those used in a laboratory test model Annular Momentum Control Device (AMCD).
A magnetic bearing operating without a bias field has supported a shaft rotating at speeds up to 12,000 rpm with the usual four power supplies and with only two. A magnetic bearing is commonly operated with a bias current equal to half of the maximum current allowable in its coils. This linearizes the relation between net force and control current and improves the force slewing rate and hence the band width. The steady bias current dissipates power, even when no force is required from the bearing. The power wasted is equal to two-thirds of the power at maximum force output. Examined here is the zero bias idea. The advantages and disadvantages are noted.
A magnetic bearing control system for a high-speed flywheel system is described. The flywheel utilizes a five axis active magnetic bearing system, using eddy current sensors for position feedback to the bearing controller. Magnetic bearing controller features designed to improve flywheel operation and testing are described. Operational improvements include feed forward control to compensate for rotor imbalance, moving notch filtering to compensate for synchronous and harmonic rotational noise, and fixed notching to prevent rotor bending mode excitation. Testing improvements include adding safe gain, bearing current hold, bearing current zero, and excitation input features. Performance and testing improvements provided by these features are measured and discussed.
Active magnetic bearings provide revolutionary advantages for gas turbine engine rotor support. These advantages include tremendously improved vibration and stability characteristics, reduced power loss, improved reliability, fault-tolerance, and greatly extended bearing service life. The marriage of these advantages with innovative structural network design and advanced materials utilization will permit major increases in thrust to weight performance and structural efficiency for future gas turbine engines. However, obtaining the maximum payoff requires two key ingredients. The first key ingredient is the use of modern magnetic bearing technologies such as innovative digital control techniques, high-density power electronics, high-density magnetic actuators, fault-tolerant system architecture, and electronic (sensorless) position estimation. This paper describes these technologies. The second key ingredient is to go beyond the simple replacement of rolling element bearings with magnetic bearings by incorporating magnetic bearings as an integral part of the overall engine design. This is analogous to the proper approach to designing with composites, whereby the designer tailors the geometry and load carrying function of the structural system or component for the composite instead of simply substituting composites in a design originally intended for metal material. This paper describes methodologies for the design integration of magnetic bearings in gas turbine engines.
Experiments were performed on a Hybrid Magnetic Bearing designed for cryogenic applications such as turbopumps. This bearing is considerably smaller and lighter than conventional magnetic bearings and is more efficient because it uses a permanent magnet to provide a bias flux. The tests were performed in a test rig that used liquid nitrogen to simulate cryogenic turbopump temperatures. The bearing was tested at room temperature and at liquid nitrogen temperature (-320 F). The maximum speed for the test rig was 14000 rpm. For a magnetic bearing stiffness of 20000 lb/in, the flexible rotor had two critical speeds. A static (nonrotating) bearing stiffness of 85000 lb/in was achieved. Magnetic bearing stiffness, permanent magnet stiffness, actuator gain, and actuator force interaction between two axes were evaluated, and controller/power amplifier characteristics were determined. The tests revealed that it is feasible to use this bearing in the cryogenic environment and to control the rotor dynamics of flexible rotors when passing through bending critical speeds. The tests also revealed that more effort should be placed on enhancing the controller to achieve higher bearing stiffness and on developing displacement sensors that reduce drift caused by temperature and reduce sensor electrical noise.
The operation of the magnetic bearing used as an excitation source in the Rocketdyne Multifunction Tester is described. The tester is scheduled for operation during the summer of 1990. The magnetic bearing can be used in two control modes: (1) open loop mode, in which the magnetic bearing operates as a force actuator; and (2) closed loop mode, in which the magnetic bearing provides shaft support. Either control mode can be used to excite the shaft; however, response of the shaft in the two control modes is different due to the alteration of the eigenvalues by closed loop mode operation. A rotordynamic model is developed to predict the frequency response of the tester due to excitation in either control mode. Closed loop mode excitation is shown to be similar to the excitation produced by a rotating eccentricity in a conventional bearing. Predicted frequency response of the tester in the two control modes is compared, and the maximum response is shown to be the same for the two control modes when synchronous unbalance loading is not considered. The analysis shows that the response of this tester is adequate for the extraction of rotordynamic stiffness, damping, and inertia coefficients over a wide range of test article stiffnesses.
The NASA John H. Glenn Research Center has developed and tested a revolutionary Radial Halbach Magnetic Bearing. The objective of this work is to develop a viable non-contact magnetic bearing utilizing Halbach arrays for all-electric flight, and many other applications. This concept will help reduce harmful emissions, reduce the Nation s dependence on fossil fuels and mitigate many of the concerns and limitations encountered in conventional axial bearings such as bearing wear, leaks, seals and friction loss. The Radial Halbach Magnetic Bearing is inherently stable and requires no active feedback control system or superconductivity as required in many magnetic bearing designs. The Radial Halbach Magnetic Bearing is useful for very high speed applications including turbines, instrumentation, medical applications, manufacturing equipment, and space power systems such as flywheels. Magnetic fields suspend and support a rotor assembly within a stator. Advanced technologies developed for particle accelerators, and currently under development for maglev trains and rocket launchers, served as the basis for this application. Experimental hardware was successfully designed and developed to validate the basic principles and analyses. The report concludes that the implementation of Radial Halbach Magnetic Bearings can provide significant improvements in rotational system performance and reliability.