Tribology International 35 (2002) 443448 www.elsevier.

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Investigations on a permanent magnetichydrodynamic hybrid journal bearing

Qingchang Tan , Wei Li, Bo Liu
Department of Mechanical Engineering, Jilin University, Nanling Campus, Changchun 130025, Peoples Republic of China Received 1 January 2002; received in revised form 5 March 2002; accepted 7 March 2002

Abstract In the present work, a permanent magnetichydrodynamic hybrid journal bearing is developed. The force of the journal bearing comes from the hydrodynamic lm and the permanent magnetic eld. When a hydrodynamic lm does not form, such as during starting and stopping a machine, the journal bearing relies on the magnetic force to support the rotor system. This paper studies a model of the permanent magnetic force and develops an experimental rig of the journal bearing. Experiments show that the hydrodynamic lm force uncouples with the magnetic force in the journal bearing. Predictions from the model are compared with experimental data. 2002 Elsevier Science Ltd. All rights reserved.
Keywords: Journal bearing; Hydrodynamic lubrication; Permanent magnetic force

1. Introduction From lubrication theory [1,2], we know that a hydrodynamic lm does not form in journal bearings and a state of hybrid friction may occur when starting and stopping a machine. The state of hybrid friction affects the work properties of journal bearings and causes bearing bushes to wear. The state of hybrid friction also affects the work of machines in a lot of situations. Therefore, it is needed to overcome the above drawbacks of journal bearings and to develop new bearing technologies. Hydrodynamichydrostatic hybrid journal bearings and magnetic suspension bearings, as new bearing technologies, indeed eliminate the drawbacks of journal bearings and improve the work properties of machinery. But the two kinds of bearings are complicated in structure, comprising components such as a hydraulic system, sensors, power ampliers and controllers, so that they are expensive for ordinary applications. The present work tries to develop a permanent magnetichydrodynamic hybrid (PMHH) journal bearing. The force of the PMHH journal bearing comes from the

permanent magnetic force and the hydrodynamic lm. When a hydrodynamic lm does not form, such as during starting and stopping a machine, the PMHH journal bearing relies on the magnetic force to support the rotor system, preventing the state of hybrid friction from occurring. This paper studies a model of force for the PMHH journal bearing and develops an experimental rig of the PMHH journal bearing. Experiments show that the hydrodynamic lm force uncouples with the magnetic force in the PMHH journal bearing, and the principle of the PMHH journal bearing can work. Predictions from the model are compared with data from the experimental rig. Parameters of PMHH journal bearings are analyzed from the model and experiments.

2. Principle of the PMHH journal bearing In the present work, the magnetic force of the PMHH journal bearing comes from a rare earth permanent magnet. Permanent magnets are used instead of electromagnets because of the following considerations. First, although electromagnets are active and controllable, sensors, power ampliers and controllers are needed for using electromagnets in the suggested hybrid bearing. And the use of sensors, power ampliers and controllers causes the structure of the suggested hybrid bearing to

Corresponding author. E-mail address: tangc514@yahoo.com (Q. Tan).

0301-679X/02/$ - see front matter 2002 Elsevier Science Ltd. All rights reserved. PII: S 0 3 0 1 - 6 7 9 X ( 0 2 ) 0 0 0 2 6 - 9

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be complicated and makes it difcult to reduce the bearing cost. Second, in the past decade, rare earth permanent magnets have been developed greatly and the properties of the materials, such as coercive force and maximum energy product, have been increased greatly. Permanent magnets can be used in repellent form to obtain large magnetic force and they do not demagnetize for 10 years. The machining properties of these permanent magnets have been improved and they can be machined into a few shapes with high accuracy. Therefore, rare earth permanent magnets have attracted a lot of applications and research in bearings, couplings, motors and gears [310]. Third, the present work utilizes magnetic force to support the rotor system only when a hydrodynamic lm does not form in the journal bearing. There is hardly any load on a rotor except its gravitation and rotor speeds are low when starting and stopping a machine. This provides a possibility to simplify the structure of the magnetic bearing. Finally, compared with electromagnets, using permanent magnets makes the suggested hybrid bearing simple in structure and cheap in cost. The PMHH journal bearing consists of a pair of permanent magnetic rings and a bush, as shown in Fig. 1.

The magnetic rings and the bush are arranged separately along the axial direction. The bush is the same as used in an ordinary journal bearing. The magnetic rings are magnetized axially and a radial repulsion force forms between the rings. Since magnetic force is inversely proportional to eccentricity between the magnetic rings, the force is made equilibrating with the rotor gravitation by adjusting the outer magnetic ring relative to the inner one. The equilibrium makes the journal not contact with the bush. Therefore, the PMHH journal bearing relies on the magnetic force to support the rotor when rotor speeds are low and a hydrodynamic lm does not form. However, the PMHH journal bearing will automatically transit to hydrodynamic lm support for rotor loads when the hydrodynamic lm forms.

3. Force model of the PMHH journal bearing Since the force of PMHH journal bearings comes from the magnetic force and the hydrodynamic lm, the force model contains two parts: one represents the magnetic force, the other the lm force. Since the bush of the PMHH journal bearing is the same as one of an ordinary journal bearing, calculations of lm force can be found in Ref. [13]. Therefore, the present works focuses on calculations of the magnetic force. Fig. 2 shows drawings of the magnetic rings for the calculation. The repulsion force between the two magnetic rings comes from the interaction among magnetic charges. The magnetic charges distribute on the faces of magnetic poles: 1, 2, 3 and 4. The magnetic force is produced by magnetic charges on faces 1 and 2 interacting with ones on faces 3 and 4. Now, the magnetic force between faces 2 and 3 is rst calculated. From the literature [11,12], the force between element Q on face 3 and element P on face 2 is expressed as: 23 dF where s1s2r3dadr3r2dbdr2 r 23, 4pm0|r 23|3 (1)

Fig. 1. Experimental rig of pemanent magnetichydrodynamic hybrid journal bearing: (a) schematic; (b) photo.

Fig. 2. Coordinates of magnetic rings.

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r2position vector between o1 and P; r3position vector between o2 and Q; r 23position vector between Q and P; s1, s2face densities of magnetic charges; m0vacuum permeability. From Fig. 2, r 23 can be expressed as: r r 3 r 2 x 0, 23 e where e eccentricity of o2 relative to o1; x 0axial displacement vector of inner magnetic ring relative to outer ring. Eq. (2) is substituted into Eq. (1). Then Eq. (1) is projected to the y-coordination direction, yielding the 23 as radial component of dF s s r dr r dr dadb 23j 1 2 3 3 2 2 r dF23 dF 23j, 4pm0 |r 23|3 where r 23j e r3cosar2cosb and |r 23| [x (e r3cosar2cosb) (r3sina
2 0 2

r2sinb)2]1/2, |r 24| [(x0 l)2 (e r3cosar2cosb)2 (r3sina r2sinb)2]1/2, |r 13| [(lx0)2 (e r3cosar2cosb)2 (r3sina r2sinb)2]1/2, (2) r 14j e r3cosar2cosb, r 24j e r3cosar2cosb, r 13j e r3cosar2cosb. The symmetry of the magnetic rings makes dF14 dF23. From the magnetic polarities of the magnetic rings, as shown in Fig. 2, summing the above expressions yields the differential form of the radial magnetic force between the two magnetic rings: dFg Ar3dr3r2dr2dadb r3cosar2cosb). Eq. (8) is integrated along the end faces of the magnetic rings, yielding the radial repulsion force:
2p2pR4R2

(3)

2 |r 23|

1 |r 24|
3

1 |r 13|3

(e

(8)

Fg A

r2sinb) ] .
2 1/2

0 0 R3R1

1 1 2 3 3 (e r3cosa 3 |r | | r | | r 23 24 14|

(9)

Suppose the densities of magnetic charges on the faces are all the same. From the magnetizing relation [12], the face densities of magnetic charges of rare earth permanent magnets can be expressed as: s1 s2 Br, (4)

r2cosb)r3dr3r2dr2dadb, where R1inner radius of inner magnetic R2outer radius of inner magnetic R3inner radius of outer magnetic R4outer radius of outer magnetic laxial width of magnetic rings. ring; ring; ring; ring;

where Br is the residual induction of permanent magnets. Eq. (3) is the differential form of radial magnetic force between faces 2 and 3. Similarly, differential forms of radial magnetic forces between faces 1 and 4, faces 2 and 4, and faces 1 and 3 can be written as: r3dr3r2dr2dadb r dF14 A 14j, |r 14|3 r3dr3r2dr2dadb r dF24 A 24j |r 24|3 and r3dr3r2dr2dadb dF13 A r 13j, |r 13|3 where A B2 r ; 4pm0 (7) (5)

Eq. (9) shows the magnetic force of the PMHH journal bearing.

4. Experiments and discussion (6) The structure of the experimental rig for the PMHH journal bearing is shown in Fig. 1. Coupling 7 is exible to reduce the effect of the coupling on the movement of shaft 1. First, the center position of bush 3, 0(x0, y0), and the radius gap between shaft 1 and bush 3, C, are determined using sensors 10 (eddy-current non-contact probes) in horizontal and vertical directions. Then, outer magnetic ring 5 is adjusted upwards relative to inner magnetic ring 4 by moving and fastening sliding plate 6 to produce a certain magnetic force between the magnetic rings. Eccentricity between the magnetic rings, eg,

2 |r 14| [x2 0 (e r3cosar2cosb) (r3sina

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is measured by gage 13, and the position of shaft 1, 1(x1, y1), is measured using sensors 10. The magnetic force produced by adjusting outer magnetic ring 5 can make shaft 1 not contact with bush 3. Next, shaft 1 is turned by motor 8 when not supplying oil to the PMHH journal bearing and known load W1 is added to shaft 1 in the vertical direction. This simulates the magnetic force supporting the rotor system when a hydrodynamic lm does not form in the journal bearing. At that moment, the total load borne by the magnetic force from a pair of magnetic rings, Wg, equals half the gravitation of shaft 1, W0/2 (W0 78.4 N) plus the added load W1/2. Changing W1 (W158.8 N) can simulate gravitation of the rotor system in a certain range by the experimental rig. The position of shaft 1, 2(x2, y2), is measured using sensors 10 after loading W1. From eg, 0(x0, y0), 1(x1, y1) and 2(x2, y2), the eccentricity between the magnetic rings, eg1, and eccentricity e of shaft 1 relative to bush 3 can be determined after loading W1. Finally, when shaft 1 with load W1 is rotating, oil is supplied to the PMHH journal bearing to produce a hydrodynamic lm. Known load W2 is added to shaft 1 after supplying oil and measurements of sensors 10 are kept to determine eg1 and e. The load W2 simulates working loads on the rotor system. At that moment, the total load borne by a PMHH journal bearing is W (W2 W1 W0) / 2. 4.1. Test for magnetic force From the above sequence, the magnetic force and the eccentricity between the magnetic rings can be measured when not supplying oil to a PMHH journal bearing. The magnetic rings used in the present work were made of permanent magnets with high-coercivity, rare earth material. Table 1 contains some properties of the material and the dimensions of the magnetic rings. Integrals for predicting the magnetic force from Eq. (9) were evaluated numerically using a trapezium cube quadrature. A comparison between the predictions from Eq. (9) and experimental results is shown in Fig. 3. From the gure, we see that the experimental data are well in correspondence with the predictions. This shows that Eq. (9) is correct for predicting the magnetic force of the PMHH journal bearing. From Fig. 1, load W1 on shaft 1 must overcome the effect of coupling 7 on the shaft displacement and friction of the loading system before

Fig. 3. Comparison between predictions of magnetic force and experimental date.

moving the shaft, and the movement of shaft 1 determines the eccentricity between the magnetic rings, eg1. Therefore, from the measured eccentricity eg1, the predicted magnetic force is smaller than the experimental data. From Fig. 3, we can see that magnetic force increases with the increase of magnetic ring eccentricity. The experiments and calculations from Eq. (9) show that the axial displacement x 0 between the magnetic rings causes the magnetic force to reduce, and ratio of the magnetic force for x 0 0 is 0 0.5 to the force for x about 0.96. Therefore, the effect of the displacement x 0 0.5 mm. 0 is negligible when x 4.2. Test of forces of the PMHH journal bearing The forces of the PMHH journal bearing are tested to determine whether the magnetic force couples with the lm force and to verify whether the magnetic force affects working of the journal bearing. The structure of the bush of a PMHH journal bearing is shown in Fig. 4. From Ref. [13], the lm force of a PMHH journal bearing is written as: (1e) , Fl NLD3m 4Snh2 min (10)

Table 1 Properties of the rare earth magnetic material and dimensions of the magnetic rings Residual induction, Br (T) Intrinsic coercive force, Hci (kA/m) Recoil permeability Inner radius of outer ring, R3 (mm) Outer radius of outer ring, R4 (mm) Axial displacement, x 0 (mm) 1.25 960 1.05 21 30 0 Coercive force, Hc (kA/m) Energy product, (BH)max (kJ/m) Inner radius of inner ring, R1 (mm) Outer radius of inner ring, R2 (mm) Width of the ring, l (mm) 820 278 10 19 7

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Fig. 4. Full journal bearing.

netic ring eccentricity is eg 1.87 mm, and Fg 55.26 N when eg 1.87 0.035 mm. The magnetic force increase caused by loading W2 on shaft 1 is less than 2 N. Compared with the loads W2 / 2218.5 N, the magnetic force increase can be neglected. From Fig. 3, the stiffness of the magnetic force of the PMHH journal bearing is estimated as about 60 N/mm for eg 1.87 mm. Compared with the oil lms stiffness, this stiffness value is very small. Therefore, from Fig. 5 and the above analyses, the magnetic force of the PMHH journal bearing uncouples with the lm force, and the forces of the PMHH journal bearing can be expressed as: F Fl Fg. (11)

where mdynamic viscosity of lubrication oil (Pa s); Ddiameter of journal (m); Nrotating speed of shaft (rev/s); Lwidth of bush (m); hminminimum thickness of oil lm (m); SnSommerfeld number from Table 2.1 of Ref. [13]; erelative eccentricity. The dimensions of the journal bearing and the conditions of the experiments were: D 0.025 m; L 0.028 m; C 0.000035 m; N 2850 rev / min; LAN46 oil; m 4.05 102 Pa s; pressure of supply oil Pl 1 MPa and 3 MPa. The temperature of the lubrication oil during the experiments was controlled as 40 C. From the above conditions, a comparison of the lm force predicted by Eq. (10) with experimental data is shown in Fig. 5. The comparisons show that the loads on the shaft are supported mainly by the hydrodynamic lm. The eccentricity between the magnetic rings eg is increased with loading W2 on shaft 1. From Fig. 1, inner magnetic ring 4 displaces with loading W2 on the shaft since outer magnetic ring 5 has been fastened to the frame. The displacements of inner magnetic ring 4 are restricted by radial gap between shaft 1 and bush 3, C 0.035 mm. Therefore, the increase of magnetic ring eccentricity eg is less than 0.035 mm. From Eq. (9), we calculated respectively that the magnetic force is Fg 53.76 N when the mag-

The magnetic force Fg and the lm force Fl in Eq. (11) are calculated from Eqs. (9) and (10). Eq. (11) shows that the two parts of the PMHH journal bearing can be designed respectively. In the experiments, the temperature of the oil lm in the bearing region was not directly measured and errors in measuring the relative eccentricity of the shaft occurred. These were main factors causing the difference between the predictions and the experimental data. But the results of the present work are enough for a qualitative analysis. During the experiments, dynamic measurements of sensors 10 showed that the magnetic force did not cause the shaft to vibrate.

5. Conclusions From the above work, we obtained the following results. 1. The principle of the PMHH journal bearing can work: the magnetic force does not disturb the hydrodynamic lm and does not cause the rotor system to vibrate. 2. A formulation for predicting the magnetic force is developed, and the magnetic force uncoupled with the lm force, so that the magnetic force part and the lm force part of PMHH journal bearings can be calculated and designed respectively.

Acknowledgements This work was supported nancially by the Science Foundation of China (No. 59975042).

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Fig. 5. Comparison of predictions of lm force with experimental data.

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