Magnetic Bearings

Overview
Magnetic Bearings
Introduction
Magnetism Review
Active Magnetic Bearings
Passive Magnetic Bearings
Industry Applications
 Introduction
Magnetic Bearing Types

 Active/passive magnetic bearings

 electrically controlled
 no control system
 Radial/axial magnetic bearings
 Introduction
Motivations

Advantages of magnetic bearings:

 contact-free
 no lubricant
 (no) maintenance
 tolerable against heat, cold, vacuum, chemicals
 low losses
 very high rotational speeds
Disadvantages:
 complexity
 high initial cost
Introduction
Survey of Magnetic Bearings
 Magnetism
Magnetic Field

south pole
north pole

magnetic iron filings

field line
Magnetism
Magnetic Field
Magnetic field, H, is found around a magnet or a
current carrying body.

H
∫ H ds = i
i

i
H= (for one
2πr current loop)
 Magnetism
Magnetic Flux Density
  multiple loops
B = µH of wire, n
B = magnetic flux density ni
µ = magnetic permeability H=
H = magnetic field
2πr

µ = µ0 µ r
µ 0 = permeability of free space
µ r = relative permeability
diamagnetic µ <1
paramagnetic µ >1
ferromagnetic µ >> 1
 Magnetism
B-H Diagram

Ferromagnetic: a material that can be magnetized

Remanence, Br
magnetic saturation
B
 
B = µH
Coercivity, Hc
H

area within loop represents

hysteresis loss
 Magnetism
Reluctance Force

Force resulting from a difference between magnetic

permeabilities in the presence of a magnetic field.
 force perpendicular to surface!

The energy in a magnetic field with

linear materials is given by:
∂U
f = 2
1 ∂l
B A
U = ∫ BHdV f =
2V 2µ
U = energy
V = volume
 Active Magnetic Bearings
Elements of System

 Electromagnet
 Rotor
 Sensor
 Controller
 Amplifier
 Active Magnetic Bearings
Force Behavior

Magnetic Force Spring Force

fm 1 fs
~ 2
xs
Force

Force

xs xs
Distance Distance
Active Magnetic Bearings
Force Linearization

Magnetic Force Spring Force

fm 1 fs
~ 2
xs

mg mg

x0 xs x0 xs
 Active Magnetic Bearings
Force Linearization

Operating Point (constant

current) Redefining distance:
f
fm
x
f = ks x
x x = −( xs − x0 )

x0 xs

ks = force-displacement factor f m,s i = ks x

m = i0
 Active Magnetic Bearings
Force Linearization
Operating Point (constant position)
im
f m ,i x s = x0
= ki i

i = im − i0

ki = force-current factor
fm fm f = ki i
2
~ im

mg i

i0 im i0 im
Active Magnetic Bearings
Force Linearization

Linearized equation: im

f ( x, i ) = f m , s i + f m ,i
m = i0 x s = x0
x

f m,s i = ks x
m = i0

i = im − i0
f m ,i = ki i
x s = x0 x = − xs + x0

Not valid for:

f ( x, i ) = k s x + k i i - rotor-bearing contact
- magnetic saturation
- small currents
 Active Magnetic Bearings
Closed Control Loop

Open Loop Equation:

Basic System
f ( x, i ) = k s x + k i i
i
Controller function?
x
- Provide force, f

x
Controller signals?
- Input: position, x
- Output: current, i
Artifical damping and stiffness: k d

 i = i(x) f = −( kx + dx ) x
 Active Magnetic Bearings
Closed Control Loop

Controller Abilities:
1) k, d can be varied in controller
2) air gap can be varied in controller
3) specify position for different loads
4) rotor balancing, vibrations,
monitoring...
Active Magnetic Bearings
Bearing Geometry

Radial Bearing Axial Bearing

Active Magnetic Bearings
Bearing Geometry
B circumferential to B parallel to rotor axis
rotor axis

- similar to electromotors - hysteresis loss low

- rotor requires lamination - lamination avoided

Orientation:
magnet pole pairs are often lined up with the principle
coordinate axes x and y (vertical and horizontal)
 control equations are simplified
 Active Magnetic Bearings
Sensors

Position Sensor
 contact-free
 measure rotating surface + sensor
 surface quality
 homogeneity of surface
material
 various values

Other Sensors
 speed
 current …other concerns:
 flux density observability
 temperature placement
… cost
 Active Magnetic Bearings
Sensors

“Sensorless“ Bearing
- calculate position
- less equipment
- lower cost
 Active Magnetic Bearings
Amplifier
Converts control signals to control currents.

Analog Amplifier: Switching Amplifier:

- simple structure - lower losses

- low power applications - high power applications
P<0.6 kVA - remagnetization loss
 Active Magnetic Bearings
Electrical Response

There is an inherent delay in the electrical system

 inductance

di
voltage drops:u L = L and u R = Ri
dt

Total voltage drop:

di
u = Ri + L + ku x
dt velocity within magnetic field
induces a voltage
ku = voltage-velocity coefficient
 Active Magnetic Bearings
Control Equations of Motion

Block diagram with voltage control:

di
u = Ri + L + ku x
dt
f ( x, i ) = k s x + k i i
mx = f
Active Magnetic Bearings
Current vs. Voltage Control
Voltage Control:
- more accurate model
- better stability
- low stiffness easier to realize
- voltage amplifier often more convenient
- possible to avoid using position sensor

Current Control:
- simple control plant description
- simple PD or PID control

Flux Control:
- very uncommon
Active Magnetic Bearings
Addressing of Assumptions

Uncertainties in bearing model

- leakage flux outside of air gap
- air gap is bigger than assumed
- iron cross section is non-
uniform
 Active Magnetic Bearings
Types of Losses

Air Losses
- air friction  divide shaft into sections
Copper Losses (Stator)
- wire resistance PCu = RCu i
2

Iron Losses (Rotor)

- hysteresis (higher w/ switching amplifier)
- eddy currents
 Active Magnetic Bearings
Copper Losses

For differential driving mode:

2
PCu ,max = 2 RCu imax
An K n = Ad n
An K n
NI max = PCu ,max
2 ρlm
Α n = slot area
Kn = bulk factor
ρ = specific resistance
lm = average length of turn
limit of permissible mmf!
 Active Magnetic Bearings
Rotor Dynamics

Areas of Consideration
 natural vibrations
 forward/backward whirl (natural vibrations)
 critical speeds
 nutation
 precession (change in rotation axis)
 Active Magnetic Bearings
Rotor Dynamics

rotor touch-down in retainer bearings

- maintenance
- sudden system shutoff
- during system shutdown
 very difficult to simulate

cylindrical motion conical motion

 Active Magnetic Bearings
Rotor Stresses
Implications of max stress: Material vmax (m/s)
 max velocity (full steel 576
disc)! brass 376
8σ S bronze 434
vmax = ra Ω =
( 3 +ν ) ρ aluminium 593
titanium 695
σ s = max tensile strength soft ferro. sheets 565

Actual reached speeds (length 600 mm, dia. 45 mm):

vmax = 300 m  Ω max ≈ 120,000rpm

s
 Passive Magnetic Bearings
Permanent Magnets
Relative Sizes
Common Materials:
1) neodymium, iron, boron (Nd Fe B)
2) samarium, cobalt, boron
(Sm Co, Sm Co B)
1) ferrite
2) aluminium, nickel, cobalt
(Al Ni, Al Ni Co)

Issues:
- material brittleness
- varying space requirements (B-H)
(equal H at 10 mm)
- operating temperatures
 Passive Magnetic Bearings
Permanent Magnets

at least one degree of

freedom unstable!

reluctance bearings:
increase in stiffness with
multiple rings - non-rotating magnets
caution: misalignment! - resistance to radial
displacement
 Passive Magnetic Bearings
Permanent Magnets

High Potential
- economical
- reliable
- practical

 already replacing some active magnetic

bearings
- smaller size equipment and systems
- systems with large air gaps
 Applications
Turbomolecular Pump

École Polytechnique Fédérale de Lausanne,

Switzerland
- eliminates complicated lubrication system
- high temperature resistance
- reduction of pollution
- vibrations, noise, stresses avoided
- improved monitoring (unbalances, defects, etc.)

Status: suboptimal design

 overheating at load (> 550°C)
 increase life span
 optimize fill factor
 reduce cost
 simplify manufacturing
 Applications
Flywheel (‘97)

New Energy and Industrial Technology Development Organization (NEDO) – Japan‘s

Ministry of International Trade and Industry (MITI)
 T=½Jω 2
 speed has larger influence than mass (better energy density)
 fiber-reinforced plastics for high strength
 fracture into small pieces upon failure  above ground
 combination of superconductor and permanent magnet bearings (η sys = 84%)
 Applications
Flywheel (‘97)

Current Development Goals (NEDO)

 increase load force
 reduce amount load force decrease with time (magnetic flux creep)
 reduce rotational loss
 increase size of bearings for larger systems
 Applications
Maglev Trains

Maglev = Magnetic Levitation

 150 mm levitation over guideway track
 undisturbed from small obstacles (snow, debris,
etc.)
 typical ave. speed of 350 km/h (max 500
km/h)
 what if? Paris-Moscow in 7 hr 10 min (2495 km)!
 stator: track, rotor: magnets on train
 Applications
Maglev Trainsx

Maglev in Shanghai
- complete in 2004
- airport to financial district (30 km)
- world‘s fastest maglev in commercial operation
(501 km/h)
- service speed of 430 km/h
Applications
Maglev Trains

Noise Reduction Noise Reduction

by Frequency by Speed