Development of high temperature magnetic bearings

HIGH TEMPERATURE, PERMANENT MAGNET BIASED, FAULT TOLERANT, HOMOPOLAR MAGNETIC BEARING DEVELOPMENT Alan Palazzolo, Randall Tucker, Andrew Kenny, Kyung-Dae Kang, and Varun Ghandi Department of Mechanical Engineering, Texas A&M University, College Station, TX Jinfang Liu and Heeju Choi Electron Energy Corporation, Landisville, PA Andrew Provenza NASA Glenn Research Center, Cleveland, OH

Presentation Outline ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

SBIR Phase II Project: Novel High Temperature Magnetic Bearings (MB) for Space Vehicle Systems ,[object Object],[object Object],[object Object],[object Object],[object Object],PHASE II GOALS – EEC and Texas A&M Univ.

PM Bias Offers a Significant Reduction in Magnetic Bearing Power Requirements ,[object Object],[object Object],[object Object]

NASA/TAMU 2003 R&D100 Award-Winning, All-Electromagnetic, 12-pole Heteropolar, High Temperature Radial Magnetic Bearing. This bearing’s DC Power Requirements for Force Production. *Note - this data takes into account a gap growth and a reduction in Hyperco50 lamination properties with temperature as well as an increase in Cu resistivity. PM Bias Offers a Significant Reduction in Magnetic Bearing Power Requirements

Project Related History of Permanent Magnets ,[object Object],[object Object],[object Object]

[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Chemical Compositions of EEC High Temperature Magnets

Permanent Magnet Grades ,[object Object],[object Object],[object Object],Grades B r (kG) (BH) max (MGOe) T M (°C) EEC 24-T400 10.2 24 400 EEC 21-T400 9.5 21 400 EEC 20-T500 9.2 20 500 EEC 18-T500 8.7 18 500 EEC 16-T550 8.5 16 550 EEC 15-T550 8.0 15 550

Typical Demagnetization Curves of EEC High Temperature T550 Magnets with a Maximum Operating Temperature of 562ºC Sm(Co 0.757 Fe 0.100 Cu 0.110 Zr 0.033 ) 7.0 Load Line Slope: Bd/Hd = AgLm/AmLg

Solid Model of the Radial Bearing Actual Radial Bearing PM-Biased Radial Bearing Design Details Back Iron Pieces Permanent Magnets Dual Lamination Stacks Rotor Lamination Stack Small Air Gap

EEC magnet arc segments glued together. EEC magnet arc assemblies stuck in place on outer diameter of bearing lamination stacks. PM-Biased Radial Bearing Design Details

Flux Contours from EM FEA with PM bias and control flux. Upper Y coils are “fully on” and bottom “fully off”. PM-Biased Radial Bearing Design Details

Notable parameters from bearing design optimization ,[object Object],[object Object],[object Object],PM-Biased Radial Bearing Design Details 0.50 0.42 540 0.45 0.37 405 0.40 0.31 270 0.23 0.20 135 0.00 0.00 0 70 F 1000 F Average Gap Control Flux (TESLA) Amp-Turns .45 T .53 T (18% improvement) Air Gap Flux at 540°C 500 lbs 656 lbs (31% improvement) Linear Load Capacity 267 N 208 N Bearing Weight 10.08 cm 8.18 cm Bearing Length 23.11 cm 23.75 cm Bearing OD Original Design New Design Parameter

Radial Bearing Electromagnet Wire Insulation Integrity Testing ,[object Object],[object Object],[object Object],[object Object],Radial Bearing Stator 1 of 2. High Potential Insulation Integrity Test Results. infinite 0 500 6 76 infinite 0 500 5 76 infinite 0 500 4 76 infinite 0 500 3 76 infinite 0 500 2 76 infinite 0 500 1 76 ROOM TEMP 2.5 200 500 6 538 2.5 200 500 5 538 2.8 180 500 4 538 4.2 120 500 3 538 3.6 140 500 2 538 20.0 25 500 1 538 HIGH TEMP Resistance M-Ohms Applied Amps Applied Volts Pole No. Temp C

Radial Bearing Test Apparatus Stiffer ‘monolithic’ rotor supports that replaced the ball screw assemblies. Radial Bearing Test Apparatus

[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Some Room Temperature Results from Radial Bearing Bench Tests

Some High Temperature Results from Radial Bearing Bench Tests A high temperature test was performed yielding the following results as listed in the paper: ,[object Object],[object Object],[object Object]

A Comparison of Analytical and Experimental Room Temperature Radial Bearing Test Results Force Transmission Yoke with only one functional load cell. Radial Bearing Force vs. Current at Room Temperature Stiff Support Internal Moment Bearing Force Dummy Load Cell Reaction Force Load Cell Reaction Force

Solid Model of High Temperature Test Rig Components

Pictures of High Temperature PM Motor being driven to determine voltage and current waveforms for controller procurement.

CONCLUDING REMARKS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],High Temperature Test Rig will be completed and available for use as a sales tool in demonstrating the technology to potential customers.

[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Key Features of EEC High Temperature Magnets

(BH) max Versus Maximum Operating Temperature

Development of high temperature magnetic bearings

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