The Principle of Operation of the Magnetic Bearing

A Magnetic Bearing is an electro magnetic device, which maintains the relative position of a rotating assembly (rotor) with respect to a stationary part (stator). The electro magnetic forces
implemented for this are controlled by an electronic control cabinet. An active Magnetic Bearing is, therefore, made up of three distinct parts:

•  the bearing itself

•  the electronic control system
•  the auxiliary bearings (known as RDS, Rotor Delevitation System).

The configuration of the component parts is as follows:

Radial Bearing Configuration

Four electro magnets are arranged around the rotor to form the bearing. Each electro magnet is driven by an amplifier. In horizontal applications, the magnet centre lines are orientated at 45° to
the perpendicular such that forces due to gravity are acted on by the upper two adjoining magnets. This adds to the load capability and increases the stability of the system.

Opposite electro magnets are adjusted to pull against one another in the absence of any externally applied force, (the bias force). When an externally applied force causes a change in position
of the rotor it is sensed by position transducers, which, via the electronic control system, cause an increase in one current and a decrease in the other current flowing through the respective
electro magnets. This produces a differential force to return the rotor to its original position. The signal from the position transducers continuously updates the differential force to produce a
stable system.

Axial Bearing Configuration

A flat, solid ferro magnetic disc, secured to the rotor is used as the collar for the axial thrust bearing. Solid disc electro magnets are situated either side of the collar and operate in a similar
manner to the radial bearing above but in one dimension only.

Position Transducers

Two dimensions are controlled at each radial bearing location and one dimension is controlled at the axial bearing. One transducer could be used for each dimension if it were totally linear and
free from drift due to aging or temperature effects. Two transducers per dimension require only that a balance or difference be maintained, thus cancelling unwanted offsets. A passive bridge
system such as this is therefore preferred as it greatly increases the accuracy and reliability without undue increase in costs or complication.

The Electronic Control System

The purpose of the electronic control system is to control the position of the rotor by varying the current in the electro magnets. The electronic control system defines the stiffness and damping
of the magnetic suspension and these values can be adjusted and adapted to the disturbance frequency of the machine itself.

Auxiliary Bearings

Auxiliary bearings are used to support the rotor when the machine is stationary with the electronic control system switched off, or in the event of a failure in the magnetic suspension system to
allow the rotor to run down without damage to the rotor itself or the stator of the Magnetic Bearings. Dry bushings are employed as the primary technology for this purpose by Waukesha
Magnetic Bearings for this purpose with a clearance between the stationary and rotating parts of half the Magnetic Bearing. This unique patented WMB system known as an RDS (Rotor
Delevitation System) is much more rugged and reliable than the older roller bearings originally used

Product Benefits & Features

   

No Mechanical Contact
Since there is no mechanical contact either during normal operation or whilst the machine is at rest, assuming the Magnetic Bearing is not turned off,
there is no wear on the bearing system both during run up, run down or normal full speed operation. This eliminates mechanical maintenance and
provides extended service life in most cases for many years.

No Oil Contamination of Process Fluid

The Magnetic Bearing does not use oil and thus there can be no oil contamination of the process fluid. This is of particular importance in pipeline
compressors and air separation plant where the cost of oil extraction resultant from leakage at bearings and seals can be extremely high.

No Liquids
A cleaner and safer environment, decreases dramatically or in most
cases eliminate the potential for fire.

No Lubrication System
Since no lubricating oil system is required for the bearing it does not have to be purchased. This eliminates the needs for pumps, filters, tanks, piping
and coolers, which in high specification applications can lead to considerable cost savings.

Capability to Operate in a Process Fluid

Operating the Magnetic Bearings in the process fluid, either directly or by canning, eliminates the need for one or both seals. This also results in
considerable cost savings.

Wide Temperature Range Capability

The Magnetic Bearing system, if constructed from the correct materials, is capable of operating through an extremely wide temperature range. We
have applications from -180°C to +480°C, thus allowing operation where traditional fluid film bearings will not function.

  

High Speed Capability

The only limitation of speed is the bursting speed of the laminations fitted to the rotor shaft. This will allow machines to operate at speeds where all
other types of bearing will fail.

Low Energy Consumption

The only significant power loss in a Magnetic Bearing is the rotor windage since there are no power losses due to the churning of oil. On high-speed
applications this can result in tens of kW savings, which over a potential 20 year operating life will result in major cost savings.

Controllable Rotor Dynamics

The rotor dynamics are a function of the electronic control cabinet and can be adjusted to suit any machine operating condition. This greatly increases
machine flexibility and has the potential to allow standard bearings to operate in any machine environment with the electronic cabinet catering for
differences in machine design. Stiffness and damping coefficients can be scheduled against rotor speed to avoid critical speeds.
Vibration Attenuation
Magnetic Bearings have the ability to reduce vibration either by allowing the rotor to rotate about its centre of inertia, rather than centre of gravity, or
else by filtering out specific frequencies.

Improved Machine Diagnostics

In order to function the Magnetic Bearing must determine rotor position, rotor vibration and bearing load. This information, which is processed in the
electronic control cabinet can be given as an output to the OEM or end user such that there is constant knowledge of the operating state of the
machine. This allows the user to plan maintenance and often avoids the cost of purchase of a separate Bently Nevada type monitoring system.

Increased Reliability/Availability
All the above contribute to this, which is the most important benefit of Magnetic Bearings. Reliability/availability in excess of that currently achieved
with traditional hydrodynamic fluid film bearings has already been proven.