Some Basic Researches of Advanced Manufacturing Technology Supporting Product Innovation, Project of Major Program, NSFC, 59990470 Research

on the Modern Design of a New Type High-Speed Rotation Machine and Knowledge Acquiring System, National Key Technical Research and Development Project, MOST, 98-15

Web-Based Innovative Collaborative Design of an Active Magnetic Bearing System for a Turbo-Expander
Internet-Based Center for Design and Manufacturing National Ministry of Education

NSFC(No.59990470) & NKTRDP(98-15)

Nov., 2003

1. Member Institutions of the Innovative Collaborative Design (1)

In order to demonstrate web-based innovative collaborative design using distributed knowledge resources, the design of an active magnetic bearing system for a turbo-expander, which was requested by a Turbo-Expander Co. Ltd. (TEC), was carried out by Internet-Based Center for Design and Manufacturing (IBCDM), National Ministry of Education. The related top-level knowledge resources within our country were integrated and the whole process of design, analysis and preparation of manufacturing were completed on the Internet. It is shown that the idea of knowledge service can be used to speed up innovative product design in our country.

NSFC(No.59990470) & NKTRDP(98-15)

1. Member Institutions of the Innovative Collaborative Design (2)

The resources are provided by: Theory of Lubrication and Bearing Institute (TLBI), Xian Jiaotong University Advanced Manufacturing Technology Laboratory (AMT), Xian Jiaotong University Department of Mechanical Engineering (DME), Tsinghua University Department of Industrial & Manufacturing Systems (DIMS), Huazhong University of Science and Technology National Engineering Research Center for CAD Software (NERC-CAD), Huazhong University of Science and Technology

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2. Introduction to Turbo-Expander (1)

The key process in air separation is to liquidize the air or natural gas. Liquidized oxygen, nitrogen, or other useful components can be obtained at different liquidizing temperature. Therefore, refrigeration devices are very important in the system and a turbo-expander is the key equipment among refrigeration devices. For a turboexpander, a bearing system with low power consumption, high reliability, ease of monitoring and maintenance, and low cost is preferred.

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2. Introduction to Turbo-Expander (2)

Oil Tank and Oil Filtrating, Cooling and Cycling Systems

Sliding Bearings
Fig 1.turbo-expander with sliding bearings A Turboexpander Adopting Sliding Bearings System

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3. Shortcomings of Traditional Turbo-Expanders

High power consumption and low efficiency A large lubrication subsystem (several times larger than the main-body turbo-expander) Pollution caused by oil leakage

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4. Principle of Active Magnetic Bearing (AMB)

5-axis AMB and rotor system

An AMB is composed of sensors, a controller, power amplifiers and actuators. The principle of the AMB is: the value of control voltage is given by the controller in accordance with the position error measured by the sensors. The control voltage is amplified to drive the actuators, and zero error is maintained.

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5. Difficulties in the Design of AMBs for Turbo-Expanders

Determining geometric parameters of the AMBs Controller design (load capacity and stability) Shaft neck protection in power off (auxiliary bearings) Analysis of critical speed of an AMB rotor system (the longer the rotor, the lower the critical speed) Satisfying the constraints on castability Satisfying the constraints on machinability of the housing and other parts Satisfying the constraints on assembility of the AMBs

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6. First step of the Integration: Knowledge Registration (1)

The precondition of the web-based product design is a knowledge service provider promulgating his/her service world wide so that a service applicant can discover the well matched knowledge resource units (KRUs) conveniently. A widely supported UDDI (Universal Description, Discovery and Integration) protocol provides the capability for knowledge service providers and applicants to discover each other. The structured service information of a KRU is registered into UDDI registration center via web.

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6. First step of the Integration: Knowledge Registration (2)

Internet UDDI

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7. Scheme of Description (Promulgation) and Discover (Search) (1)

1. KRUs register their service information to UDDI center manually or automatically. 2. A design entity searches for useful KRUs manually or automatically. 3. The matched KRUs return information, such as the method of service application, to the design entity. 4. The design entity sends design service application in XML format to one or more KRU(s). 5. The KRUs return their service in XML format to the design entity.

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7. Scheme of Description (Promulgation) and Discover (Search) (2)

5 4

2 3

UDDI

Knowledge description and discovery using UDDI protocol

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8. An Enterprise Applicant (a real company)

TEC

A turbo-expander produced by TEC has double-impellerstructure with working speed of 3000040000rpm. The rotor is supported by sliding bearings. The efficiency of the expander is low, a large lubricant subsystem is neededand pollution may be caused by oil leakage. According to market investigation, TEC decided to develop a turbo-expander using AMBs and applied knowledge service for the design of AMBs. NSFC(No.59990470) & NKTRDP(98-15)

9. Searching a Knowledge Service Provider

AMT Xian TEC

TEC browsed UDDI registration center provided by IBCDM Several KRUs listed as A-G for AMB design were obtained in search using active magnetic bearing as key words. NSFC(No.59990470) & NKTRDP(98-15)

10Knowledge Service Provider Assessment (KSPA)

AMT Xian

TEC

TEC found that AMT provided KSPA service by searching UDDI registration center further. Using KSPA software of AMT, TLBI was chosen as a cooperator for the design of AMBs.

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11. Submitting Design Requirements

AMT Xian
TEC

TLBI Xian

TEC submitted design requirements and related design drawings to TLBI via web.

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12. A Dynamic Primary Corporation Alliance (1)

As the first level design entity, TEC designed the air flow path for the expander and gave constraints on the design of AMBs using its own knowledge resources. As the second level design entity, TLBI designed the AMBs, including deciding the geometric parameters, evaluating dynamic property, etc. In order to analyze castability, machinability and assembility of the design, TLBI asked services from other KRUs. Continuously using UDDI registration center and KSPA of AMT, TLBI located further cooperators among registered knowledge service providers. A primary alliance of TEC, TLBI and AMT was formed, new partners joined the alliance dynamically in the process of the design in according with the requirements.

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12. A Dynamic Primary Corporation Alliance (2)

AMT Xian TLBI Xian TEC

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13. Web-Based Collaborative Design (WCD) Platform

AMT Xian TEC TLBI Xian

IBCDM provides a WCD platform, on which authorized users can manage project related KRUs and drawing/data exchange dynamically.

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14. Geometric Design of the AMB

AMT Xian TEC
Web

TLBI Xian

According to the requirements, TLBI carried out a conceptual design of the AMB. Using selfowned resource of web-based Web-based knowledge service software, geometric parameters were obtained and saved in XML format. NSFC(No.59990470) & NKTRDP(98-15)

15. Result of the Geometric Design of the AMB

AMT Xian TEC

TLBI Xian

By calling a VC program for SolidWorks 2nd application development, the data in XML file were read. The program is a self-owned resource of TLBI. A primary design of 3D-CAD drawings in Solid- Works format was produced dynamically.

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16. Dynamic Property Evaluation

In the design, the rotor is longer and slimmer, so that the critical speed is lower. TLBI carried out the dynamic property evaluation using a Matlab program by calling self-owned resource. It is shown that the critical speed is not satisfied.
Controller Sensors Amplifier Magnets (Actuator)

Auxiliary Bearings
Fig 2. expander with AMBs and auxiliary bearings The Turboexpander Adopting Active Magnetic Bearing System with Auxiliary Bearings Protecting Shaft Neck in Power Off

for shaft neck protection in power off

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17. Dynamics Analysis and Redesign

Controller Sensors Amplifier Magnets (Actuator)

Fig 3. Turboexpander Adopting Active Magnetic Bearing The expander with System without Auxiliary Bearings

auxiliary-bearing-free AMBs

In redesign, the auxiliary bearings were removed for shortening the rotor and a satisfied critical speed of the rotor system was obtained.

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18. Coating Film Design

The auxiliary bearings are used for shaft neck protection in power off. In redesign, an innovative idea of coating films on the poles of the magnets to protect the shaft neck was proposed. By inquiring the coating film data base of TLBI, a kind of coated film was found, which protects the shaft necks when power off takes place at 40000 rpm and at the corresponding compress ratio.

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18. Coating Film Design

Controller Sensors

Amplifier Magnets (Actuator)

Polymer Films
Fig 3. Turboexpander Adopting Active Magnetic Bearing System with Polymer Films Protecting Shaft Neck in Power Off

The expander with AMBs and polymer films

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19. Exchanging Ideas with TEC

AMT Xian TEC TLBI Xian

The design was presented to TEC via Netmeeting and Communitor. The member institutes with different interests agreed with each other on the design after exchanging the ideas by repeated web-based dialogue. NSFC(No.59990470) & NKTRDP(98-15)

20. Castability
AMT Xian

DME Beijing

TEC TLBI Xian

TLBI gave parts and assembly drawings of the design in UG for further knowledge service. The housing of the primary design was very complex. TLBI searched and assessed service providers of castability, and chose DME to provide the service. TLBI applied from DME for the service. The CAD files were downloaded by DME via WCD platform. The castability of the cover and base were assessed. NSFC(No.59990470) & NKTRDP(98-15)

21. Submission Castability

AMT Xian

DME Beijing

TEC TLBI Xian

The castability of the cover and base was analyzed by DME. A report of the analysis and comments was returned to TLBI via WCD platform.
Optimizing the cast process of the base

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22. Machinability
DME Beijing
AMT Xian TEC TLBI Xian DIMS Wuhan

The 3D drawing of the stator of the thrust AMB

With the help of UDDI and KSPA system, TLBI found that DIMS was qualified in machinability assessment, and asked it to conduct the service. DIMS downloaded CAD files of the design to assess the machinability. NSFC(No.59990470) & NKTRDP(98-15)

23. Submission Machinability Results

DME Beijing
AMT Xian TEC

TLBI Xian

DIMS Wuhan

Machining process of the stator of the thrust AMB

Machinability analyzed by DIMS was returned to WCD platform.

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24. Assemblity
DME Beijing
AMT Xian TEC TLBI Xian DIMS Wuhan NERC-CAD Wuhan

With the help of UDDI center and KSPA system, TLBI found that NERC-CAD was qualified for assembility assessment, and asked NERC-CAD to conduct the service. NSFC(No.59990470) & NKTRDP(98-15)

25. Submission Assemblity Results (1)

NERC-CAD downloaded the CAD files of the design from WCD Platform. The files were converted to the model in VRML2 format for the analysis of web-based concurrent assembly. The planning, simulation and assessment of the web-based concurrent assembly were realized. A report on the analysis of the virtual assembly and comments on the design were submitted to the WCD platform.

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25. Submission Assemblity Results (2)

DME Beijing AMT Xian TEC TLBI Xian DIMS Wuhan NERC-CAD Wuhan

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26. Manufacturing (1)

TLBI composed the final design by collecting all reports, in which new knowledge of the design was included. The primary design was revised. Machining codes of the parts for hot- and cold-working were prepared in parallel with the assessment. Once the design was finished, manufacturing could be started at once.

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26. Manufacturing (2)

DME Beijing
AMT Xian TEC TLBI Xian DIMS Wuhan NERC-CAD Wuhan

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27. Internet-Based Remote Experiment

DME Beijing
AMT Xian TEC TLBI Xian DIMS Wuhan Client interface of remote experiment NERC-CAD Wuhan

Internet-based remote experiment technique was developed by TLBI, and the design was assessed in the physical test.

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28. Design Result

DME Beijing
AMT Xian TEC TLBI Xian DIMS Wuhan NERC-CAD Wuhan

TLBI synthesized the reports on redesign, castability, assembility, manufacturing, and physical test, etc. The final result was reached and returned to TEC.

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29. Web-Based Remote Monitoring and Diagnosis Center (1)

So far, a test model of an innovative design of a turboexpander with AMBs had been manufactured. The running performance would be checked thereafter. It is necessary to monitor and acquire its life-cycle information. TLBI developed a web-based remote monitoring and diagnosis center for the purpose. The center provided the service of acquiring product running information.

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29. Web-Based Remote Monitoring and Diagnosis Center (2)

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30. Product Life Cycle Information Acquirement

Design
1 2

The running period of a product is the longest and the most important period in its life-cycle. The running behavior and information of a product may show whether the design is reasonable. Therefore, to acquire design knowledge, a very important path is to collect the running information and then compose it into knowledge. NSFC(No.59990470) & NKTRDP(98-15)

31. Success in Experiment (1)

Experiments in TEC showed that the test model increased and decreased speed smoothly, it ran stably and the performance was satisfied. The research ensures our country to be able to design and manufacture the hightech turbo-expander with AMBs, which has a wide social interests and tremendous economic benefits.

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31. Success in Experiment (2)

TLBI Xian TEC

A photo of experiment

The rotor and AMBs

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32. Conclusion
TLBI Xian TEC

The rotor

With the efforts of all cooperators, an innovative design of an AMB for a turbo expander was carried out by integrating distributed knowledge resources.
The rotor and bearing

NSFC(No.59990470) & NKTRDP(98-15)

Thank you!