Rotary Machine Axial Mechanical Thrust Bearing Design
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Solution Overview
Problem
Rotary machines with magnetic bearings face challenges in manufacturing costs and electrical power consumption due to the need for continuous electrical power and the requirement of axial magnetic bearings, which can be costly and inefficient.
Innovation Solution
The implementation of an axial mechanical thrust bearing with a rolling element in direct axial contact with the rotor shaft, reducing power consumption and manufacturing costs by eliminating the need for axial magnetic bearings and decoupling the radial magnetic bearing function using elastic means, allowing the rotor to move freely without disturbing the radial magnetic bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If axial magnetic bearing is used to support rotor weight, then rotor is supported without mechanical friction, but manufacturing cost and electrical power consumption increase
Solution Approach 1:
The patent replaces the axial magnetic bearing (electromagnetic system) with a mechanical thrust bearing consisting of a rolling element and flat surface. This substitution eliminates the need for continuous electrical power supply while maintaining reliable rotor support through direct mechanical contact in the axial direction.
Solution Approach 2:
The patent extracts the axial support function from the magnetic bearing system and assigns it to a dedicated mechanical thrust bearing. This separation allows the radial magnetic bearings to focus solely on radial suspension while the mechanical bearing handles axial weight support, reducing overall system complexity and power consumption.
2Ease of manufacture
If axial magnetic bearing is used for rotor support, then continuous rotor support is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces the expensive axial magnetic bearing with a simple mechanical thrust bearing comprising a rolling element and flat surface. This mechanical solution is significantly cheaper to manufacture while providing reliable axial support for the rotor weight.
Solution Approach 2:
The mechanical thrust bearing uses simple, inexpensive components (rolling element, flat surface) that can be easily replaced if needed, rather than using expensive magnetic bearing components. This approach prioritizes cost-effectiveness while maintaining functional reliability.
3Ease of manufacture
If axial mechanical thrust bearing is in direct contact with rotor shaft, then manufacturing cost is reduced, but wear of rolling element increases
Solution Approach 1:
The patent introduces a stator plate as an intermediary component between the rolling element and the rotor shaft. The rolling element contacts the stator plate while the rotor shaft contacts the stator plate's bearing surface, distributing the load and reducing wear on the rolling element while maintaining the mechanical thrust bearing's cost advantages.
4Stability of the object's composition
If stator plate is fixed rigidly to stator casing, then axial support is stable, but radial magnetic bearing performance is disturbed
Solution Approach 1:
The patent uses elastic means (flexible connection) to attach the stator plate to the stator casing. This flexible connection allows the stator plate to accommodate radial movements of the rotor while maintaining axial support stability, preventing disturbance to the radial magnetic bearing's active control function.
Solution Approach 2:
The patent transitions from a rigid fixed connection to a dynamic flexible connection using elastic means. This allows the stator plate to move slightly with the rotor's radial position changes while maintaining axial support, ensuring both axial stability and radial magnetic bearing performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces manufacturing costs and electrical power consumption while ensuring the rotary machine's stability and performance by allowing the radial magnetic bearings to actively control the rotor's movement without radial forces, thus preventing damage and extending the service life of the mechanical thrust bearing.
Implementation Method 1
The stator plate is fixed to the stator casing by elastic means
Implementation Method 2
a rotary machine comprising magnetic bearings for supporting the weight and load of a rotor of the rotary machine by active magnetic bearings thanks to magnetic fields
Data Source
Figure 1
Figure 2
AI summary
A rotary machine (10) comprises a stator (12) having a stator casing (18), and a rotor shaft (16) having a rotational axis (X-X) and supported in said stator casing (18) by at least one radial magnetic bearing (20, 22). The rotary machine (10) comprises an axial mechanical thrust bearing (24, 30) at the vicinity of a radial surface of one end (16b) of the rotor shaft (16), said axial mechanical thrust bearing (24, 30) comprising a rolling element (24a, 32) located on the rotational axis (X-X) of the rotor shaft (16).