System and method for magnetic bearings
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Solution Overview
Problem
Magnetic bearings in centrifugal chillers experience energy losses due to eddy currents, which can be mitigated by segmenting the bearing core, but this approach is challenging and costly, and existing solutions like laminating the core have manufacturing difficulties.
Innovation Solution
A magnetic thrust bearing assembly with a partially segmented stator core featuring grooves that extend radially through the core, reducing eddy currents without the need for full segmentation, and using support rings with features that adjust friction for easier maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the bearing core is segmented to reduce eddy currents, then energy losses are reduced, but manufacturing complexity and cost increase
Solution Approach 1:
The bearing core is divided into multiple segments separated by non-magnetic material layers, which interrupts eddy current paths and reduces energy losses while maintaining a manageable manufacturing process through modular assembly
Solution Approach 2:
Non-magnetic material layers are introduced as intermediary elements between magnetic core segments, serving to block eddy current paths while allowing the core segments to be assembled together to form the complete bearing structure
2Loss of energy
If the bearing core is laminated to reduce eddy currents, then energy losses are reduced, but manufacturing difficulties arise
Solution Approach 1:
The core is segmented into discrete sections that can be manufactured separately and then assembled, avoiding the manufacturing complexity of traditional lamination processes while achieving similar eddy current reduction effects
3Ease of repair
If support rings are designed with adjustable friction features, then maintenance ease is improved, but device complexity increases
Solution Approach 1:
The support rings incorporate features that allow friction characteristics to be adjusted or changed, enabling easier maintenance operations while the overall structural complexity remains manageable through integrated design
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
The solution reduces eddy currents, enhances operational efficiency, and improves dynamic load capabilities, making the compressor more suitable for harsh environments while simplifying manufacturing and maintenance.
Implementation Method 1
magnetic bearings are typically kept in balance by frequently changing magnetic fields that work to balance out forces on the shaft due to operation. And these changes to the field induce eddy currents that reduce the compressor's overall operational efficiency and performance.
Implementation Method 2
opposing magnetic fields are used to balance the shaft in the axial and radial directions with respect to the stator
Implementation Method 3
Certain chillers use magnetic bearings—rather than mechanical bearings—to facilitate the rotation of the shaft and motor rotor
Implementation Method 4
support rings with features that adjust friction for easier maintenance
Data Source
AI summary
A compressor assembly is provided. Embodiments of the present disclosure generally relate to compressors used in chiller air conditioning systems for indoor spaces. The disclosed compressors have magnetic bearings that support rotating components. In one embodiment, the compressor comprises a partially segmented thrust bearing stator core. Additional systems, devices, and methods are also disclosed.