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Research Papers: Gas Turbines: Structures and Dynamics

Design, Modeling, Fabrication, Back-to-Back Test of a Magnetic Bearing System for High-Speed BLDCM Application

[+] Author and Article Information
Bangcheng Han

Science and Technology on Inertial Laboratory,
Beihang University,
Xueyuan Road,
Beijing 100191, China
e-mail: hanbangcheng@buaa.edu.cn

Shiqiang Zheng

Science and Technology on Inertial Laboratory,
Beihang University,
Xueyuan Road,
Beijing 100191, China
e-mail: zhengshiqiang@buaa.edu.cn

1Corresponding author.

Contributed by the Structures and Dynamics Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received March 3, 2015; final manuscript received March 19, 2015; published online May 12, 2015. Editor: David Wisler.

J. Eng. Gas Turbines Power 137(11), 112504 (Nov 01, 2015) (9 pages) Paper No: GTP-15-1076; doi: 10.1115/1.4030283 History: Received March 03, 2015; Revised March 19, 2015; Online May 12, 2015

This paper describes in detail the design, construction, and testing of an active magnetic bearing (AMB) system for high-speed permanent magnet (PM) brushless DC motor (BLDCM) application. A back-to-back (BTB) test setup which consists of two BLDCMs connected by a high-speed flexible coupling is designed and built: the first one acts as the motor and the other one acts as the generator with resistive load. The dynamic model of the rigid rotor supported by AMBs, and its electromagnetic and feedback control design aspects are also provided. Mechanical design aspects are rotor assembly, radial AMB (RAMB), and thrust AMB (TAMB). Finally, full-loaded test results of the AMBs are given using the BTB experimental test setup that adopts two 100 kW electric machines supported by AMBs.

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References

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Figures

Grahic Jump Location
Fig. 1

Section view of the BTB test setup. (1) Cast iron platform, (2) bending plate bracket, (3) tee head bolt, (4) axial sensor, (5) touch-down bearings (angular contact ball bearings with face-to-face arrangement), (6) thrust magnetic bearing, (7) radial sensor, (8) RMB, (9) motor stator, (10) high-speed rotor, (11) touch-down bearing (deep groove ball bearing), and (12) high-speed flexible coupling.

Grahic Jump Location
Fig. 2

RMB with eight poles. (a) Schematic of the RMB and (b) photo of the RMB.

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Fig. 3

Thrust magnetic bearing with PM bias. (a) Schematic of the thrust magnetic bearing and (b) photo of one stator of the thrust magnetic bearing.

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Fig. 4

Flexible coupling for high speed. (a) Schematic of the flexible coupling and (b) photo of the flexible coupling.

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Fig. 5

Description of rigid rotor AMBs system and its coordinate systems

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Fig. 6

The SISO model based on the ANF for one channel of the RAMB system

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Fig. 7

The generalized root locus affected by the rotational frequency of the rotor

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Fig. 9

The PM BLDCM supported by AMBs and its main parts

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Fig. 10

Testing Campbell diagram showing splitting of natural frequency (first bending mode) into forward and backward modes of the rigid rotor-AMBs in BLDCM

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Fig. 11

The measuring displacement signals of the sensors in AMBs under three kinds of test condition for driving BLDCM. (a) The measuring displacement signals when the rotor weight is levitated by the TAMB not the RAMBs for driving BLDCM with no-load speed of 27,780 r/min. (b) The measuring displacement signals when the rotor weight is levitated by the RAMBs not the TAMB for BTB setup with no-load speed of 27,696 r/min. (c) The measuring displacement signals when the rotor weight is levitated by the RAMBs not the TAMB for BTB setup with full-load power of 100 kW and speed of 28,470 r/min.

Grahic Jump Location
Fig. 12

The measuring displacement signals of the sensors in AMBs under three kinds of test condition for driven BLDCM. (a) The measuring displacement signals when the rotor weight is levitated by the TAMB for driving BLDCM with no-load speed of 27,924 r/min. (b) The measuring displacement signals when the rotor weight is levitated by the RAMBs for BTB setup with no-load speed of 27,696 r/min. (c) The measuring displacement signals when the rotor weight is levitated by the RAMBs for BTB setup with full-load power of 100 kW and speed of 28,470 r/min.

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