Vibration Mitigation of Rotors Suspended on Low-Cost Hybrid Gas Foil Bearing

2019 ◽  
Author(s):  
Kamal Kumar Basumatary ◽  
Karuna Kalita ◽  
Sashindra K. Kakoty ◽  
Seamus D. Garvey
Keyword(s):  
High Speed ◽  
Low Cost ◽  
Current Source ◽  
Magnetic Bearing ◽  
Active Magnetic Bearing ◽  
Electromagnetic Actuators ◽  
Manufacturing Method ◽  
Foil Bearings ◽  
Foil Bearing ◽  
Small Series

Abstract The hybrid Gas Foil Bearings combining the Gas Foil Bearing and Active Magnetic Bearing is a possibility for application in high-speed turbomachinery and a few developments have been made in this context. As such, the cost of conventional Gas Foil Bearing increases due to its requirement of precise manufacturing method and the coating material for the top foil and bump foil. In case of Active Magnetic Bearing, the normal electrical arrangement includes a multiplicity of independently controlled current sources usually at least four drives per bearing which increases its cost. Therefore, the hybrid Gas Foil Bearing will have much higher cost. In this work, a new electrical arrangement for the electromagnetic actuators of the hybrid Gas Foil Bearing has been proposed. The new arrangement requires only two drives per bearing and the bias current has been provided (in the same set of windings) through a simple rectifier with small series choke and shunt capacitor. As the number of drives required is less, the proposed bearing will have low cost. Implementing the new approach, the force vectors are achieved using only two current-source drives whereas the usual conventional arrangement requires four such drives. Numerical simulations are performed to explore the capabilities of the low cost bearing.

On the Performance of Hybrid Foil-Magnetic Bearings

1999 ◽  
Vol 122 (1) ◽  
pp. 73-81 ◽  
Author(s):  
H. Heshmat ◽  
H. Ming Chen ◽  
J. F. Walton,
Keyword(s):  
Carrying Capacity ◽  
High Speed ◽  
Magnetic Bearing ◽  
Journal Bearings ◽  
Load Carrying Capacity ◽  
Foil Bearings ◽  
Foil Bearing ◽  
Magnetic Elements ◽  
Load Carrying ◽  
Hybrid Bearing

Recent technological advancements make hybridization of the magnetic and foil bearings both possible and extremely attractive. Operation of the foil/magnetic bearing takes advantage of the strengths of each individual bearing while minimizing each other’s weaknesses. In this paper one possible hybrid foil and magnetic bearing arrangement is investigated and sample design and operating parameters are presented. One of the weaknesses of the foil bearings, like any hydrodynamic bearing, is that contact between the foil bearing and the shaft occurs at rest or at very low speeds and it has low load carrying capacity at low speeds. For high speed applications, AMBs are, however, vulnerable to rotor-bending or structural resonances that can easily saturate power amplifiers and make the control system unstable. Since the foil bearing is advantageous for high speed operation with a higher load carrying capacity, and the magnetic bearing is so in low speed range, it is a natural evolution to combine them into a hybrid bearing system thus utilizing the advantages of both. To take full advantage of the foil and magnetic elements comprising a hybrid bearing, it is imperative that the static and dynamic characteristics of each bearing be understood. This paper describes the development of a new analysis technique that was used to evaluate the performance of a class of gas-lubricated journal bearings. Unlike conventional approaches, the solution of the governing hydrodynamic equations dealing with compressible fluid is coupled with the structural resiliency of the bearing surfaces. The distribution of the fluid film thickness and pressures, as well as the shear stresses in a finite-width journal bearing, are computed. Using the Finite Element (FE) method, the membrane effect of an elastic top foil was evaluated and included in the overall analytical procedure. Influence coefficients were generated to address the elasticity effects of combined top foil and elastic foundation on the hydrodynamics of journal bearings, and were used to expedite the numerical solution. The overall program logic proved to be an efficient technique to deal with the complex structural compliance of various foil bearings. Parametric analysis was conducted to establish tabulated data for use in a hybrid foil/magnetic bearing design analysis. A load sharing control algorithm between the foil and magnetic elements is also discussed. [S0742-4795(00)01201-1]

Vibration control of high-speed rotor supported by hybrid foil-magnetic bearing with sudden imbalance

2015 ◽  
Vol 23 (8) ◽  
pp. 1296-1308 ◽  
Author(s):  
Sena Jeong ◽  
Yong Bok Lee
Keyword(s):  
Mass Loss ◽  
Vibration Control ◽  
High Speed ◽  
Turbine Rotor ◽  
Magnetic Bearing ◽  
Active Magnetic Bearing ◽  
Control Force ◽  
Transient Vibration ◽  
Stability Performance ◽  
Foil Bearing

A hybrid foil-magnetic bearing (HFMB) was successfully studied as a vibration isolator by introducing a sudden imbalance or an unexpected disturbance during turbine/rotor operation. This HFMB is used to achieve stability during transient vibration behavior. The HFMB consists of two oil-free bearing technologies: an active magnetic bearing (AMB) and air foil bearing (AFB). Using both technologies takes advantage of the strengths of each bearing while compensating for their inherent weaknesses. In addition, the HFMB has good dynamic characteristics, and the damping can be adjusted using the appropriate gain selection for the AMB controller. Based on these unique features, dynamic stability can be enhanced, even if a sudden imbalance occurs while the rotor is operating. In this study, a rigid rotor was operated at up to 12,000 rpm and tested using a control algorithm to reduce the sudden imbalance vibration amplitudes. The experiment was conducted under the situation that the mass dropped out at 6,000 rpm. In order to validate the stability performance of the HFMB with a sudden mass loss, the vibration response results for the AFB and HFMB were compared. When applying the HFMB, the asynchronous vibration was suppressed, and the 1x vibration results showed reductions of almost 30%. When the sudden mass loss occurred, the magnetic control force was remarkably effective at reducing the asynchronous vibration of the rotor supported by the HFMB. In conclusion, it was experimentally verified that using the HFMB made sudden imbalance vibration control possible during rotor operation with an air foil bearing. In this respect, the HFMB has the characteristics of high stiffness/damping, which prevent rubbing and suppress excessive vibration due to a sudden imbalance event.

scholarly journals Application of Gas Foil Bearings in China

2021 ◽  
Vol 11 (13) ◽  
pp. 6210
Author(s):  
Yu Hou ◽  
Qi Zhao ◽  
Yu Guo ◽  
Xionghao Ren ◽  
Tianwei Lai ◽  
...  
Keyword(s):  
High Speed ◽  
Low Cost ◽  
Small Scale ◽  
Environmental Friendliness ◽  
Wear Resistant Coatings ◽  
Foil Bearings ◽  
Foil Bearing ◽  
Turbo Machinery ◽  
Principle Theory ◽  
Rotor Dynamic

Gas foil bearing has been widely used in high-speed turbo machinery due to its oil-free, wide temperature range, low cost, high adaptability, high stability and environmental friendliness. In this paper, state-of-the-art investigations of gas foil bearings are reviewed, mainly on the development of the high-speed turbo machinery in China. After decades of development, progress has been achieved in the field of gas foil bearing in China. Small-scale applications of gas foil bearing have been realized in a variety of high-speed turbo machinery. The prospects and markets of high-speed turbo machinery are very broad. Various high-speed turbomachines with gas foil bearings have been developed. Due to the different application occasions, higher reliability requirements are imposed on the foil bearing technology. Therefore, its design principle, theory, and manufacturing technology should be adaptive to new application occasions before mass production. Thus, there are still a number of inherent challenges that must be addressed, for example, thermal management, rotor-dynamic stability and wear-resistant coatings.

scholarly journals On the Performance of Hybrid Foil-Magnetic Bearings

1998 ◽  
Author(s):  
Hooshang Heshmat ◽  
H. Ming Chen ◽  
James F. Walton
Keyword(s):  
Carrying Capacity ◽  
High Speed ◽  
Magnetic Bearing ◽  
Journal Bearings ◽  
Load Carrying Capacity ◽  
Foil Bearings ◽  
Foil Bearing ◽  
Magnetic Elements ◽  
Load Carrying ◽  
Hybrid Bearing

Recent technological advancements make hybridization of the magnetic and foil bearings both possible and extremely attractive. Operation of the foil/magnetic bearing takes advantage of the strengths of each individual bearing while minimizing each others weaknesses. In this paper one possible hybrid foil and magnetic bearing arrangement is investigated and sample design and operating parameters are presented. One of the weaknesses of the foil bearings, like any hydrodynamic bearing, is that contact between the foil bearing and the shaft occurs at rest or at very low speeds and it has low load carrying capacity at low speeds. For high speed applications, AMBs are, however, vulnerable to rotor-bending or structural resonances that can easily saturate power amplifiers and make the control system unstable. Since the foil bearing is advantageous for high speed operation with a higher load carrying capacity, and the magnetic bearing is so in low speed range, it is a natural evolution to combine them into a hybrid bearing system thus utilizing the advantages of both. To take full advantage of the foil and magnetic elements comprising a hybrid bearing, it is imperative that the static and dynamic characteristics of each bearing be understood. This paper describes the development of a new analysis technique that was used to evaluate the performance of a class of gas-lubricated journal bearings. Unlike conventional approaches, the solution of the governing hydrodynamic equations dealing with compressible fluid is coupled with the structural resiliency of the bearing surfaces. The distribution of the fluid film thickness and pressures, as well as the shear stresses in a finite-width journal bearing, are computed. Using the Finite Element (FE) method, the membrane effect of an elastic top foil was evaluated and included in the overall analytical procedure. Influence coefficients were generated to address the elasticity effects of combined top foil and elastic foundation on the hydrodynamics of journal bearings, and were used to expedite the numerical solution. The overall program logic proved to be an efficient technique to deal with the complex structural compliance of various foil bearings. Parametric analysis was conducted to establish tabulated data for use in a hybrid foil/magnetic bearing design analysis. A load sharing control algorithm between the foil and magnetic elements is also discussed.

Oil-Free Foil Bearings as a Reliable, High Performance Backup Bearing for Active Magnetic Bearings

2002 ◽  
Author(s):  
E. E. Swanson ◽  
H. Heshmat
Keyword(s):  
High Speed ◽  
High Performance ◽  
Dynamic Performance ◽  
Magnetic Bearing ◽  
Magnetic Bearings ◽  
Stable Operation ◽  
Foil Bearings ◽  
Foil Bearing ◽  
Limited Life ◽  
Rolling Element

Gas turbine engines and other high speed rotating machinery supported by magnetic bearings require some form of backup bearing to ensure reliable and safe operation. To date, this backup capability has been provided by either rolling element bearings or solid lubricated bushings. Both of these solutions have drawbacks — must notably limited life and uncertain dynamic performance. In many cases, the backup bearing system requires substantial maintenance following an activation event. An alternative approach investigated in this work is the use of a compliant foil bearing as a backup bearing. This work discusses tests of this concept on a test rig with a 63 kg rotor. In this application, the foil bearing demonstrated smooth, stable operation during a variety of simulated magnetic bearing failure events, and allowed for continued operation of the rotor following the simulated failures.

Rotordynamics Performance of Hybrid Foil Bearing Under Forced Vibration Input

2017 ◽  
Author(s):  
Daejong Kim ◽  
Brian Nicholson ◽  
Lewis Rosado ◽  
Garry Givan
Keyword(s):  
Impulse Response ◽  
High Speed ◽  
Load Capacity ◽  
Supply System ◽  
Forced Response ◽  
Experimental Results ◽  
Lateral Acceleration ◽  
Foil Bearings ◽  
Foil Bearing ◽  
Gas Supply

Foil bearings are one type of hydrodynamic air/gas bearings but with a compliant bearing surface supported by structural material that provides stiffness and damping to the bearing. The hybrid foil bearing (HFB) in this paper is a combination of a traditional hydrodynamic foil bearing with externally-pressurized air/gas supply system to enhance load capacity during the start and to improve thermal stability of the bearing. The HFB is more suitable for relatively large and heavy rotors where rotor weight is comparable to the load capacity of the bearing at full speed and extra air/gas supply system is not a major added cost. With 4,448N∼22,240N thrust class turbine aircraft engines in mind, the test rotor is supported by HFB in one end and duplex rolling element bearings in the other end. This paper presents experimental work on HFB with diameter of 102mm performed at the US Air force Research Laboratory. Experimental works include: measurement of impulse response of the bearing to the external load corresponding to rotor’s lateral acceleration of 5.55g, forced response to external subsynchronous excitation, and high speed imbalance response. A non-linear rotordynamic simulation model was also applied to predict the impulse response and forced subsynchronous response. The simulation results agree well with experimental results. Based on the experimental results and subsequent simulations, an improved HFB design is also suggested for higher impulse load capability up to 10g and rotordynamics stability up to 30,000rpm under subsynchronous excitation.

Rotordynamic Performance of a Shaft With Large Overhung Mass Supported by Foil Bearings

2016 ◽  
Vol 139 (4) ◽  
Author(s):  
Nguyen LaTray ◽  
Daejong Kim
Keyword(s):  
High Speed ◽  
Foil Bearings ◽  
Speed Test ◽  
Foil Bearing ◽  
Stable Conditions ◽  
Bending Mode ◽  
Mode Vibration ◽  
Lift Off ◽  
Compact Design ◽  
Bearing System

This work presents the theoretical and experimental rotordynamic evaluations of a rotor–air foil bearing (AFB) system supporting a large overhung mass for high-speed application. The proposed system highlights the compact design of a single shaft rotor configuration with turbomachine components arranged on one side of the bearing span. In this work, low-speed tests up to 45 krpm are performed to measure lift-off speed and to check bearing manufacturing quality. Rotordynamic performance at high speeds is evaluated both analytically and experimentally. In the analytical approach, simulated imbalance responses are studied using both rigid and flexible shaft models with bearing forces calculated from the transient Reynolds equation along with the rotor motion. The simulation predicts that the system experiences small synchronous rigid mode vibration at 20 krpm and bending mode at 200 krpm. A high-speed test rig is designed to experimentally evaluate the rotor–air foil bearing system. The high-speed tests are operated up to 160 krpm. The vibration spectrum indicates that the rotor–air foil bearing system operates under stable conditions. The experimental waterfall plots also show very small subsynchronous vibrations with frequency locked to the system natural frequency. Overall, this work demonstrates potential capability of the air foil bearings in supporting a shaft with a large overhung mass at high speed.

An Evaluation of Stability Indices Using Sensitivity Functions for Active Magnetic Bearing Supported High-Speed Rotor

2006 ◽  
Vol 129 (2) ◽  
pp. 230-238 ◽  
Author(s):  
Naohiko Takahashi ◽  
Hiroyuki Fujiwara ◽  
Osami Matsushita ◽  
Makoto Ito ◽  
Yasuo Fukushima
Keyword(s):  
High Speed ◽  
Transfer Functions ◽  
Mimo System ◽  
Magnetic Bearing ◽  
Singular Value ◽  
Active Magnetic Bearing ◽  
Sensitivity Functions ◽  
Phase Lags ◽  
The Stability ◽  
Stability Indices

In active magnetic bearing (AMB) systems, stability is the most important factor for reliable operation. Rotor positions in radial direction are regulated by four-axis control in AMB, i.e., a radial system is to be treated as a multi-input multioutput (MIMO) system. One of the general indices representing the stability of a MIMO system is “maximum singular value” of a sensitivity function matrix, which needs full matrix elements for calculation. On the other hand, ISO 14839-3 employs “maximum gain” of the diagonal elements. In this concept, each control axis is considered as an independent single-input single-output (SISO) system and thus the stability indices can be determined with just four sensitivity functions. This paper discusses the stability indices using sensitivity functions as SISO systems with parallel/conical mode treatment and/or side-by-side treatment, and as a MIMO system with using maximum singular value; the paper also highlights the differences among these approaches. In addition, a conversion from usual x∕y axis form to forward/backward form is proposed, and the stability is evaluated in its converted form. For experimental demonstration, a test rig diverted from a high-speed compressor was used. The transfer functions were measured by exciting the control circuits with swept signals at rotor standstill and at its 30,000 revolutions/min rotational speed. For stability limit evaluation, the control loop gains were increased in one case, and in another case phase lags were inserted in the controller to lead the system close to unstable intentionally. In this experiment, the side-by-side assessment, which conforms to the ISO standard, indicates the least sensitive results, but the difference from the other assessments are not so great as to lead to inadequate evaluations. Converting the transfer functions to the forward/backward form decouples the mixed peaks due to gyroscopic effect in bode plot at rotation and gives much closer assessment to maximum singular value assessment. If large phase lags are inserted into the controller, the second bending mode is destabilized, but the sensitivity functions do not catch this instability. The ISO standard can be used practically in determining the stability of the AMB system, nevertheless it must be borne in mind that the sensitivity functions do not always highlight the instability in bending modes.

Stability analysis of rigid rotors supported by gas foil bearings coupled with electromagnetic actuators

2019 ◽  
Vol 234 (2) ◽  
pp. 427-443 ◽  
Author(s):  
Kamal Kumar Basumatary ◽  
Gaurav Kumar ◽  
Karuna Kalita ◽  
Sashindra K Kakoty
Keyword(s):  
Stability Analysis ◽  
Equations Of Motion ◽  
Electromagnetic Actuator ◽  
Electromagnetic Actuators ◽  
Foil Bearings ◽  
Damping Characteristics ◽  
Foil Bearing ◽  
Model Combining ◽  
The Stability ◽  
Rigid Rotors

Rotors supported on gas foil bearings have low damping characteristics, which limits its application. A possible solution could be an integration of a gas foil bearing with an electromagnetic actuator. This paper discusses the effect of electromagnetic actuators on the stability of a rotor supported on gas foil bearings. A coupled dynamic model combining the dynamics of gas foil bearing and electromagnetic actuator has been developed. The fluid film forces from the gas foil bearings and the electromagnetic forces from the electromagnetic actuators are integrated into the equations of motion of the rotor. The sub-synchronous vibration present in case of conventional gas foil bearings is reduced and the stability band of the rotor is increased due to the implementation of electromagnetic actuator.

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