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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
MagneticMagnetic BearingsBearings
forfor SmartSmart AeroAero--EnginesEngines
MAGFLYMAGFLY
K.-H. Becker
MTU Aero Engines
FifthFifth AeronauticsAeronautics Days 2006Days 2006
1919thth –– 2121stst JuneJune 20062006
2
MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
TechnionTechnionTRDFTRDF
TheThe ConsortiumConsortium::
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
Today's aeroToday's aero--engines are designed withengines are designed withmechanical bearing systems, whichmechanical bearing systems, whichconsist of ball or roller bearings, oftenconsist of ball or roller bearings, oftensupported by squeeze film dampers.supported by squeeze film dampers.
ballball oror thrustthrust bearingbearing
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
combustioncombustionchamberchamber
Low Pressure CompressorLow Pressure Compressor
High Pressure CompressorHigh Pressure Compressor
Low Pressure TurbineLow Pressure Turbine
bearing locations (roller and ball)bearing locations (roller and ball)
FanFan casingcasing
High Pressure TurbineHigh Pressure Turbine
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
bearingbearingcagecage
brgbrg outer raceouter race
rollerroller
squeeze filmsqueeze film
oil feedoil feed
brgbrg inner raceinner race
to bearingto bearinglubricationlubrication
sealingsealing
roller bearing withroller bearing with squeeze film dampersqueeze film damperboth cooled and lubricated with oilboth cooled and lubricated with oil
oil inoil in
oil jetoil jet
bearingbearing lubricationlubrication throughthroughcentercenter ofof thethe inner ringinner ring
outer raceouter race
innerinnerracerace
ballball
rotating partsrotating parts
cagecage
oil streamoil stream
oiloiloutletoutlet
oiloil inin
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
All over the world, but particularly in the United States and in Europe, there is a drive towardsgreater efficiency with the 'More Electric Aircraft''More Electric Aircraft' and 'More Electric Engines''More Electric Engines' programmes andthe prognosis is that future aero-engines will increasingly incorporate mechatronicmechatronic systemssystems.
Radial Bearing Statorrotorlaminationstack
statorlaminationstack& coil holders
magneticmagnetic bearingbearing
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
Bearing Stiffness
Ro
tor
Cri
tica
lSp
eed
Adjustable MagneticAdjustable MagneticBearing StiffnessBearing Stiffness
Mode ShapesMode Shapes
11stst criticalcriticalbending modebending mode
22ndnd criticalcriticalbending modebending mode
33rdrd criticalcriticalbending modebending mode
Magnetic bearingscontrol stiffnessand damping tominimizetransmission ofunbalance forcesto casings andmountings
rigidrigid bodybodymodesmodes
mixedmixedmodemode
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
more compact and efficient engine designmore compact and efficient engine design
lower friction losses, and hence increasedlower friction losses, and hence increasedefficiencyefficiency
ultraultra--low wear in the bearingslow wear in the bearings
reduced emissionsreduced emissions
reduced fire hazard (no oil in the engine)reduced fire hazard (no oil in the engine)
longer maintenance intervalslonger maintenance intervals
lower direct operating and lifetime costslower direct operating and lifetime costs
higher speeds and performancehigher speeds and performance
control and reduction of vibrations, noisecontrol and reduction of vibrations, noiseand stressesand stresses
One of the ideas in this direction is to substitute the current mechanical bearingsystem by Active Magnetic Bearings (AMBsAMBs). This substitution offers the prospect ofseveral advantages, specifically:
Nominal diameter: 110 mm
Radial: Max. force: 2400 N
Thrust: Max. force: 5000 N
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
Magnetic Bearing LimitationsMagnetic Bearing Limitations
Larger BearingsLarger Bearingsspecific load capacity (maximum load per unit of areaof application) lower than most other bearings systems.
Higher ComplexityHigher Complexity (control)(control)Control system and interface
Requires Electrical PowerRequires Electrical PowerMagnetic bearing require power to drive theelectromagnets, control systems and sensors.
TodayToday:
power unit is still heavy for aeroplanes but removing oilsystem and its auxiliaries eliminates nearly this effect
applicable for non flying engines
but progress in superconduction and improvement ofweight to power ratio will reduce weight and size
ExampleExample: AMB: AMB controlcontrol unitunit10 channel AMB control unitMax. Output Power: 2400 VA or4800 VA per channel
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
Schematic overviewSchematic overviewof MAGFLYof MAGFLYWorkpackagesWorkpackagesandandInteractionsInteractions
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
LoadshareLoadshare Bearing forBearing forHeavy Rotating Machinery (rig 2)Heavy Rotating Machinery (rig 2)
Rotors up to 150kg
Two pairs of bearings:
one set with axial play
one set with zero preload
Elastic damper mounting
Grease or dry lubrication
WP 1:WP 1: ActiveActive MagneticMagnetic Bearing DesignBearing Design
LoadLoad--sharing bearingssharing bearingsdesigns and design rules for loaddesigns and design rules for loadsharing bearingssharing bearingsalternative designs to provide loadalternative designs to provide load--sharing and emergency bearingssharing and emergency bearings
12
MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
51.551.5mmmm
Characteristics:
Very good linearity
High sensitivity
Working from room temperature up to 600°C
High cost efficiency
Temperature compensated
High Temperature bearingsHigh Temperature bearingsdesign AMBs using highdesign AMBs using hightemperature resistant materialstemperature resistant materialslong term performance andlong term performance andcontrollabilitycontrollability
WP 1:WP 1: ActiveActive MagneticMagnetic Bearing DesignBearing Design
Principle:Eddy current position sensorsprinted on ceramic substrate
DevelopmentDevelopment ofof newnew sensorssensorsforfor thethe highhigh temperaturetemperature rigrig
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
WP 1:WP 1: ActiveActive MagneticMagnetic Bearing DesignBearing Design
Overall AMB designOverall AMB designrequirements for AMBs in aerorequirements for AMBs in aero--engines are very specific,engines are very specific,to create a optimum AMB designto create a optimum AMB design
toto adoptadopt thethe magnaticmagnatic bearingsbearings toto thethe specificspecificrequirementsrequirements
at normalat normal temperaturetemperature operationoperation
at highat high temperaturetemperature operationoperation
rotorrotor
statorstator
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
WP 2:WP 2: WholeWhole SystemSystem ModellingModelling
Develop Models of :• casing, bearing supports, shaft and rotor;• AMBs;• load-sharing bearings;
Integration of the component models into an overall representative modelof the complete system.
Incorporation of the modelling methods into a user-friendly, fast andreliable modelling tool for commercial application.
It is aimed to develop a set of validated dynamic analysis modelling tools for themajor components of a rotor system supported in AMBs, and an overall modelfor the SMART aero-engine:
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
Develop Validated AMB ModelDevelop Validated AMB Model
StructuralStructural Model ofModel of MagneticMagnetic bearingbearing ElectromagneticElectromagnetic fluxfluxdistributiondistribution ModelModel
• Validating Model of Electromagnetic Forces
(i) Verify the design of the electromagnetic system making surethat no magnetic saturation takes place;
(ii) Provide an understanding of the nonlinear behaviour of thecoupled electromagnetic and structural fields;
(iii) Provide accurate estimation for the parameters from which asimplified model is made.
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
WP 3:WP 3: WholeWhole EngineEngine DesignDesign
Main Objective: Verification of component and system models of thecomplete system including controllerIntegrated model used for several design analyses to assess overallperformance under different operating conditionsFocal task, needs and combines input from all other work packages
Simulate the whole system to evaluate dynamic performance
Develop robust sensitivity and optimisation procedures.
Sensor design and location
Damage Sensitivity
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
WP 3:WP 3: WholeWhole EngineEngine DesignDesign
whole system simulation and possible sensor locations
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
WP 3:WP 3: WholeWhole EngineEngine DesignDesign
whole system simulation and possible sensor locations
19
MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
Develop robust sensitivity and optimisationDevelop robust sensitivity and optimisationproceduresprocedures
- Initial design unlikely to be optimum- Full model enables parameter variation and
investigation of parameters’ interaction- Influence of AMB’s bearing stiffness
to rotor dynamic behaviour
rear bearing
0
5 0
1 0 0
1 5 0
2 0 0
2 5 0
3 0 0
3 5 0
4 0 0
bearing stifness [N/mm]
freq
uen
cy[H
z]
Adaptation of optimisation tool Boss-Quadro tomodified SAMCEF rotor dynamic solutions allowsoptimisation of multiple analyses
Monte CarloMonte Carlo MethodMethod
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
parallel / serial link or modem
sensorsensor signalsignal
++
––
powerpoweramplifiersamplifiers
rotorrotor
DSPDSPAAAA
DDDD
Fast digitalFast digitalcontrollercontroller
magnetmagnet
sensorsensor
++
--
ControlControl System and InterfaceSystem and Interface forfor SMARTSMART
improved monitoring, diagnosis, prognosis and correction capabilities in the sense of SMARTMachine Technology. SMART is used here in its original context of:
Self-Monitoring, Analysis and Reporting Technology
WP 4: SmartWP 4: Smart EnginesEngines
SMARTSMART
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
Active diagnostics of rotating partsActive diagnostics of rotating parts in Aeroin Aero--EnginesEngines
• Motivation• Rotating parts are not accessible during normal operation
• Must service periodically time consuming costly• Computer controlled Active Magnetic Bearings enable in-situ inspection
• Method• Apply extremely small probing forces (no effect of magnetic levitation)• Probing forces are tuned in real-time according to a calibrated model and
instantaneous speed of rotation• Special signal processing extracts the information about any deviation from
perfect condition in rotating parts (shaft, blades)
• Advantages• Use of existing Magnetic bearings, non-contacting forces• Separate faults in rotating part from casing and non-rotating elements• Detect extremely small faults (e.g. 0.1% deviation in asymmetry)
WP 4: SmartWP 4: Smart EnginesEngines
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
Activemagneticbearings
diagnosticsdisplay&probingexcitation
shaft
Disc withdefect
TechnionTechnionTRDFTRDF
Active diagnostics of rotating partsActive diagnostics of rotating parts in Aeroin Aero--EnginesEngines
WP 4: SmartWP 4: Smart EnginesEngines
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
Small-defect
Asymmetric
No-defectsymmetric
Vib
ratio
nle
vel (
log )
Vib
ratio
nle
vel (
log]
Test during runup
Speed: 0 2250 RPM
Probing ω= 101.5Hz
1% fault
probing
1% defect in rotating part
Probing force by magnetic bearings
detection of fault in rotating part
WP 4: SmartWP 4: Smart EnginesEngines
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
AMB AAMB A
AMB BAMB B
RingbalancerRingbalancerAA BB
MotorMotor turbineturbinedisksdisks
WP 5:WP 5: DemonstrationsDemonstrations Rig 1 (MTU) running at TU Darmstadt
0 200 400 600 800 1000
Mode Shapes (calculated, freeMode Shapes (calculated, free--free)free)
0 rpm | 51 Hz 0 rpm | 140 Hz 0 rpm | 439 Hz
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
WP 5:WP 5: DemonstrationsDemonstrations Rig 2 (Turbomeca) running at ICL
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
WP 5:WP 5: DemonstrationsDemonstrations High-temperature rig running EPFL
50 mm50 mm highhigh temperaturetemperature rigrig
the walls of the furnace are dismounted
highhigh temperaturetemperaturemagneticmagnetic bearingbearing
rotorrotor
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MagneticMagnetic Bearings for Smart AeroBearings for Smart Aero--EnginesEngines
K.-H. Becker MTU Aero Engines
WP 5:WP 5: DemonstrationsDemonstrations Task 5.4 HighTask 5.4 High--temperature rigtemperature rig
Life span tests athigh temperature:
Magnetic andmechanical properties