WebBased Innovative Collaborative Design of an Active Magnetic Bearing System for a TurboExpander

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Web-Based Innovative Collaborative Design of an
Active Magnetic Bearing System for a
Turbo-Expander
Some Basic Researches of Advanced Manufacturing
Technology Supporting Product Innovation, Project
of Major Program, NSFC, 59990470 Research on the
Modern Design of a New Type High-Speed Rotation
Machine and Knowledge Acquiring System, National
Key Technical Research and Development Project,
MOST, 98-15
Internet-Based Center for Design and
Manufacturing National Ministry of Education
Nov., 2003
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1. Member Institutions of the Innovative
Collaborative Design (1)
In order to demonstrate web-based innovative
collaborative design using distributed knowledge
resources, the design of an active magnetic
bearing system for a turbo-expander, which was
requested by a Turbo-Expander Co. Ltd. (TEC), was
carried out by Internet-Based Center for Design
and Manufacturing (IBCDM), National Ministry of
Education. The related top-level knowledge
resources within our country were integrated and
the whole process of design, analysis and
preparation of manufacturing were completed on
the Internet. It is shown that the idea of
knowledge service can be used to speed up
innovative product design in our country.
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1. Member Institutions of the Innovative
Collaborative Design (2)

• The resources are provided by
• Theory of Lubrication and Bearing Institute
  (TLBI), Xian Jiaotong University
• Advanced Manufacturing Technology Laboratory
  (AMT), Xian Jiaotong University
• Department of Mechanical Engineering (DME),
  Tsinghua University
• Department of Industrial Manufacturing Systems
  (DIMS), Huazhong University of Science and
  Technology
• National Engineering Research Center for CAD
  Software (NERC-CAD), Huazhong University of
  Science and Technology

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2. Introduction to Turbo-Expander (1)
The key process in air separation is to
liquidize the air or natural gas. Liquidized
oxygen, nitrogen, or other useful components can
be obtained at different liquidizing temperature.
Therefore, refrigeration devices are very
important in the system and a turbo-expander is
the key equipment among refrigeration devices.
For a turbo-expander, a bearing system with low
power consumption, high reliability, ease of
monitoring and maintenance, and low cost is
preferred.
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2. Introduction to Turbo-Expander (2)
A turbo-expander with sliding bearings
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3. Shortcomings of Traditional Turbo-Expanders

• High power consumption and low efficiency
• A large lubrication subsystem (several times
  larger than the main-body turbo-expander)
• Pollution caused by oil leakage

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4. Principle of Active Magnetic Bearing (AMB)
An AMB is composed of sensors, a controller,
power amplifiers and actuators. The principle
of the AMB is the value of control voltage is
given by the controller in accordance with the
position error measured by the sensors. The
control voltage is amplified to drive the
actuators, and zero error is maintained.
5-axis AMB and rotor system
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5. Difficulties in the Design of AMBs for
Turbo-Expanders

• Determining geometric parameters of the AMBs
• Controller design (load capacity and stability)
• Shaft neck protection in power off (auxiliary
  bearings)
• Analysis of critical speed of an AMB rotor
  system (the longer the rotor, the lower the
  critical speed)
• Satisfying the constraints on castability
• Satisfying the constraints on machinability of
  the housing and other parts
• Satisfying the constraints on assembility of the
  AMBs

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6. First step of the Integration Knowledge
Registration (1)
The precondition of the web-based product
design is a knowledge service provider
promulgating his/her service world wide so that a
service applicant can discover the well matched
knowledge resource units (KRUs) conveniently. A
widely supported UDDI (Universal Description,
Discovery and Integration) protocol provides the
capability for knowledge service providers and
applicants to discover each other. The
structured service information of a KRU is
registered into UDDI registration center via web.
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6. First step of the Integration Knowledge
Registration (2)
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7. Scheme of Description (Promulgation) and
Discover (Search) (1)
1. KRUs register their service information to
UDDI center manually or automatically. 2. A
design entity searches for useful KRUs manually
or automatically. 3. The matched KRUs return
information, such as the method of service
application, to the design entity.4. The design
entity sends design service application in XML
format to one or more KRU(s).5. The KRUs return
their service in XML format to the design entity.
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7. Scheme of Description (Promulgation) and
Discover (Search) (2)
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8. An Enterprise Applicant (a real company)
TEC
A turbo-expander produced by TEC has
double-impeller-structure with working speed of
3000040000rpm. The rotor is supported by sliding
bearings. The efficiency of the expander is low,
a large lubricant subsystem is needed,and
pollution may be caused by oil leakage. According
to market investigation, TEC decided to develop a
turbo-expander using AMBs and applied knowledge
service for the design of AMBs.
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9. Searching a Knowledge Service Provider
AMT Xian
TEC
TEC browsed UDDI registration center provided
by IBCDM? Several KRUs listed as A-G for AMB
design were obtained in search using active
magnetic bearing as key words.
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10?Knowledge Service Provider Assessment (KSPA)
AMT Xian
TEC
TEC found that AMT provided KSPA service by
searching UDDI registration center further. Using
KSPA software of AMT, TLBI was chosen as a
cooperator for the design of AMBs.
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11. Submitting Design Requirements
AMT Xian
TEC
TLBI Xian
TEC submitted design requirements and related
design drawings to TLBI via web.
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12. A Dynamic Primary Corporation Alliance (1)
As the first level design entity, TEC
designed the air flow path for the expander and
gave constraints on the design of AMBs using its
own knowledge resources. As the second level
design entity, TLBI designed the AMBs, including
deciding the geometric parameters, evaluating
dynamic property, etc. In order to analyze
castability, machinability and assembility of the
design, TLBI asked services from other KRUs.
Continuously using UDDI registration center and
KSPA of AMT, TLBI located further cooperators
among registered knowledge service providers. A
primary alliance of TEC, TLBI and AMT was formed,
new partners joined the alliance dynamically in
the process of the design in according with the
requirements.
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12. A Dynamic Primary Corporation Alliance (2)
AMT Xian
TEC
TLBI Xian
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13. Web-Based Collaborative Design (WCD) Platform
AMT Xian
TEC
TLBI Xian
IBCDM provides a WCD platform, on which
authorized users can manage project related KRUs
and drawing/data exchange dynamically.
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14. Geometric Design of the AMB
AMT Xian
TEC
TLBI Xian
According to the requirements, TLBI carried
out a conceptual design of the AMB. Using
self-owned resource of web-based software,
geometric parameters were obtained and saved in
XML format.
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15. Result of the Geometric Design of the AMB
AMT Xian
TEC
TLBI Xian
By calling a VC program for SolidWorks 2nd
application development, the data in XML file
were read. The program is a self-owned resource
of TLBI. A primary design of 3D-CAD drawings in
Solid- Works format was produced dynamically.
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16. Dynamic Property Evaluation
In the design, the rotor is longer and
slimmer, so that the critical speed is lower.
TLBI carried out the dynamic property evaluation
using a Matlab program by calling self-owned
resource. It is shown that the critical speed is
not satisfied.
The expander with AMBs and auxiliary bearings for
shaft neck protection in power off
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17. Dynamics Analysis and Redesign
The expander with auxiliary-bearing-free AMBs
In redesign, the auxiliary bearings were
removed for shortening the rotor and a satisfied
critical speed of the rotor system was obtained.
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18. Coating Film Design
The auxiliary bearings are used for shaft
neck protection in power off. In redesign, an
innovative idea of coating films on the poles of
the magnets to protect the shaft neck was
proposed. By inquiring the coating film data base
of TLBI, a kind of coated film was found, which
protects the shaft necks when power off takes
place at 40000 rpm and at the corresponding
compress ratio.
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18. Coating Film Design
The expander with AMBs and polymer films
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19. Exchanging Ideas with TEC
AMT Xian
TEC
TLBI Xian
The design was presented to TEC via
Netmeeting and Communitor. The member institutes
with different interests agreed with each other
on the design after exchanging the ideas by
repeated web-based dialogue.
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20. Castability
DME Beijing
AMT Xian
TEC
TLBI Xian
TLBI gave parts and assembly drawings of the
design in UG for further knowledge service.
The housing of the primary design was very
complex. TLBI searched and assessed service
providers of castability, and chose DME to
provide the service. TLBI applied from DME
for the service. The CAD files were downloaded by
DME via WCD platform. The castability of the
cover and base were assessed.
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21. Submission Castability
DME Beijing
AMT Xian
TEC
TLBI Xian
The castability of the cover and base was
analyzed by DME. A report of the analysis and
comments was returned to TLBI via WCD platform.
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22. Machinability
DME Beijing
AMT Xian
TEC
TLBI Xian
DIMS Wuhan
The 3D drawing of the stator of the thrust AMB
With the help of UDDI and KSPA system, TLBI
found that DIMS was qualified in machinability
assessment, and asked it to conduct the service.
DIMS downloaded CAD files of the design to assess
the machinability.
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23. Submission Machinability Results
DME Beijing
AMT Xian
TEC
TLBI Xian
DIMS Wuhan
Machinability analyzed by DIMS was returned
to WCD platform.
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24. Assemblity
DME Beijing
AMT Xian
TEC
TLBI Xian
NERC-CAD Wuhan
DIMS Wuhan
With the help of UDDI center and KSPA system,
TLBI found that NERC-CAD was qualified for
assembility assessment, and asked NERC-CAD to
conduct the service.
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25. Submission Assemblity Results (1)
NERC-CAD downloaded the CAD files of the
design from WCD Platform. The files were
converted to the model in VRML2 format for the
analysis of web-based concurrent assembly. The
planning, simulation and assessment of the
web-based concurrent assembly were realized. A
report on the analysis of the virtual assembly
and comments on the design were submitted to the
WCD platform.
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25. Submission Assemblity Results (2)
DME Beijing
AMT Xian
TEC
TLBI Xian
NERC-CAD Wuhan
DIMS Wuhan
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26. Manufacturing (1)
TLBI composed the final design by collecting
all reports, in which new knowledge of the design
was included. The primary design was revised.
Machining codes of the parts for hot- and
cold-working were prepared in parallel with the
assessment. Once the design was finished,
manufacturing could be started at once.
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26. Manufacturing (2)
DME Beijing
AMT Xian
TEC
TLBI Xian
NERC-CAD Wuhan
DIMS Wuhan
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27. Internet-Based Remote Experiment
DME Beijing
AMT Xian
TEC
TLBI Xian
NERC-CAD Wuhan
DIMS Wuhan
Internet-based remote experiment technique
was developed by TLBI, and the design was
assessed in the physical test.
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28. Design Result
DME Beijing
AMT Xian
TEC
TLBI Xian
NERC-CAD Wuhan
DIMS Wuhan
TLBI synthesized the reports on redesign,
castability, assembility, manufacturing, and
physical test, etc. The final result was reached
and returned to TEC.
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29. Web-Based Remote Monitoring and Diagnosis
Center (1)
So far, a test model of an innovative design
of a turbo-expander with AMBs had been
manufactured. The running performance would be
checked thereafter. It is necessary to monitor
and acquire its life-cycle information. TLBI
developed a web-based remote monitoring and
diagnosis center for the purpose. The center
provided the service of acquiring product running
information.
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29. Web-Based Remote Monitoring and Diagnosis
Center (2)
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30. Product Life Cycle Information Acquirement
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The running period of a product is the
longest and the most important period in its
life-cycle. The running behavior and information
of a product may show whether the design is
reasonable. Therefore, to acquire design
knowledge, a very important path is to collect
the running information and then compose it into
knowledge.
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31. Success in Experiment (1)
Experiments in TEC showed that the test model
increased and decreased speed smoothly, it ran
stably and the performance was satisfied. The
research ensures our country to be able to design
and manufacture the hightech turbo-expander with
AMBs, which has a wide social interests and
tremendous economic benefits.
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31. Success in Experiment (2)
TLBI Xian
TEC
A photo of experiment
The rotor and AMBs
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32. Conclusion
TLBI Xian
TEC
The rotor
With the efforts of all co- operators, an
innovative design of an AMB for a turbo expander
was carried out by integrating distributed
knowledge resources.
The rotor and bearing
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Thank you!