Air Foil Bearing

2011
Neuros Co., Ltd

Air Foil Bearing

Air film is generated automatically by the hydrodynamic interaction between

viscous fluid and foil structure in a rotating sleeve.
Elasto-Hydrodynamics : Elasticity + Reynolds Eqn. for Lubrication
Running Air Film Thickness : 5 ~ 20 m
Application : Oil-Free Small & High Speed Rotor
Pressure Distribution

Velocity Distribution

Hydrodynamic Pressure Generation

Principle of Air Bearing

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Applied Configuration

Bump Type : 2 Journal Bearings + 2 Thrust Bearings

Journal Bearings : Rotor Weight + Unbalance Load + Instability Operability

Thrust Bearings : Thrust Load + Tip Clearance Control + Power Loss Performance

Journal Bearing
3

Thrust Bearing

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Principle

Elasto-Hydrodynamics
Semi-Empirical Method
Hydrodynamics

Reynolds Eqn
Compressible Viscous Fluid Dynamics
FDM : Nonlinear
Pressure Distribution
Geometry (by Elastic Deformation of Top Foil)

Iterative Solution
Relaxation Factor

Elasticity
Beam or Plate Theory
Linear Elastic Deformation
FEM
Foil Deflection
Force (by Pressure from Hydrodynamics)

Journal Bearing
4

Thrust Bearing
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Elasticity of Foil Structure

Top foils are supported by bump springs

Top foil : Geometry for hydrodynamics
Bump foil : Considered as spring with k B
Foil structure is designed to be in elastic range of
material Infinite life with normal operation

Stress,

f
m
u
u'

Limit

f
m
u
u'

i
i

i+1

Top Foil

i+1

kB

i+1

i+1

LE
EI

Limit : Elastic Range

Bump Foil

2 (30%)

1 (10%)
Strain,
2 : Max. Value in Running
FEM Analysis of Bump

1: Rotor Weight

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Advantages of Air Foil Bearing

Noncontact Bearing

Oil-Free

Higher Reliability : Simple, No Oil Lub. System

System Weight Reduction : over 15% of Total Weight

Soft Failure : Easy to Replace

High Speed Operation : ~ 4 million DN (Others ~ 1 million DN)
Environmental Durability

Long Life / No. Scheduled Maintenance

Improved Performance : Low Power Loss
Low Noise and Vibration

Low and High Temp. : Cryogenic ~ 650 C

Process Fluid Operation : Air, Neon,Helium, Xenon, Refrigerants, Liquid Oxygen, Liquid
Nitrogen

More Stable Rotor Structure

Larger Bearing Journal Size : D 40mm at 100,000 RPM

Increase Stiffness Property of Rotor
Bigger Critical Speed Margin
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Comparison with Other Bearings

High DN Number : D (Diameter in mm) x N (RPM)
Reliable, Long Life, Simple, and Environment-friendly

Fluid Film Bearing

Rolling Element Bearing

Air Foil Bearing

Small
Low Loss
High Load

Long Life
Low Vibration
Hydrodynamic

High Speed
Simple/Oil-less
Low Loss

Low Load
Coating
Small Rotor

ACM
Small Machine

Aero Engine
Small Machine

Noisy
Short Life
Limited DN

Complex
High Loss
Limited DN

Industrial Machine

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Rotordynamics using Air Foil Bearing

Industrial Turbo Machine : Motor + Compressor + Turbine

Stable Critical Speed Design with Air Foil Bearing
60000

Ball Bearing

Rotational Speed, RPM

Ball Bearing
Air Foil Bearing

50000
3rd

79%

40000

7%

30000
Operating Range

20000
2nd

10000
1st

Air Foil Bearing

0
6
10

10

Supports Stiffness, N/m

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Application of Air Foil Bearing

ACM for ECS (Cabin Pressurizing/Avionics Cooling)

Increasing Demands for Larger Industrial Turbomachinery

Small / High Speed Rotor : <1kg, 60,000 ~ 100,000 RPM

Very Reliable and Infinite Life : B747, B777, F18, B1B, M1A1, etc.
Environment-Friendliness (Low Noise & Vibration, Oil-Free)
Improved Performance (Low Power Loss, Simple Configuration)

Few large machines are available on the Market

Journal Bearing Diameter (mm)

100

80

60

Demanding
Region
Potential Region

40

Applied Region

20

0
20000

40000

60000

80000

100000

120000

140000

Rotor Speed (RPM)

ACM

Application Spectrum
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Bearing Trends
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Application to Industrial Machines

Journal Bearing Diameter (mm)

Applied to Various Turbo Machines: ~ 100,000 RPM, ~ 600 C

Turbo Blowers with High Speed Motor : Advanced Application

100

80

Potential Region
Region III

Turbo Blower
Turbo Compressor
Microturbine
Cryocooler
Pathfinder

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Region I : Conventional
ACM, Turbo Expander
Mircroturbine

Region II : Medium
Turbo Compressor
Microturbine

Region II
40

Region I

Region III : Advanced

Turbo Blower

20

0
20000

40000

60000

80000

100000

120000

Rotor Speed (RPM)

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Developed Air Foil Bearings

Group 1

Group 2

Group 3

Group 4

Group 5

Group 6

Turbo Blower

Cryocooler

Micro Turbine

NRL Motor

Compressor for
PEM FC

ACM for
Aircraft

30 ~ 300 hp

38 kW

65 kW

200 kW

15kW

Cooling 2kW

PMSM

PMSM

PMSM

PMSM

PMSM

17,000~60,000

100,000

61,300

70,000

96,000

60,000

Journal Dia.

40~90 mm

40 mm

50 mm

60 mm

25 mm

25 mm

Rotor Mass

3~26 kg

2.6 kg

12 kg

8.6 kg

0.9 kg

0.6 kg

3.6 million

4 million

3 million

4.2 million

2.4 million

1.5 million

Temp.

~ 200 C

~ 200 C

~ 600C

~ 200 C

~ 200 C

~ 200 C

Fluid

Air, Gas

Air, Gas

Air

Air

Air

Air

Application
Power
Motor
RPM

DN

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Application 1
Features
Motor : 50 ~ 300 HP
PD : 0.3 ~ 1.0 kgf/cm2
TD : 58 ~ 106 C

High Efficient Compressor

High Speed Motor/Inverter
Air Foil Bearing
Cooled by Itself

Sewage Treatment
Pneumatic Conveying
Air Supply for
Chemical Process
Ventilation
Cooler

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Application 1

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Application 2

PMSM for Neon Compressor

38 kW at 100,000 RPM
Gas Foil Bearing

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Application 3

Cogeneration System using a Microturbine : 65 kW

Life : 30,000 hrs (Time Between Overhauls)
Noise : 65dB @10m

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Application 3

Vibration Free Rotor System

Oil Free System

Air Foil Bearing

Flexible Coupling Design

Critical Speeds
(RPM)
1st

2nd

3rd

4th

Analysis

11,760

12,150

15,160

19,387

Experiment

10,300

10,650

14,970

17,970

5th
140,260

Flexible Coupling

Mircroturbine Rotor Assembly

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Application 4

Micro Air Compressor for PEM Fuel Cell

15 kW @ 96,000 RPM

Operating temperature : -20C to 50C

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Application 5

ACM for Aircraft POD

Cooling Capacity 2 kW
40,000 ~ 60,000 rpm

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Air Foil Bearing Test Rig 1

Air Turbine Driven : ~ 30,000 RPM

Loading by Pneumatic Device : ~ 80 kgf
Journal & Thrust Bearing Test

Journal Bearing Test

Thrust Bearing Test

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Air Foil Bearing Test Rig 2

Motor Driven : ~ 120,000 RPM

Loading by Pneumatic Device : ~ 30 kgf
Journal & Thrust Bearing Test

Journal Bearing Test

Thrust Bearing Test

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Air Foil Bearing Test Rig 3

Motor Driven : ~ 42,000 RPM

Loading by Pneumatic Device : ~ 80 kgf
High Temperature Environment : ~ 600 C

High Temp. Test

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Air Foil Bearing Test Rig 4

On/Off Test for Endurance of Coating : 20,000 Cycles

Rotor Mass : 2.6 kg
Motor Driven
Automation Using LabView

On/Off Test
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Endurance Test Results

RPM Profile

Vibration (Shaft Disp.)

Shaft Surface

Journal Bearing Surface

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Air Foil Bearing Test Rig 5

Rotor-Bearing Simulator : Air-lubricated, Rotor Mass 13.2 kg

75kW Motor(PMSM) with Inverter : Accurate Speed Control
Axial Loading Mechanism : Pressurizing on Rotating Disk
Power Loss Evaluation by Temperature & Cooling Flow Rate
Max. 30,000 RPM and 100 kgf
High Speed Motor
Pressurinzing Air In
Load Cell

Cooling Air Out

LM
Guide

Cooling Air In

Pressurizing Chamber
Air Foil Thrust Bearings
Air Foil Journal Bearings

Labyrinth Seal

Rotor-Bearing Simulator
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Air Foil Bearing Test Rig 6

Rotor-Bearing Simulator : Air-lubricated, Rotor Mass 26 kg

223kW Motor(PMSM) with Inverter
Axial Loading Mechanism
Max. 25,000 RPM and 100 kgf

Rotor-Bearing Simulator

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Lift Off Speed of Journal Bearing

Rotor Mass : 14.7 kg

Lift Off Speed : 2,000 RPM <- Coast Down RPM Data
[RPM]

Speed (RPM) - Input

W orking : Input : Mu lti-buffer 1 : Tachometer

28000
24000
20000
16000
12000
8000
4000
0
692

696

700

704

708
[s] (Time)

26

712

716

720

724

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Endurance at Field Operation

50hp Turbo Blower : Steel Company

Field Operation : 20,000 On/Off
Cycles

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Endurance Test of FC Compressor

20hp Compressor for PEM FC

1,000,000 On/Off Cycles

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Blower : Low Pressure Compressor

Pressure Ratio : 1.3 ~ 2.0

Type

Positive Displacement Blower : Roots

Turbo Blower : Gear Box Type / High Speed Motor
Efficiency, Maintenance, Noise : Roots Type
Turbo Type

Application

Air Supply : Waste Water Treatment, Power Plant Desulfurization

Raw Power Transportation : Cement Industry, Petrochemical Industry
Ventilation / Cooling / Vacuum

Turbo Blower

Roots Blower
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Applications of Blower

Waste Water Treatment

Aerobic microorganisms dissolve contaminants by blowing air into sewage

Air
3 ~ 10 m

Blower

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Turbo Blower
High Speed Turbo Blower

Gear Driven Turbo Blower

High Speed Motor

Single Rotor : Compressor + Motor
Air Foil Bearing

Low Speed AC Motor

Coupling + Gear Box + Compressor
Fluid Film Bearing

Large & Complex

Oil System & Cooling System
Periodical Maintenance (G/B, Coupling,Bearing)

Small & Simple

Oil Free System
Maintenance Free

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Dr. Dellacorte(NASA) visit (2007.9 / 2010.9)

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