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NASA NTRS2009

Radial Halbach Magnetic Bearings

Radial Halbach magnetic bearings have been investigated as part of an effort to develop increasingly reliable noncontact bearings for future high-speed rotary machines that may be used in such applications as aircraft, industrial, and land-vehicle power systems and in some medical and scientific instrumentation systems. Radial Halbach magnetic bearings are based on the same principle as that of axial Halbach magnetic bearings, differing in geometry as the names of these two types of bearings suggest. Both radial and axial Halbach magnetic bearings are passive in the sense that unlike most other magnetic bearings that have been developed in recent years, they effect stable magnetic levitation without need for complex active control. Axial Halbach magnetic bearings were described in Axial Halbach Magnetic Bearings (LEW-18066-1), NASA Tech Briefs, Vol. 32, No. 7 (July 2008), page 85. In the remainder of this article, the description of the principle of operation from the cited prior article is recapitulated and updated to incorporate the present radial geometry. In simplest terms, the basic principle of levitation in an axial or radial Halbach magnetic bearing is that of the repulsive electromagnetic force between (1) a moving permanent magnet and (2) an electric current induced in a stationary electrical conductor by the motion of the magnetic field. An axial or radial Halbach bearing includes multiple permanent magnets arranged in a Halbach array ("Halbach array" is defined below) in a rotor and multiple conductors in the form of wire coils in a stator, all arranged so the rotary motion produces an axial or radial repulsion that is sufficient to levitate the rotor. A basic Halbach array (see Figure 1) consists of a row of permanent magnets, each oriented so that its magnetic field is at a right angle to that of the adjacent magnet, and the right-angle turns are sequenced so as to maximize the magnitude of the magnetic flux density on one side of the row while minimizing it on the opposite side. The advantage of this configuration is that it makes it possible to approach the theoretical maximum force per unit area that could be exerted by a given amount of permanent-magnet material. The configuration is named after physicist Klaus Halbach, who conceived it for use in particle accelerators. Halbach arrays have also been studied for use in magnetic-levitation ("maglev") railroad trains. In a radial Halbach magnetic bearing, the basic Halbach arrangement is modified into a symmetrical arrangement of sector-shaped permanent magnets mounted on the outer cylindrical surface of a drum rotor (see Figure 2). The magnets are oriented to concentrate the magnetic field on their radially outermost surface. The stator coils are mounted in a stator shell surrounding the rotor.

Eichenberg, Dennis J.↗

NASA NTRS2012

Performance of Simple Gas Foil Thrust Bearings in Air

Foil bearings are self-acting hydrodynamics devices used to support high speed rotating machinery. The advantages that they offer to process fluid lubricated machines include: high rotational speed capability, no auxiliary lubrication system, non-contacting high speed operation, and improved damping as compared to rigid hydrodynamic bearings. NASA has had a sporadic research program in this technology for almost 6 decades. Advances in the technology and understanding of foil journal bearings have enabled several new commercial products in recent years. These products include oil-free turbochargers for both heavy trucks and automobiles, high speed electric motors, microturbines for distributed power generation, and turbojet engines. However, the foil thrust bearing has not received a complimentary level of research and therefore has become the weak link of oil-free turbomachinery. In an effort to both provide machine designers with basic performance parameters and to elucidate the underlying physics of foil thrust bearings, NASA Glenn Research Center has completed an effort to experimentally measure the performance of simple gas foil thrust bearing in air. The database includes simple bump foil supported thrust bearings with full geometry and manufacturing techniques available to the user. Test conditions consist of air at ambient pressure and temperatures up to 500 C and rotational speeds to 55,000 rpm. A complete set of axial load, frictional torque, and rotational speed is presented for two different compliant sub-structures and inter-pad gaps. Data obtained from commercially available foil thrust bearings both with and without active cooling is presented for comparison. A significant observation made possible by this data set is the speed-load capacity characteristic of foil thrust bearings. Whereas for the foil journal bearing the load capacity increases linearly with rotational speed, the foil thrust bearing operates in the hydrodynamic high speed limit. In this case, the load capacity is constant and in fact often decreases with speed if other factors such as thermal conditions and runner distortions are permitted to dominate the bearing performance.

Bruckner, Robert J.↗

DOE OSTI2025

Status Update for the Bearing Test Article Design Development – FY2025

Argonne National Laboratory’s (ANL) Mechanism Engineering Test Loop (METL) team has completed the design of a new Bearing Test Article (BTA) to test mechanical bearings for sodium fast reactor (SFR) mechanism applications. Recognition of the need for further bearing testing arose due to failure of rolling element bearings during testing of components for in-vessel fuel handling machines (FHMs) conducted at ANL in the METL facility. While the initial concept of the BTA arose from a need for bearing testing for FHM applications, the BTA design is configurable to test bearings of various sizes, types, and materials submerged in liquid sodium. Requirements for loading, shaft speed, temperature, and bearing size range were chosen based on requirements for SFR fuel handling. Modular components in the test bearing housings and shaft sleeves allow the design to accommodate a wide range of bearing sizes without modification to the larger assembly. Loading will be applied with screw jacks on the air side of the test article that will be adjusted to apply radial, thrust, or combined loading conditions. Applied force will be measured by load cells in-line with the loading mechanisms. In FY25 we have completed the design of the test article that will be fabricated and undergo testing at the METL facility. Drawing packages for the fabrication of the test article have been drafted and are being reviewed to add part tolerances and we have started ordering off-the-shelf components. The report will summarize the development of the Bearing Test Article design starting with an overview of the entire test article, then a more detailed examination of the bearing test section, loading mechanisms, test article ports and seals, and support structures, including analysis that went into significant design choices.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1972

Optimal speed sharing characteristics of a series-hybrid bearing

A series-hybrid bearing assembly consisting of a conical hydrostatic fluid-film bearing and a ball bearing is described. Computer studies are used to predict friction torque and life characteristics of a 150-millimeter ball bearing. A conical hydrostatic fluid-film bearing is designed for minimum friction and maximum speed reduction of the ball-bearing component of the series-hydrid bearing. At a thrust load of 4000 pounds and speeds corresponding to DN (bearing bore in millimeters times shaft speed in rpm) values of 3 and 4 million, ball-bearing speed may be reduced by 30 percent. This speed reduction corresponds to ball-bearing fatigue life improvement factors of 3.4 at 3 million DN and 5.9 at 4 million DN. An oil flow rate of 18.2 pounds per minute is required to maintain a fluid-film thickness of 0.001 inch in the hydrostatic bearing.

Nypan, L. J.↗

NASA NTRS1972

Optimal speed sharing characteristics of a series-hybrid bearing.

A series-hybrid bearing assembly consisting of a conical hydrostatic fluid-film bearing and a ball bearing is described. Computer studies are used to predict friction torque and life characteristics of a 150-mm ball bearing. A conical hydrostatic fluid-film bearing is designed for minimum friction and maximum speed reduction of the ball-bearing component of the series-hybrid bearing. At a thrust load of 4000 lb and speeds corresponding to DN (bearing bore in millimeters times shaft speed in rpm) values of 3 and 4 million, ball-bearing speed may be reduced to 30%. This speed reduction corresponds to ball-bearing fatigue life improvement factors of 3.4 at 3 million DN and 5.9 at 4 million DN. An oil flow rate at 18.2 lb/min is required to maintain a fluid-film thickness of 0.001 in. in the hydrostatic bearing.

Nypan, L. J.↗

NASA NTRS1974

Comparison of experimental and predicted performance of 150-millimeter-bore solid and drilled ball bearings to 3 million DN

Seven 150-millimeter-bore ball bearings were run under 8900-newton (2000-lbf) thrust load at speeds from 6670 to 20,000 rpm (1 million to 3 million DN). Four of the bearings had conventional solid balls, and three bearings had drilled (cylindrically hollow) balls with 50-percent mass reduction. The bearings were under-race cooled and slot lubricated with a type 2 ester oil at flow rates from 4.35 x 0.001 to 5.94 x 0.001 cubic meter/min (1.15 to 1.57 gal/min). Friction torque and temperature were measured on all bearings. While there was considerable spread in the temperature data, the drilled ball bearings tended to run slightly cooler than the solid ball bearings at higher speeds. No significant difference in torque was noted, however, between the solid and drilled ball bearings. One bearing of each type was rerun at 17,800-newton (4000-lbf) thrust load. The solid ball bearings performed satisfactorily at 3 million DN. However, at about 2 million DN the drilled ball bearing experienced a broken ball, and cracks appeared in other balls as a result of flexure fatigue. Metallurgical examination of the cracked balls indicated a brittle structure in the bore of the drilled balls.

Scibbe, H. W.↗

NASA NTRS1975

Evaluation of a series hybrid thrust bearing at DN values to three million. 2: Fabrication and testing

Results of tests made to determine the experimental performance of a series hybrid bearing are reported. The bearing consists of a 150 mm ball bearing and a centrifugally actuated, conical, fluid film bearing fitting an envelope with an outer radius of 86.4 mm (3.4 in.) and inner radius of 71 mm (2.8 in.). Tests were conducted up to 16,500 rpm, at which speed an axial load of 15,568 N (3500 lb) was safely supported by the hybrid bearing system. Through the employment of the series hybrid bearing principle, it was possible to reduce the effective ball bearing speed to approximately one-half of the shaft speed. A reduction of this magnitude should result in a tenfold increase in the ball bearing fatigue life. A successful simulation of fluid film bearing lubricant supply failure, performed repeatedly at an operating speed of 10,000 rpm, resulted in complete and smooth change over to full scale ball bearing operation when the oil supply to the fluid film bearing was discontinued. Reactivation of the fluid film supply system produced a flawless return to the original mode of hybrid operation.

Eusepi, M.↗

NASA NTRS1976

Design and evaluation of a 3 million DN series-hybrid thrust bearing

The bearing, consisting of a 150-mm ball bearing and a centrifugally actuated, conical, fluid-film bearing, was fatigue tested. Test conditions were representative of a mainshaft ball bearing in a gas turbine engine operating at maximum thrust load to simulate aircraft takeoff conditions. Tests were conducted up to 16000 rpm and at this speed an axial load of 15568 newtons (3500 lb) was safely supported by the hybrid bearing system. Through the series-hybrid bearing principle, the effective ball bearing speed was reduced to approximately one-half of the shaft speed. It was concluded that a speed reduction of this magnitude results in a ten-fold increase in the ball bearing fatigue life. A successful evaluation of fluid-film bearing lubricant supply failure was performed repeatedly at an operating speed of 10,000 rpm. A complete and smooth changeover to full-scale ball bearing operation was effected when the oil supply to the fluid-film bearing was cut off. Reactivation of the fluid-film oil supply system resulted in a flawless return to the original mode of hybrid operation.

Scibbe, H. W.↗

NASA NTRS1979

Gimbal bearing design considerations and friction control

The design considerations of bearing selection, bearing fits, bearing installation, and thermal control are discussed for a gimbal with a high stiffness, low friction torque requirement. Tradeoffs between a quad set of small diameter spread apart or a large diameter bearing pair resulted in a cleaner, lighter, stiffer unit with the latter selection. Bearing fits were designed to eliminate clearances with tolerances of .00127 mm 00005 in) on the bearing shafts and housings. The problems in metrology are discussed and a perferred technique for measurement of small cross-section bearings described. A technique for installation to assure proper seating of the bearing is offered. Where transient thermal conditions are involved, a method of controlling bearing friction by active control of bearing temperature gradients including the use of bearing unload test curves is described.

Kramer, N. R.↗

NASA NTRS1991

Analysis of foil bearings for high speed operation in cryogenic applications

The general objective of this project is to develop analysis tools which are required for the design of foil bearings to be used in cryogenic applications. During the second year of this project, a general analysis approach and code for journal bearings operating under steady state conditions will be completed. This will be followed by the initiation of an investigation into transient behavior of foil bearings to determine their performance in rotor systems. Foil bearings have been proposed as an alternative to rolling element bearings for use in cryogenic turbopumps in liquid propellant rocket engines. This type of bearing offers several advantages over rolling element bearings since they would use the cryogenic pump fluid for a lubricant and have structural flexibility. These bearings have the potential of high reliability and long life. The bearing surface is constructed of a 'foil' which resists deflection by a combination of bending, membrane, and elastic foundation effects. The relative motion between the rotating shaft and the foil causes pressure in the fluid film to develop. This pressure deflects the the foil surface away from the shaft. Once a full fluid film is established between the foil and the rotor shaft, contact no longer takes place and there is no subsequent wear of the surfaces. The flexible foil structure of the bearing allows it to compensate for minor tolerance and manufacturing defects. This same flexibility also has a significant effect on the dynamic performance of the rotor-bearing system.

Carpino, Marc↗

NASA NTRS1992

A feasibility assessment of magnetic bearings for free-piston Stirling space power converters

This report describes a design and analysis study performed by Mechanical Technology Incorporated (MTI) under NASA Contract NAS3-26061. The objective of the study was to assess the feasibility and efficacy of applying magnetic bearings to free-piston Stirling-cycle power conversion machinery of the type currently being evaluated for possible use in long-term space missions. The study was performed for a 50-kWe Reference Stirling Space Power Converter (RSSPC) system consisting of two 25-kWe free-piston Stirling engine modules. Two different versions of the RSSPC engine modules have been defined under NASA Contract NAS3-25463. These modules currently use hydrostatic gas bearings to support the reciprocating displacer and power piston assemblies. Results of this study show that active magnetic bearings of the attractive electromagnetic type are technically feasible for RSSPC application provided that wire insulation with 60,000-hr life capability at 300 C can be developed for the bearing coils. From a design integration standpoint, both versions of the RSSPC were found to be conceptually amenable to magnetic support of the power piston assembly. However, only one version of the RSSPC was found to be amendable to magnetic support of the displacer assembly. Unacceptable changes to the basic engine design would be required to incorporate magnetic displacer bearings into the second version. Complete magnetic suspension of the RSSPC can potentially increase overall efficiency of the Stirling cycle power converter by 0.53 to 1.4 percent (0.15 to 0.4 efficiency points). Magnetic bearings will also overcome several operational concerns associated with hydrostatic gas bearing systems. However, these advantages are accompanied by a 5 to 8 percent increase in specific mass of the RSSPC, depending on the RSSPC version employed. Additionally, magnetic bearings are much more complex, both mechanically and particularly electronically, than hydrostatic bearings. Accordingly, long-term stability and reliability represent areas of uncertainty for magnetic bearings. Considerable development effort will be required to establish the long-term suitability of these bearings for Stirling space power applications.

Curwen, Peter W.↗

NASA NTRS1993

Magnetic bearings for a high-performance optical disk buffer

An optical disk buffer concept can provide gigabit-per-second data rates and terabit capacity through the use of arrays of solid state lasers applied to a stack of erasable/reusable optical disks. The RCA optical disk buffer has evoked interest by NASA for space applications. The porous graphite air bearings in the rotary spindle as well as those used in the linear translation of the read/write head would be replaced by magnetic bearings or mechanical (ball or roller) bearings. Based upon past experience, roller or ball bearings for the translation stages are not feasible. Unsatisfactory, although limited experience exists with ball bearing spindles also. Magnetic bearings, however, appear ideally suited for both applications. The use of magnetic bearings is advantageous in the optical disk buffer because of the absence of physical contact between the rotating and stationary members. This frictionless operation leads to extended life and reduced drag. The manufacturing tolerances that are required to fabricate magnetic bearings would also be relaxed from those required for precision ball and gas bearings. Since magnetic bearings require no lubricant, they are inherently compatible with a space (vacuum) environment. Magnetic bearings also allow the dynamics of the rotor/bearing system to be altered through the use of active control. This provides the potential for reduced vibration, extended regions of stable operation, and more precise control of position.

Hockney, Richard↗

NASA NTRS1995

Design and development of a high-speed bearing test rig

The development of a high-speed test rig, to be used for compiling an experimental data base of bearing signatures for bearings with known faults, is described. This bearing test rig can be adapted to test oil-film bearings as well as rolling element bearings. This is achieved by mounting the test bearing in one of two special test housings, either of which can be mounted onto a common test shaft which can be driven up to 30,000 rpm. The test bearing housing for rolling element bearings can accommodate proximity displacement transducers, accelerometers, thermocouples, and acoustic emission sensors. The test bearing housing for the fluid-film bearings can accommodate the same instrumentation as well as Bourdon tube-type transducers for measuring oil film pressures around the bearing circumference.

Cockburn, J. A.↗

NASA NTRS2003

Investigation of Pressurized Wave Bearings

The wave bearing has been pioneered and developed by Dr. Dimofte over the past several years. This bearing will be the main focus of this research. It is believed that the wave bearing offers a number of advantages over the foil bearing, which is the bearing that NASA is currently pursuing for turbomachinery applications. The wave bearing is basically a journal bearing whose film thickness varies around the circumference approximately sinusoidally, with usually 3 or 4 waves. Being a rigid geometry bearing, it provides precise control of shaft centerlines. The wave profile also provides good load capacity and makes the bearing very stable. Manufacturing techniques have been devised that should allow the production of wave bearings almost as cheaply as conventional full-circular bearings.

Keith, Theo G., Jr.↗

NASA NTRS2004

An Overview of Magnetic Bearing Technology for Gas Turbine Engines

The idea of the magnetic bearing and its use in exotic applications has been conceptualized for many years, over a century, in fact. Patented, passive systems using permanent magnets date back over 150 years. More recently, scientists of the 1930s began investigating active systems using electromagnets for high-speed ultracentrifuges. However, passive magnetic bearings are physically unstable and active systems only provide proper stiffness and damping through sophisticated controllers and algorithms. This is precisely why, until the last decade, magnetic bearings did not become a practical alternative to rolling element bearings. Today, magnetic bearing technology has become viable because of advances in micro-processing controllers that allow for confident and robust active control. Further advances in the following areas: rotor and stator materials and designs which maximize flux, minimize energy losses, and minimize stress limitations; wire materials and coatings for high temperature operation; high-speed micro processing for advanced controller designs and extremely robust capabilities; back-up bearing technology for providing a viable touchdown surface; and precision sensor technology; have put magnetic bearings on the forefront of advanced, lubrication free support systems. This paper will discuss a specific joint program for the advancement of gas turbine engines and how it implies the vitality of magnetic bearings, a brief comparison between magnetic bearings and other bearing technologies in both their advantages and limitations, and an examination of foreseeable solutions to historically perceived limitations to magnetic bearing.

Clark, Daniel J.↗

NASA NTRS2007

Reexamination of Ball-Race Conformity Effects on Ball Bearing Life

The analysis in this report considers the life of the ball set as well as the respective lives of the races to reassess the effect of ball-race conformity on ball bearing life. The related changes in ball bearing life are incorporated in life factors that can be used to modify the bearing predicted life using the Lundberg-Palmgren equations and the ANSI/ABMA and ISO Standards. Two simple algebraic relationships were established to calculate life factors LF(sub c) to determine the effect of inner- and outer-race conformity combinations on bearing L(sub 10) life for deepgroove and angular-contact ball bearings, respectively. Depending on the bearing type and series as well as conformity combinations, the calculated life for deep-groove ball bearings can be over 40 percent less than that calculated by the Lundberg-Palmgren equations. For angular-contact ball bearings, the life can vary between +16 and -39 percent from that calculated by the Lundberg-Palmgren equations. Comparing the two ball bearing types, the life factors LF(sub c) for the deep-groove bearings can be as much as 40 percent lower than that for angular-contact ball bearings.

Zaretsky, Erwin V.↗

NASA NTRS2008

Misalignment in Gas Foil Journal Bearings: An Experimental Study

As gas foil journal bearings become more prevalent in production machines, such as small gas turbine propulsion systems and microturbines, system-level performance issues must be identified and quantified in order to provide for successful design practices. Several examples of system-level design parameters that are not fully understood in foil bearing systems are thermal management schemes, alignment requirements, balance requirements, thrust load balancing, and others. In order to address some of these deficiencies and begin to develop guidelines, this paper presents a preliminary experimental investigation of the misalignment tolerance of gas foil journal bearing systems. Using a notional gas foil bearing supported rotor and a laser-based shaft alignment system, increasing levels of misalignment are imparted to the bearing supports while monitoring temperature at the bearing edges. The amount of misalignment that induces bearing failure is identified and compared to other conventional bearing types such as cylindrical roller bearings and angular contact ball bearings. Additionally, the dynamic response of the rotor indicates that the gas foil bearing force coefficients may be affected by misalignment.

Howard, Samuel A.↗

NASA NTRS1947

An Analysis of the Full-Floating Journal Bearing

An analysis of the operating characteristics of a full-floating bearing - a bearing in which a floating sleeve is located between the journal and bearing surfaces - is presented together with charts - from which the performance of such bearings may be predicted. Examples are presented to illustrate the use of these charts and a limited number of experiments conducted upon a glass full-floating bearing to verify some results of the analysis are reported. The floating sleeve can operate over a wide range of speeds for a given shaft speed, the exact value depending principally upon the ratio of clearances and upon the ratio of radii of the bearing. Lower operating temperatures at high rotative speeds are to be expected by using a full-floating bearing. This lower operating temperature would be obtained at the expense of the load-carrying capacity of the bearing if, for comparison, the clearances remain the same in both bearings. A full-floating bearing having the same load capacity as a conventional journal bearing may be designed if decreased clearances are allowable.

Shaw, M.C.↗