7.0 System Overview
The magnetic bearing system provides contactless rotational support and stabilization for the central shaft system (turbine‑generator or dynamic core elements). It eliminates mechanical friction and enables ultra‑low wear operation, high‑speed rotational stability, active vibration control, and real‑time positional correction.
Primary System Characteristics
- Total Bearing Sets: 12
- Configuration: Radial + Thrust (Active Magnetic Bearings)
- Maximum Rotational Speed: 600 RPM
- Operating Temperature Range: −20°C to 120°C
- Design Life: 150+ years
- Fire Resistance: Passive system integration
7.1 Bearing System — Exploded Configuration
- Shaft Journal (Inconel 718)
- Upper Bearing Housing (Duplex Stainless Steel)
- Radial Magnet Coils (8‑pole configuration)
- Position Sensor Ring (Eddy Current)
- Active Control Module (DSP system)
- Lower Bearing Housing (Duplex Stainless Steel)
- Upper Thrust Magnet Assembly
- Backup Bearing Ring (Carbon Graphite)
- Lower Thrust Magnet Assembly
- Base Mount Flange (Duplex Stainless Steel)
- Cooling Jacket (Water‑cooled)
- Proximity Sensors (Redundant)
7.1A Bearing Set — Critical Dimensions
| Shaft Diameter (Journal) | Ø508 mm |
|---|---|
| Bearing Outside Diameter | Ø914 mm |
| Total Stack Height | 650 mm |
| Radial Air Gap | 0.8 mm |
| Axial (Thrust) Air Gap | 0.6 mm |
| Total Weight (Per Set) | 820 kg |
7.2 System Elevation (Typical Set)
- Overall Width: Ø914 mm
- Shaft Diameter: Ø508 mm
- Height: 650 mm
Engineering Logic
- Compact axial footprint minimizes vertical stacking constraints
- Large radial diameter increases magnetic force capacity
- Tight air gaps maximize control precision
7.3 Radial Magnetic Bearing System (8‑Pole)
Geometry
- Outer Diameter: Ø914 mm
- Inner Diameter: Ø508 mm
- Section Width: 128 mm
Coil Specifications
- Coil Width: 60 mm
- Coil Height: 40 mm
- Coil Depth: 50 mm
- Turns per Coil: 320
- Wire Diameter: Ø1.2 mm
- Current: 8.0 A RMS
Performance
- Max Radial Load: 250 kN
- Air Gap: 0.8 mm
- Pole Pitch: 45°
- Operating Temp: −20°C to 120°C
Function
- Provides active radial stabilization
- Continuously adjusts shaft position via electromagnetic forces
7.4 Thrust Magnetic Bearing System
Specifications
- Magnet Type: NdFeB (N52)
- Number of Poles: 16
- Max Axial Load: 350 kN
- Air Gap: 0.6 mm
- Axial Stiffness: 150 MN/m
- Operating Temp: −40°C to 80°C
Magnet Geometry
- Magnet Width: 40 mm
- Magnet Height: 25 mm
- Arc Length: 90 mm
- Pole Pitch: 22.5°
Function
- Resists axial loads
- Maintains vertical shaft alignment
- Works with radial system for full 3D stabilization
7.5 Position Sensor Ring (Eddy Current)
Geometry
- Outer Diameter: Ø914 mm
- Inner Diameter: Ø508 mm
- Ring Width: 40 mm
- Thickness: 12 mm
Sensor Specifications
- Sensor Type: Eddy Current
- Number of Sensors: 8 radial + 2 axial
- Resolution: 1 µm
- Linear Range: ±2.0 mm
- Bandwidth: 0–2.0 kHz
- Output Signal: 0–10 VDC
Function
- Provides real‑time shaft position data
- Feeds control loop for magnetic actuation
7.6 Active Control Module
Hardware
- Input Voltage: 48 VDC
- Max Output Current: 10 A RMS per axis
- Processor: DSP 32‑bit
- Sampling Rate: 20 kHz
- Communication: CAN / Fiber Optic
- Protection Rating: IP65
Physical Dimensions
- Size: 300 × 220 × 120 mm
- Weight: 6.5 kg
Function
- Executes real‑time control algorithms
- Maintains shaft stability within micrometer tolerances
- Interfaces with building control system
7.7 Proximity Sensor System
Specifications
- Sensor Type: Inductive Proximity
- Sensing Distance: 2.0 mm
- Output: Digital (PNP)
- Supply Voltage: 10–30 VDC
- Response Frequency: 5 kHz
- Protection: IP67
Function
- Redundant position verification
- Safety fallback monitoring
7.8 Cooling Jacket System
Design
- Type: Water‑cooled ring jacket
- Outer Diameter: Ø968 mm
- Inner Diameter: Ø914 mm
- Height: 60 mm
- Wall Thickness: 4.0 mm
Performance
- Flow Rate: 10 L/min per set
- Max Pressure: 1.0 MPa
Function
- Removes heat from coils and electronics
- Maintains thermal stability for precision control
7.9 Installation Distribution (Vertical Core)
Placement Strategy
- Base (Level 20 – 90 m): Thrust + Radial
- Intermediate levels (~every 20 stories): Radial sets
- Mid‑height (~Level 100): Combined thrust + radial
- Upper levels: Radial stabilization sets
- Near top: Final thrust + radial control
Engineering Logic
- Even load distribution along shaft
- Reduces bending moments
- Enhances rotational stability
7.10 Material Specifications
| Shaft Journal | Inconel 718 — ASTM B637 |
|---|---|
| Bearing Housing | Duplex SS 2205 — EN 1.4462 |
| Magnet Coils | Copper — IEC 60317 |
| Magnets | NdFeB (N52) — ISO 20816 |
| Sensor Ring | Duplex SS — EN 1.4462 |
| Control Housing | Aluminum 6061‑T6 — ASTM B209 |
| Cooling Jacket | Duplex SS — EN 1.4462 |
| Backup Bearing | Carbon Graphite — ISO 9001 |
| Fasteners | Duplex SS 2205 — ISO 3506 |
| Insulation | Polyimide (Class H) — ISO 9001 |
7.11 Design Performance
| Radial Load Capacity | 250 kN |
|---|---|
| Axial Load Capacity | 350 kN |
| Max Rotational Speed | 600 RPM |
| Position Accuracy | ±5 µm |
| Vibration Level (RMS) | < 5 µm |
| Power Consumption | 150 W per set |
| System Availability | > 99.99% |
| MTBF | > 1,000,000 hours |
7.12 Engineering Logic
Core Principles
- Magnetic levitation eliminates mechanical contact
- Active feedback control ensures continuous correction
- Redundant sensors and backup bearings provide safety
System Behavior
- Sensors detect shaft displacement
- Control module calculates correction forces
- Magnetic coils adjust field strength
- Shaft is stabilized in real time
Advantages
- Zero friction losses
- No lubrication required
- Minimal maintenance
- Extremely high precision
7.13 General Notes
- All bearings are active magnetic type with real‑time feedback
- Backup bearings engage only during power loss
- System designed for continuous 24/7 operation
- Fabrication tolerance: ±5 mm
- Installation tolerance: ±10 mm
7.14 Quality & Standards
- All materials comply with EN / ASTM standards
- All welds: Full penetration groove welds
- All fasteners: Stainless Steel Grade 8.8 equivalent
- All dimensions in millimeters unless noted
