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Design methodology of electrodynamic bearings

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AIAS ASSOCIAZIONE ITALIANA PER LANALISI DELLE SOLLECITAZIONI

XXXVIII CONVEGNO NAZIONALE, 9-11 SETTEMBRE 2009, POLITECNICO DI TORINO

AIAS 2009 - 109

DESIGN METHODOLOGY OF ELECTRODYNAMIC BEARINGS

N. Amati a, A. Tonolia, E. Zenerinob, J. Detonib, F. Impinnab
a

Politecnico di Torino, Dipartimento di Meccanica

corso Duca degli Abruzzi 24 10129 Torino
b
Laboratorio di Meccatronica, Politecnico di Torino
corso Duca degli Abruzzi 24 10129 Torino

Sommario

I cuscinetti elettrodinamici (EDBs) costituiscono una nuova tipologia di supporti utilizzabili per la
sospensione in assenza di contatto di alberi rotanti. Rispetto ai cuscinetti attivi, la natura passiva dei
cuscinetti eletrodinamici consente la costruzione di sistemi pi semplici, affidabili ed economici,
aprendo cos il campo di applicazione ad apparecchi di largo consumo. In questo articolo sono
presentati gli strumenti necessari alla caratterizzazione meccanica dei cuscinetti elettrodinamici,
focalizzando lattenzione sulla relazione tra le caratteristiche in condizioni quasi stazionarie e la
simulazione ad elementi finiti di conduttori in moto, in modo da stabilire una metodologia per
determinare le caratteristiche meccaniche degli EDBs. Alcune analisi di sensitivit sono state condotte
per evidenziare linfluenza delle caratteristiche geometriche di un cuscinetto elettrodinamico rispetto
alle sue propriet meccaniche.
Abstract

Electrodynamic bearings (EDBs) are novel, promising systems that can be used to realize contactless
suspension of rotating shafts. Relative to active AMB the passive nature of the levitation achieved by
EDBs allows a simpler, more reliable and cheaper solution opening the field of application to medium
and large scale production. The working principle, based on the induction of eddy currents in a
rotating conductor, introduces destabilizing rotating damping, creating the necessity for a study of the
rotordynamics stability. In this paper the tools necessary to characterize EDBs are presented focusing
on the link between the quasi-static characteristic and the finite element modeling of moving
conductors to establish a way to determine the mechanical properties of EDBs. Several Sensitivity
analysis were carried out to evidence the influence of the EDBs geometric characteristics in its
overall performance, giving some insight on design choices to optimize their performance.
Parole chiave: Electrodynamic bearings, eddy current, sensitivity analysis.
1. INTRODUCTION

Electrodynamic bearings (EDBs) are a typology of magnetic bearings that can be used to realize the
contactless suspension with interesting and promising characteristic. The levitation is achieved by
passive means, which implies that no electronic equipment, such as power electronics or sensors, are
necessary for them to be functional. The working principle relies on the combination of a conductor in
motion and a constant magnetic field. The relative motion causes eddy currents within the conductor
that interact with the magnetic field to produce a force [1-3].
These characteristics make them an interesting alternative to classical AMBs in all kinds of machines
or applications where the contactless nature of the levitation allows to sacrifice the requirement of
high radial stiffness. This type of rotors can be found in flywheels, turbomolecular pumps, small

XXXVIII CONVEGNO N AZIONALE TORINO, 9-11 SETTEMBRE 2009

compressors, vacuum cleaners, high speed electricmandrels, etc. Furthermore, electrodynamic

bearings allow clean and maintenance free working and are less complex, less subject to failure, and
possibly, far lower in cost than AMBs.
Nevertheless, EDBs have drawbacks: the achievable stiffness and damping are relatively low
compared to active magnetic devices. Besides, similarly to hydrodynamic supports, electrodynamic
systems provide levitation only when the relative speed is above a threshold value, which opens
stability issues at low speeds.
Previous studies on this kind of mechanical component are mainly focused on the application of EDBs
to support flywheels [1-11] and turbomolecular pumps [12,13].
Latest researches on radial EDBs are focused on configurations capable of reducing eddy current
losses by the use of homopolar axial flux[7-9] and radial flux [12,13] configurations. Axial
electrodynamic bearings using shunted coils excited by Halbach arrays constitute another possibility
of application [10,11].
Altogether, literature on electrodynamic bearings is relatively poor if compared to active magnetic
bearings. Nowadays, the design of electrodynamic bearings is based on the force to angular speed
characteristic obtained for a fixed eccentricity. Although this characteristic describes the behavior of
the bearing in quasi-static conditions, it is not suitable for dynamic conditions where the rotor is
animated by a non-synchronous whirl, or even a non periodic motion about the stator axis. Recently, a
model capable of taking explicitly into account both the quasi-static and dynamic behavior of a rotor
supported by electrodynamic bearings was presented by Amati, Tonoli and De Lpine in [14]. This
study was based on the electromechanical dynamics of a conductor in translation in a constant
magnetic field and then transposed to the case of a rotating conductor. This model is characterized by
a limited number of parameters that can be determined either from an experimental characterization or
by the FE modeling of the electromagnetic field within the conductor.
The aim of the present paper it to propose a way to determine, by means of the finite element method,
the parameters of radial electrodynamic bearings. A sensitivity analysis is then performed by varying
the main design parameters to investigate a design procedure of radial electrodynamic bearings.
2. MODELING OF ELECTRODYNAMIC BEARINGS

The two configurations of homopolar electrodynamic bearings studied so far in literature are the axial
flux and the radial flux configurations. Figure 1 shows a schematic model of axial and radial flux
EDBs. The name of each one relates to the direction of the magnetic flux lines applied to the
conductor responsible for the induction of eddy currents. In the axial flux configuration the magnetic
circuit is very efficient and almost all the magnetic flux is usable to generate the force. In the radial
flux configuration, the magnetic circuit is less efficient as the overall air gap is bigger and also due of
the inevitable leakage of magnetic flux to the outer side of the magnetic circuit.
Based on an axial flux configuration, a general model of a conducting disc rotating in a constant
magnetic field fixed to the stator is developed in reference [14].
Axial Flux

Permanent
magnets in
attraction

Radial Flux

Permanent
magnets in
repulsion

Conducting
disc

Conducting
cylinder
Figure 1: Typical configurations of axial and radial flux electrodynamic bearings.

XXXVIII CONVEGNO N AZIONALE TORINO, 9-11 SETTEMBRE 2009

a)

b)

Figure 2: a) Schematic representation of a conductor rotating in a magnetic field. b) Mechanical

equivalent representation of an electrodynamic bearing supporting a Jeffcott rotor.
To develop the stability study of a rotor supported by EDBs, this model can be assembled, for
example, to that of a Jeffcott rotor, and dynamic issues can be investigated. A complete discussion of
the studies of the dynamics of rotors supported by EDBs is done in reference [14]. These topics and
wont be treated in this paper.
The model of a conducting disc rotating in a constant magnetic field fixed to the stator is briefly
described in the following section to investigate the mechanical parameters necessary to the realization
of the dynamic studies.
2.1 Modeling of forces generated by a conductor rotating in a magnetic field

A simplified scheme of a conductor rotating in a constant magnetic field is presented in fig. 2a. The
magnetic field is defined as going towards the reader. O and C are the geometrical centers of the
magnetic field and the rotating conductor, respectively. Axes (O, x, y) are an inertial reference frame
fixed to the magnetic field. Axes (O, , ) constitute a rotating reference frame fixed to the
conductor which rotates with angular speed equal to .
The pairs ( x c , yc ) and ( c , c ) are the coordinates of C in the inertial and the rotating frame
respectively (fig. 2b). The state and output equations of the conductor are then obtained in the rotating
frame in terms of the complex coordinate j [14]:

q RL q C

F kq

(1)

where C c j c is the position of point C, q q jq and F F jF are the spring

elongation and the force generated by the bearing respectively, expressed in complex notation. The
coordinates of point C in the inertial frame are also expressed in complex notation as z C x c jy c .
The position of the point C is considered as the input in the system, i.e., this position is constrained by
an external cause to follow a prescribed motion. Besides, RL is the electrical pole of the eddy
currents that develop within the conductor.

RL

R k

L c

(2)

The parameters k and c are the mechanical stiffness and viscous damping coefficients that are
equivalent to the electromechanical interaction between the conductor and the magnetic field (fig. 2b).

XXXVIII CONVEGNO N AZIONALE TORINO, 9-11 SETTEMBRE 2009

The relation between rotating and inertial frames can be defined as:

G Gz e jt

(3)

where G represents a complex variable in the rotating frame and G z represents the same one in the
inertial frame. Other quantities can be derived using this form.
The force developed by the bearing because of the given displacement of point C can be expressed in
the inertial frame as:

Fz ( s ) k

s j
z C ( s)
s RL j

(4)

where s is the Laplace variable and the constant angular speed of the rotor.
Equation 4 involves some parameters evidenced in the model of fig. 2b: the bearings stiffness and
damping (or, alternatively the stiffness and the pole frequency).
2.2 Quasi static characteristic

If the displacement of point c is constant ( z C z 0 const ), equation 4 reduces to:

Fz F e jt

k( j RL )
z0
2
RL
2

(5)

This corresponds to rotate the conducting disc with a constant speed and fixed eccentricity z0 .The
obtained force to speed function can be indicated as quasi-static characteristic. This characteristic can
be used to identify the equivalent stiffness and damping parameters of the bearing. For simplicity, eq.
5 can be expressed more conveniently as:

Fz

k

1 RL

z0 j

c

1
RL

z0

(6)

where the real and imaginary parts are the components of the force parallel and perpendicular to the
eccentricity z 0 , respectively. Figure 3 shows a plot of both the components of the force with respect
to the angular velocity. These curves represent the quasi-static performance curves of an
electrodynamic bearing.
3. SENSITIVITY ANALYSIS

The properties of the EDB, by the nature of the phenomena involved in the creation of the magnetic
forces depend mainly of the relative speed between conductor and magnetic field, the magnetic flux
density applied to the conductor, the volume where the eddy currents interact with the magnetic flux
and the magnetic configuration (radial or axial flux). From this point of view, in the following sections
a sensitivity analysis is performed only for axial flux EDBs.
The objective of the following analysis is to obtain insight on the geometrical parameters having
influence on the electrical characteristics, and thus on the dynamic behavior of the rotating system
supported by EDBs. The electric pole frequency and mechanical stiffness of the bearing are studied in
detail to this end.

XXXVIII CONVEGNO N AZIONALE TORINO, 9-11 SETTEMBRE 2009

j0 j

k
j? j

j0 j
2

Figure 3: Quasi-static performance curve obtained from eq. 6. The solid line represents the component
of the force parallel to the eccentricity, responsible for the stiffness contribute. The dotted line shows
the component perpendicular to the eccentricity and responsible for the losses in the bearing.
3.1 Numerical modeling of electrodynamic bearings

In the previous sections the quasi-static analysis was described as consisting in positioning the axis of
rotation of the conductor at fixed eccentricity and imposing a constant angular velocity. This kind of
situation represents a typical moving conductor problem, and can be solved using a finite element
model.
The solution of time-varying electromagnetic problems in terms of finite elements require the
discretization of both the problems regions and the time domain, using moving mesh time-stepping
methods.
The absence of axial or cyclic symmetry due to the eccentricity creates difficulties to model the
phenomena using 2-dimensional approximations. It is possible to overcome this problem by using a
model of the unrolled geometry in a time-harmonic formulation, where a disturbance is introduced
on the magnetic field in such a way that the magnetic flux density seen by the conductor behaves as it
would for an off centered rotating conductor [9].
To obtain more accurate solutions a three dimensional approach is nevertheless necessary. Three
dimensional moving conductor eddy-current problems can be solved in steady state conditions using a
stationary mesh provided that the conductor has invariant cross-section at right angles to the direction
of motion (smooth conductor). A detailed discussion of the relevant electromagnetic field equations is
presented in reference [15]. In this case explicit time derivatives of the magnetic flux density aren't
necessary to obtain the electric field, eliminating the need for time-stepping and sliding surfaces in the
finite element model. To solve the EDB in quasi-static condition the COMSOL Multiphysics finite
element solver, which is capable of solving this formulation in three dimensions, was chosen.
The sensitivity analysis requires a very large number of finite element solutions, and in the particular
case studied, for every change in a geometric parameter a new performance curve must be obtained.
For doing so, an approach based on script modeling was used making all the parametric changes inside
a loop, and inside this loop the speed is increased with a fixed step to construct the performance curve,
automatizing the construction of the EDBs performance curves.
The configurations studied present an anti-symmetry plane, perpendicular to the axis of rotation and
located in the middle of the conducting disc. This plane was modeled using an electric insulation
boundary condition, reducing the total size of the problem by approximately half. Figure 4 shows a
sketch of the finite element model adopted for the analysis, evidencing the main characteristics and
boundary conditions of the models.
From each finite element model both the components of the force produced by the electrodynamic
bearing (fig. 3) are calculated for several different values of angular velocity of the conductor. In this
way a set of points of the performance curves is obtained. To identify the mechanical stiffness and
damping of the bearing a nonlinear curve fitting tool is used to do the best fit of eq. 6 to the points
obtained from the finite element model. The result of this procedure is evidenced in fig. 5. The figure
shows the points obtained from numerical simulation and the curve from eq. 6 that best fits it.

XXXVIII CONVEGNO N AZIONALE TORINO, 9-11 SETTEMBRE 2009

External
boundaries
(magnetic
insulation
electric
n A 0 and
insulation
nJ 0
boundary conditions).

Anti-symmetry plane
( n H 0 electric
insulation boundary
condition).

Finite element mesh of

quadratic
tetrahedral
elements.
Total mesh: around
60000 elements.

Refined mesh in the eddy current

domain (approximately 23000 elements)

Figure 4: Scheme of the finite element models used for the sensitivity analysis.
45
40
35

Force [N]

30

Numerical results
Analitic curve

25
20
15

RL = 5870.87 rpm

10

k = 53261.5 N/m

5
0
0

1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000

Angular velocity [rpm]

Figure 5: Curve fitting of equation 6 with results from the numerical model.
This curve in particular was obtained from the MFA sensitivity analysis with an internal radius of the
magnet equal to 32 mm.
3.2 Results and discussion

The studies were carried on by changing only one geometric parameter at a time and identifying the
equivalent stiffness and damping coefficient from the quasi-static curves as described in section 3.1.
The two axial flux configurations studied are shown in fig. 6. The geometrical parameters are
evidenced in the figure by the quotations.
a)

b)

Figure 6: Geometrical characteristics of the finite element models for the sensitivity analysis. a)
Parameters of the normal configuration. b) Parameters of the double flux configuration.

XXXVIII CONVEGNO N AZIONALE TORINO, 9-11 SETTEMBRE 2009

Table 1: Geometrical and physical properties of the finite element models.

Units
Value
Symbol
Physical Parameter
SC
MFA
CT
DF

Electric conductivity of
AV-1
5.998e7
copper
Remanent magnetic
T
1.22
BR
flux density
Magnetic permeability
H/m
4 10-7
0
of vacuum
Relative magnetic
4000
r
permeability of iron
Geometrical
parameter
g
Air gap
mm
1

Eccentricity
mm
1
ERS
External radius of the
mm
variable
83
83
55
stator
IRS
Internal radius of stator
mm
variable
67
67
variable
ERM
External radius of the
mm
variable
60
60
magnet
IRM
Internal radius of the
mm
variable
variable
32
magnet
RCOND Radius of the
mm
variable
50
50
50
conductor
H
Total height of the
mm
66
66
variable
66
magnetic circuit
CTH
Conducting disc
mm
3
3
variable
3
thickness
MTH
Magnet thickness
mm
5.5
5.5
5.5
5.5
MC
Clearance between
mm
7.5
magnets
The values of the geometrical and physical characteristics of the models used for the sensitivity
analysis are reported in table 1 and make reference to the quotations presented in fig. 6. The four
columns of values refer to the four different types of sensitivity analysis developed which results are
presented in diagrams of fig. 8. Each column refer to one diagram, where SC, MFA, CT and DF stand
for scaling, magnetic field area, conductor thickness and double flux respectively.
The distribution of the most important quantities obtained as results for the two configurations studied
are reported in fig. 7 as qualitative results.
In fig. 8a shows the influence of scaling. This analysis was done by increasing the radius of the
conductor (RCOND in fig. 6) and maintaining constant the scale ratio between all the radial dimensions
without changing any axial dimension. This causes all radial dimensions to vary as can be seen in table
1. The scale between the dimension was obtained from an initial model with the same characteristics
of the MFA case where the parameter IRM is equal to 32 mm. The scale has the effect of increasing the
value of achievable stiffness while decreasing the electric pole frequency. This is a beneficial effect as
allows to improve the overall performance of the bearing, increasing load capacity and useful
frequency range.
The problems with scaling are related to the increase of size of the magnetic circuit and rotor, creating
difficulties for stabilization and mechanical failure of the conducting disc due to centrifugal forces.
In fig. 8b the result of the sensitivity study made to optimize the use of magnetic material are shown.
Since the permanent magnets are the most expensive part of the electrodynamic bearing, it's important
to minimize their weight. The analysis is performed by fixing all the dimensions an varying the
internal radius of the ring magnet (IRM in fig. 6). Its possible to evidence a maximum for the stiffness
and a minimum for the electric pole frequency. These two extremes are consequences of that in both

XXXVIII CONVEGNO N AZIONALE TORINO, 9-11 SETTEMBRE 2009

a)

c)

b)

d)

Figure 7: a) Direction of the magnetic flux density distribution on a slice of the normal configuration.
b) Direction of the magnetic flux density distribution on a slice of the double flux configuration. c)
Path of the eddy currents inside the conductor for the normal configuration. d) Path of the eddy
currents inside the conductor for the double flux configuration.
limit situations (internal radius of the ring magnet bigger than conductor radius, or equal to zero) the
magnetic force is zero and the electric pole frequency tends to infinity. The stiffness increases with
increasing the inner radius of the magnet almost linearly.
The influence of the thickness of the conductor was investigated in fig. 8c. The reduction in the
resistance and the increase of reluctance of the magnetic path, result in a reduction of both electric
pole frequency and achievable stiffness with an increase in the thickness.
A maximum point for the force is expected because in one extreme, for a conductor with thickness
equal to zero also the force must be zero. On the other extreme, for a very thick conductor the force
will tend to a constant value small in magnitude because of the increase of reluctance in the magnetic
circuit. For constructive and simulation reasons discs with these characteristics are not of interest.
In fig. 8d the stiffness and electric pole frequency of configuration that optimizes the magnetic circuit
were investigated. This configuration was referred to as double flux configuration. For this case only
the sensitivity to the internal radius of the stator IRS was studied. The width of the magnets (MW in fig.
6b) is the same for the two magnets, and is varied in function of the internal radius of the stator. A
great increase in the stiffness can be noted without such a great penalty for the electric pole frequency.
Using this kind of configuration its possible to reduce the total mass of the magnetic circuit obtaining
not only a more performative system in terms of stiffness but also in terms of total size.
4. CONCLUSIONS

The performance of axial flux electrodynamic bearings was studied focusing on the link between the
quasi static characteristics that can be found from the FE simulation of the electromagnetic field and
the equivalent mechanical stiffness and damping coefficient that characterize its behavior. This study
led to the establishment of a method to identify the mechanical stiffness and damping based on an
hybrid approach using analytic and numerical models.

XXXVIII CONVEGNO N AZIONALE TORINO, 9-11 SETTEMBRE 2009

a)

b)
Magnetic field area

Scaling
25000

60
Electric pole frequency

36000

45

30000

37.5

24000

30

18000

22.5

12000

15

7.5
10

15

20

25

30

35

40

45

50

20000

60

17500

50

15000

40

12500

30

10000

20

7500

10

5000
5

10

E lectric p o le freq u en cy [rp m ]

16000

61.25

14000

9000

52.50

7500

43.75

6000

35.00

4500

26.25

3000

17.5

1500

8.75

0
1

Thickness of the conducting disc [mm]

25

30

35

40

0
45

Double Flux

70.00

0
9

E lectric p o le freq u en cy [rp m ]

Stiffness
Electric pole frequency

10500

20

d)

Conductor thickness

12000

Stiffn ess [N /m m ]

c)

15

Internal radius of the magnet [mm]

Radius of the conducting disc [mm]

240
Stiffness
Electric pole frequency

210

12000

180

10000

150

8000

120

6000

90

4000

60

2000

30

0
0

12

16

20

24

28

Stiffn ess [N /m m ]

6000

70

Electric pole frequency

Stiffn es s [N /m m ]

22500

52.5

E lectric p o le freq u en cy [rp m ]

Stiffness

42000

80
Stiffness

Stiffn ess [N /m m ]

E lectric p o le freq u en cy [rp m ]

48000

0
32

Internal radius of the magnetic circuit [mm]

Figure 8: Results obtained from the analysis of sensitivity of EDBs mechanical properties to its
geometrical characteristics. a) Sensitivity to the scale. b) Sensitivity to the magnetic field area. c)
Sensitivity to the thickness of the conductor. d) Sensitivity to the magnetic field area in the double flux
configuration.
The mechanical properties of EDBs were investigated with the help of sensitivity analysis. Several
analysis of the sensitivity of EDBs mechanical properties to its geometrical characteristics were
carried out to give an objective view and understanding of the phenomena. The analysis evidenced the
mechanical characteristics that can be obtained from this kind of component and that some
optimization issues are still open. From the analysis some design guidelines to realize the optimization
of the capabilities of the EDB arise. The graphical results show that these mechanical components can
produce interesting radial stiffness at high speed with rather compact and simple layouts. The analysis
realized to reduce the use of permanent magnets, that constitute the most expensive part of the bearing,
show that its not necessary to have a big volume of magnetic material to obtain more performative
systems resulting in more economic bearings.
In synthesis, it was evidenced that electrodynamic bearings have capabilities suitable to commercial
applications once the component is optimized and may turn out to be a solution for medium and large
scale production of high speed machines.
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XXXVIII CONVEGNO N AZIONALE TORINO, 9-11 SETTEMBRE 2009

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