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1. Frictionless_Compressor

2. CONTENT
• Introduction
• Mechanical components of frictionless compressor
• Magnetic bearings and bearing sensors
• Electrical Components of Frictionless Compressor
• Magnetic-bearing technology
• Shutdowns And Power Failures
• Advantages
• Disadvantages
• Application
• Conclusion

3. Introduction
Traditional centrifugal compressors use roller bearings and hydrodynamic bearings, both of which consume
power and require oil and lubrication system. This can be overcome by the introduction of new compressor
technology called frictionless compressor technology.
The frictionless compressor technology is compressor with the application of magnetic bearings and
permanent magnet synchronous motor. In frictionless compressor instead of roller bearings and
hydrodynamic bearings, magnetic bearings are used. Magnetic bearings consume less power and there is no
need for oil and lubrication systems. Permanent magnet brushless synchronous motor has permanent
magnet instead of copper windings.
After 10 years of development, magnetic bearing compressors offer economic, energy, and environmental
benefits. Chief among them are increased energy efficiency, the elimination of oil and oil management and
considerable less weight, noise, and vibration. This is initial mid-range package offers centrifugal
compression efficiencies previously reserved for large tonnage systems only.
This compressor has high reliability, efficiency, less maintenance cost and staff. With the help of digital
control system the controlling and monitoring of work is very easy. The frictionless compressor technology
makes newrevolutions in the field of air conditioning, refrigeration etc. Frictionless Compressor
Technology is one of the fast growing Technology in the engineering field.

4. Mechanical components of frictionless compressor

5. Magnetic bearings and bearing sensors
Ø Composed of both permanent and electromagnets
Ø Enables precisely controlled frictionless compressor shaft rotation on a levitated magnetic cushion
Ø Bearing sensors, located at each magnetic bearing, feedback rotor orbit and thrust/axialinformation in real
time to bearing control
Permanent-magnet synchronous motor
Ø Carbon-lined radially and axially located bearings supportthe rotor when the compressor isnot energized
Ø Prevents contact between the rotor and othermetallic surfaces
Shaft and impellers
Ø Only one major moving compressor component
Ø Acts as rotor for permanent-magnet synchronous motor
Ø Impellers are keyed directly to the motor rotor

6. Electrical Components of Frictionless Compressor
Soft start module
• Significantly reduces high in-rush
current at startup
• The startup inrush current is only 2
amps vs. typically up to 500-600 amps
• Experienced by traditional screw
compressors in this tonnage range
truly redefining soft start

7. Variable frequency drive
IGBT (Insulated Gate Bipolar Transistor) is an inverter that converts a DC
voltage into an adjustable three-phase AC voltage
Signals from the motor/bearing controller determine the inverter output
frequency, voltage
and phase, thereby regulating the motor speed converts mechanical energy
back into electrical energy.
In case of power failure, this patented control scheme allows for a normal
deLevitation and shutdown.

8. Three-phase terminal block
• Connection point for primary power supply
Rectifier
• Converts AC line power into a high-voltage DC power source for
motor, bearings and control operations
Capacitors
• Energy storage and filter for smooth DC voltage
• Provide power to the magnetic bearings, alon with motor
rotation, to ensure rotor shaft levitation through compressor coast
down in the event of an external power loss

9. Magnetic-bearing technology
Magnetic-bearing technology is significantly different. A digitally controlled magnetic-bearing system,
consisting of both permanent magnets and electromagnets, replaces conventional lubricated bearings. The
frictionless compressor shaft is the compressor’s only moving component. It rotates on a levitated magnetic
cushion. Magnetic bearings—two radial and one axial—hold the shaft in position. When the magnetic
bearings are energized, the motor and impellers, which are keyed directly to the magnetic shaft, levitate.
Permanent magnetic bearings do the primary work, while digitally controlled electromagnets provide the
fine positioning. Four positioning signals per bearing hold the levitated assembly to a tolerance of 0.00002
in.
As the levitated assembly moves from the center point, the electromagnets’ intensity is adjusted to correct
the position. These adjustments occur 6 million times a minute. The software has been designed to
automatically compensate for any out-of-balance condition in the levitated assembly. The rotor shaft’s
position is held by front and rear electro-magnetic cushions. The shafts position is monitored with 10
sensors that send a signal to a digital controller which then sends a command to the 5 separate pulse width
modulators (PWM), for a proper shaft repositioning

10. Magnetic-bearing

11. Shutdowns And Power Failures
When the compressor is not running, the shaft assembly rests on graphite-lined, radially located
touchdown bearings. The magnetic bearings normally position the rotor in the proper location,
preventing contact between the rotor and other metallic surfaces.
If the magnetic bearings fail, the touchdown bearings (also known as backup bearings) are used to
prevent a compressor failure. The compressor uses capacitors to smooth ripples in the DC link in
the motor drive. Instantaneously after a power failure, the motor becomes a “generator,” using its
angular momentum to create electricity (sometimes known as back EMF) and keeping the
capacitors charged during the brief coast down period.
The capacitors, in turn, provide enough power to maintain levitation during coast down, allowing
the motor rotor to stop and delimitate. This feature allows the compressor to see a power outage as
a normal shutdown

12. Advantages
Easy to work with
Easy on product cost
Easy on the ears
Easy to handle
Easy refrigerant choice
Easy to control
Easy on energy

13. Disadvantages
High Cost
Price is 50-70% more than normal
Compressor

14. Applications
Water-cooled chiller applications
Rooftop and packaged system
applications
Air-cooled chiller applications
Multiple compressor applications

15. Conclusion
Frictionless Compressor Technology is one of the fast growing Technology in the mechanical engineering
field. In the case of Traditional centrifugal compressors, we use roller bearings & hydrodynamic bearings,
both of them consume power & require oil & lubrication system. This can be overcome by frictionless
compressor technology And it offer economic, energy and environmental benefits.
Chief among them are energy efficiency, eliminating oil and control oil and much less weight, noise and
vibration. This is the initial intermediate package offers the efficiency of centrifugal compression
previously intended only for large systems has a high reliability, efficiency, lower maintenance costs and
staff. Using digital control and monitoring management system of operation is very simple. Frictionless
compressors make new revolutions in air-conditioning, refrigeration and so Frictionless.
Compressor technology is one of the fastest growing technologies in the field of engineering. The design
of these compressors is clearly innovative, elegant, and efficient, and all indications are that it is a quality
product. The idea of using magnetic bearings is provocative, but it turns out that this feature in itself is
rarely enough to justify considering the 50-70% price premium you are likely to pay for a frictionless
compressor.
However, with associated benefits, it may be well worth considering

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