Magnetic Bearing Technology in HVAC Compressors

Axial flux motors for HVAC&R systems that enhance efficiency and reliability through optimized magnetic design. The motors employ a unique stator configuration with electromagnets and windings that create a controlled magnetic field around the rotor. This design minimizes interference between windings and enables precise control of magnetic flux, resulting in improved motor performance and reduced losses. The motors are specifically designed for HVAC&R applications where high efficiency and reliability are critical, particularly in systems with compressors that require precise control of working fluid flow.

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Turbo compressor and refrigerator that maintain cost stability while maintaining magnetic bearing operation. The compressor incorporates a housing with an integrated heat transfer plate, which is mounted on the outer surface of the housing. The plate is positioned on the outer surface of the housing and serves as a heat sink for the compressor's electrical components. This design eliminates the need for separate heat sinks or thermal management systems, thereby reducing the overall cost of the compressor while maintaining its magnetic bearing operation.

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Magnetically suspended screw refrigeration compressor that addresses the limitations of conventional screw compressors. The compressor features a magnetic suspension system that eliminates the need for mechanical seals and bearings, while maintaining the same compact design as conventional screw compressors. The magnetic suspension system utilizes permanent magnets to suspend the compressor components, eliminating the mechanical components that can cause friction and wear. The design also incorporates advanced oil management systems, including a sophisticated oil circulation system and improved oil recovery mechanisms, to maintain optimal refrigerant quality and performance.

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A turbocooler that achieves reduced environmental impact through the use of R1233zd(E) refrigerant in a turbocompressor configuration. The turbocooler employs a direct drive turbocompressor with a magnetic bearing, where the rotating shaft of the impeller directly connects to the motor. This design eliminates the need for a separate lubrication system, eliminating maintenance requirements and refrigerant release. The R1233zd(E) refrigerant, with its low global warming potential and low ozone depletion potential, enables the turbocooler to achieve significant environmental benefits while maintaining performance.

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A high-efficiency axial flux motor for HVAC&R systems that enables direct drive of compressors. The motor features a unique rotor design with two separate rotors and stators, where the rotors are positioned adjacent to each other and axially offset from one another along a central axis. The stator windings are arranged in a sandwich configuration between the rotors, with electromagnets disposed around the core. This configuration enables direct interaction between the rotor magnets and the compressor shaft, eliminating the conventional stator-bent windings and flux path inefficiencies associated with traditional radial flux motors. The motor's unique rotor configuration and sandwich stator design enable high-torque operation while minimizing the number of components and improving efficiency.

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A high-speed hermetic induction motor for direct drive applications in chiller systems, particularly for centrifugal compressors with low-pressure refrigerants. The motor features a compact design that enables direct drive operation while maintaining low-pressure operation characteristics typically associated with permanent magnet motors. The motor incorporates specialized bearing arrangements, including radial and thrust bearings, to support the rotor and shaft while maintaining precise positioning within the motor housing. The motor's rotor and shaft design enables efficient operation at lower speeds compared to conventional permanent magnet motors, while the hermetic housing provides reliable protection against refrigerant leakage.

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Magnetic suspension refrigeration compressor with enhanced heat management. The compressor features a shell, motor stator, rotor, impeller assembly, magnetic levitation bearing group, motor drive module, and magnetic levitation control module. The shell is mounted on the motor stator and rotor, with the rotor's ends connected to the shell through the magnetic levitation bearing group. The compressor incorporates separate cooling systems for the motor drive module and magnetic levitation control module, ensuring efficient heat dissipation from these critical components while maintaining stable operation.

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A magnetic suspension motor sealing-cooling system for refrigeration systems that optimizes cooling performance by integrating air and water cooling. The system employs a coaxial arrangement of magnetic levitation compressors and an expander, with the compressors' working fluid and cooling gas streams flowing in a coordinated manner. The compressors' outlet cooling gas is directed to the motor cavity, while the expander's outlet cooling gas is directed back to the compressor inlet. This dual-cooling approach ensures precise temperature and pressure matching, preventing motor overheating and ensuring stable operation. The system can operate in both air-cooled and water-cooled configurations, with the compressors' working fluid and cooling gas streams being optimized for the specific refrigerant used.

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Magnetic levitation compressor with improved load balancing and surge management. The compressor features a unique configuration where the impeller and pneumatic components are symmetrically arranged in the casing, with the motor connected to the bearing assembly and the refrigerant heat sink integrated into the casing. This configuration enables the compressor to maintain load balance under high-pressure conditions while preventing surge events. The control system monitors compressor performance and adjusts the impeller and bearing speed accordingly, with real-time compensation for suspension accuracy and surge margin.

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Micro-channel magnetic levitation centrifugal chiller with enhanced energy efficiency. The chiller comprises a magnetic levitation centrifugal compressor, a dry evaporator, a first electronic expansion valve, and a micro-channel condenser that are connected in sequence to form a refrigerant circulation loop.

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Magnetic bearings for centrifugal chillers that minimize eddy currents and improve compressor efficiency. The bearings feature a segmented stator core with radial grooves that support electrical windings. The core is assembled from multiple pie-shaped segments, each with its own radial grooves, to create a balanced magnetic field. This segmented design eliminates the traditional single-piece stator core and its associated eddy current issues, enabling more efficient operation of the compressor.

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Magnetic levitation screw refrigeration compressor with improved seal performance and reduced oil consumption. The compressor features a magnetic levitation system, comprising a rotor, driven rotor, magnetic coupling, and bearings. The magnetic bearings form a complete assembly, eliminating the need for separate bearings and seals. This design integrates the magnetic levitation components into a single, compact unit, providing improved seal performance and reduced oil consumption compared to traditional screw compressors.

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High-speed and high-pressure magnetic levitation centrifugal two-stage air compressor with advanced control system. The compressor employs magnetic levitation technology to support the main shaft, significantly reducing frictional power consumption compared to conventional ball bearings. The control system includes displacement sensing for precise shaft positioning, enabling optimal operation in high-speed and high-pressure conditions. The system calculates compressor pressure and temperature based on the position of the main shaft relative to the magnetic suspension bearings, ensuring consistent performance across different operating conditions.

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A magnetic levitation (MCL) compression system with direct motor-suspension connection eliminates traditional mechanical coupling requirements. The system integrates a magnetic levitation motor directly with the MCL compressor through a magnetic coupling, eliminating the need for speed-increasing boxes. The motor shaft and magnetic coupling transmit torque without contact between the compressor shafts, achieving lower concentricity requirements. This design enables rapid assembly of the equipment while maintaining precise concentricity.

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A direct-motor-compressor (DMC) system that eliminates the need for speed-increasing boxes in magnetic levitation (Maglev) applications. The system integrates a Maglev motor with a direct-drive compressor, where the motor's rotor is directly connected to the compressor's shaft. This eliminates the conventional speed-increasing box requirement, reduces equipment volume and weight, and eliminates the need for lubrication. The compressor's magnetic bearings support the rotor, allowing higher speed operation without mechanical support.

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A high-performance single-side double-impeller maglev high-speed direct-drive turbocompressor structure for gas compression and dust conveying applications. The structure employs a novel axial impeller arrangement where the non-working surface of the first impeller is positioned adjacent to the non-working surface of the second impeller, with a sealing ring separating them. This configuration enables improved performance characteristics compared to conventional double-impeller designs.

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A high-speed compressor featuring magnetic bearings that enable efficient operation at high rotational speeds. The compressor employs radial and axial magnetic bearings with integrated magnetic components that support the compressor shaft through magnetic interaction. The bearings are positioned at the shaft's ends, with the radial bearings aligned with the compressor rotor and the axial bearings positioned at the thrust plate. This configuration enables the compressor to maintain high rotational speeds while maintaining precise shaft alignment and preventing shaft deflection. The bearings are supported by a protective bearing seat and protective bearing, with the outer ring of the protective bearing and seat forming a precise interference fit at the shaft's ends.

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Magnetic levitation centrifugal compressor system for industrial applications that eliminates oil contamination through the unique operation mechanism of magnetic levitation. The system utilizes a rare-earth permanent magnet motor and high-precision centrifugal impeller to achieve oil-free operation, while maintaining high efficiency and reliability. The system enables the use of compressed air as a clean energy source in industrial processes, particularly in applications where oil-based systems would otherwise be required.

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A magnetic levitation centrifugal compressor that eliminates the need for mechanical bearings and sealing oil stop rings, achieving significant weight and space savings while maintaining high efficiency. The compressor employs a magnetic levitation system to suspend the rotor, eliminating the conventional mechanical bearing and sealing requirements. This design enables the compressor to operate with a reduced overall weight and size compared to traditional centrifugal compressors, while maintaining its high performance characteristics.

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A compact residential air conditioning system that achieves high efficiency through optimized compressor design and operation. The system employs a high-speed, variable-speed centrifugal compressor with a low-pressure refrigerant (R1233zd) that operates below atmospheric pressure. The compressor is coupled to an inter-loop heat exchanger that provides close-loop operation, allowing the compressor to operate at lower pressures than traditional systems. The system incorporates a unique bearing arrangement that enables the compressor to maintain optimal performance while minimizing noise and vibration. The system also features a low-pressure refrigerant with lower GWP compared to traditional R410A.

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