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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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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Compact electric centrifugal compressor for automotive applications that addresses the challenges of conventional motor-driven compressors. The compressor features a radial bearingless motor configuration with two separate motors positioned along the shaft, each maintaining a defined radial position through contactless operation. The axial magnetic bearing is positioned between the motors, maintaining the shaft's axial position. This design eliminates the need for separate bearings, reduces friction, and simplifies system management. The axial magnetic bearing can be integrated with the motor windings, eliminating the need for separate windings. The radial bearingless motors provide the necessary radial force and positioning, while the axial magnetic bearing ensures precise axial positioning.

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A magnetic levitation centrifugal power heat pipe multi-unit air conditioning integrated machine that eliminates the need for oil return through a novel magnetic suspension compressor design. The system features a magnetic levitation compressor that operates without lubrication, eliminating the conventional oil return issues associated with conventional multi-line systems. The magnetic suspension technology enables the compressor to maintain optimal performance without the need for oil, while the system's compact condenser design eliminates the requirement for medium pipeline length and height.

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Centrifugal compressor with magnetic bearing backup system for enhanced reliability and efficiency in chiller systems. The compressor incorporates a magnetic bearing backup system that enables continuous operation during compressor failure, maintaining refrigerant flow and pressure. This system utilizes a magnetic bearing that can maintain its position even when the compressor's conventional bearings fail, ensuring continuous operation of the compressor. The magnetic bearing backup system is integrated with the compressor's control system to automatically activate in the event of bearing failure.

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Cooling method for refrigerant systems containing R1233zd, which is a candidate for low-GWP refrigerants in HVACR applications. The method involves compressing the refrigerant in a magnetic bearing assembly within a chiller system, rather than the conventional centrifugal compressor. The compressed refrigerant is then cooled in the condenser, expanded through an expansion valve, and subsequently cooled in the evaporator. This approach eliminates the need for conventional lubricating oils in the system, significantly reducing environmental impact.

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A rotor assembly for high-performance applications, particularly in gearboxes, that achieves superior bearing support through advanced magnetic levitation technology. The assembly comprises a rotor with integrated magnetic bearings that utilize microprocessor-controlled power amplifiers to maintain precise bearing alignment and position. The bearings are mounted on a precision-machined rotor platform and are supported by a robust electronics enclosure within the compressor body.

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A double permanent magnet double-stage screw compressor for air compression that achieves higher efficiency through optimized magnetic design. The compressor features a double-stage configuration with two permanent magnet loops connected by a tapered shaft, enabling improved coaxial transmission and reliable transmission. The design incorporates tapered shafts that enable interference between the magnetic loops, enhancing the compressor's performance and reliability. The compressor also employs a reverse oil-cooled permanent magnet machine architecture, which enables stepless cooling and pressure protection.

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Magnetic suspension compression device with improved energy efficiency and cost-effectiveness. The device comprises a scroll with an impeller region, motor region, and tail region. The motor region is fixed with an annular permanent magnet stator. The rear rotor features an axial thrust bearing and an impeller with a flow channel. The device achieves optimal compression performance through optimized impeller design and flow channel configuration. The scroll design enables compact compression while maintaining high efficiency.

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A compressor with adjustable clearance between the impeller and housing to optimize performance and capacity. The compressor features a housing assembly with suction and discharge ports, an impeller supported by a rotating shaft, and a magnetic bearing system. The controller, coupled to an axial position sensor, monitors the impeller position and adjusts clearance between the impeller and housing through the bearing to achieve optimal operation across varying capacities and lift levels.

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A magnetic levitation type inverter air conditioner compressor shaft that eliminates the need for mechanical bearings and lubricants in the compressor rotor. The compressor rotor is divided into two sections: a main rotor and a stator. The main rotor is equipped with a magnetic levitation system that enables it to rotate without mechanical bearings, while the stator is a conventional scroll compressor. The main rotor's magnetic levitation system eliminates the need for bearings and lubricants, reducing maintenance and wear on the compressor.

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A permanent magnet synchronous motor (PMSM) direct drive air compressor that achieves high-speed operation with reduced energy consumption. The compressor incorporates a permanent magnet motor with a unique rotor design featuring permanent magnets integrated into the rotor structure. The rotor's permanent magnets are arranged in a specific mosaic pattern to optimize magnetic field distribution and minimize energy losses. The rotor is mounted on a bearing assembly that supports the motor shaft, which is connected to a high-speed compressor impeller. The compressor's front bearing assembly features a magnetic suspension bearing that enables high-speed operation while maintaining low maintenance costs. The design enables the compressor to achieve high-speed operation (up to 10,000 rpm) while significantly reducing energy consumption compared to conventional motors.

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A magnetic bearing system for direct drive compressors that improves rotor displacement detection and control through advanced sensor placement. The system employs two radial displacement sensors positioned on either side of the bearing to detect rotor displacement, with one sensor positioned at the bearing's center and the other at the bearing's outer edge. This configuration enables precise measurement of both radial and axial displacements, enabling more accurate control of the bearing's magnetic field. The system's axial displacement sensors detect the rotor's movement in the direction of rotation, allowing precise control of the magnetic field distribution. This configuration provides improved bearing performance compared to conventional radial displacement sensors, particularly in applications where high precision displacement measurement is critical.

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A magnetic suspension single shaft direct drive compressor that achieves high efficiency, reliability, and environmental protection through advanced bearing technology. The compressor features a radial magnetic bearing system with dual displacement sensors, where one sensor measures the radial displacement of the left bearing and the other measures the radial displacement of the right bearing. This configuration enables precise control of both bearings through differential displacement measurement, significantly improving bearing performance and reducing maintenance requirements compared to traditional single-bear configurations. The system also incorporates axial displacement sensors on the shaft to monitor the rotor's axial movement, further enhancing bearing control.

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Centrifugal compressor assembly and method for optimizing refrigeration system performance through precise control of compressor speed and energy recovery. The assembly features a variable speed drive that enables continuous operation of the compressor within a specified speed range, while also incorporating an energy recovery system to maximize efficiency. The drive system incorporates a compact permanent magnet motor with a variable speed capability, allowing continuous operation while maintaining optimal compressor performance. The system integrates with the compressor to optimize refrigerant compression and energy recovery, enabling higher-capacity compressors with improved efficiency compared to conventional designs.

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