For the past two decades, conventional centrifugal pumps continued to face the challenge. Lubrication oil and fluid leakage cause pump failures. The conventional centrifugal pump separates the pump and the motor, and it needs a seal placed between the shaft and the pump housing. As the seals age and harden, it results in leakages. According to the studies [1], in the chemical industry, 80% of centrifugal pump failures are caused by the mechanical seals, and 20% are caused by bearing, couplings and others. It is possible to remove the seal by using 2-in-1 pump and canned motor design or a magnetic coupler, but sleeve bearings are needed. Chemical slurries such as CMP slurry aid cooling and lubricating the sleeve bearings. They generate abrasive particles stuck in the gap between the bearing and the shaft. The condition accelerates bearing wear. To eliminate the problem of bearing wear, bearingless maglev motors (BLMMs) [2]-[4] have recently emerged as a potential alternative solution in the chemical pump market. Although, there are other alternative solutions [5], BLMM meets the size and the energy saving demand of the market. Centrifugal pumps with BLMM can be totally bearing free. BLMM centrifugal pumps are contactless, oil-free, particle-free, compact, cost-effective, and produce much lower vibrations. Our institute is devoted to developing BLMM for use in centrifugal pumps. The target of the first phase is to develop the BLMM with a maximum shaft output power and speed of the motor which are 120W and 5,000 rpm. However, high-speed, high-power density BLMM has levitation stability, thermal, and centrifugal stress issues which may result in unstable levitation, permanent-magnet (PM) demagnetization[6], and blade deformation. In addition, the coupling effect between magnetic circuits of magnetic bearing and motor has to be considered. Therefore, the main goal of this paper is to propose a total solution to overcome the aforementioned issues. We present the design, analysis, fabrication and test results of our BLMM pump prototype. Due to the non-linear nature of the rotor position sensors, we designed a tunable eddy-current sensor with a sensing circuit which incorporates control algorithms from a digital signal processor (DSP). A measurement method for validating the linearity and sensitivity of a single-pair position sensor (Fig. 1) is demonstrated in this paper. After the position of the rotor is correctly detected, the rotor is levitated with precision bearingless levitation control which includes start up, steady state, dynamic, and shut down processes. Furthermore, key magnetic indices such as current density, torque ripple to output torque ratio, back-EMF are calculated to evaluate motor performance. CFD and mechanical analysis and simulations are completed to predict static and dynamic stabilities at high-speed revolution to demonstrate the thermal distribution, shear strength, unbalance, and deformation of the PM blade. The heat sources of whole system are also monitored to avoid PM demagnetization and system failure. A new BLMM centrifugal pump (Fig. 2) with a delta pressure of 0.36 bar and a flow rate of 5 LPM is designed based on our analysis, and a rotor orbit &lt; 20% radial air gap can be maintained at 120W/5,000 rpm.

**References:**

 [1]R. Schob, World Pumps, Vol. 2002, p. 34 (2002). [2]S. Silber, W. Amrein, and P. Boesch, IEEE Trans. on Mechatronics, Vol. 10, p. 611 (2005). [3]X. Sun, L. Chen, and Z. Yang, IEEE Trans. Ind. Electron., Vol. 60, p. 5528 (2013). [4]J. Asama, D. Kanehara, and T. Oiwa, IEEE Trans. Ind. Appl., Vol. 50, p. 288 (2014). [5]D. Guangren and D. Howe, IEEE Trans. on Control Systems Technology, Vol. 11, p. 204 (2003). [6]R. N. Johnson, G. B. Kliman, and Y. F. Liao, U.S. Patent 5 801 470 (1998).

**Images:**

![](https://assets.underline.io/uploads/markdown_image/1/image/06b866232a7fcc21b52087044af9fdec.jpg)
Fig. 1. Position sensor test rig.

![](https://assets.underline.io/uploads/markdown_image/1/image/411000e82e0e0c2af11e847ea0b29db8.jpg)
Fig. 2. BLMM components.

 Development of a 120W Bearingless Maglev Motor for Centrifugal Pumps

*Session Chair: Somporn Ruangsinchaiwanich, Naresuan University, Thailand*

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Development of a 120W Bearingless Maglev Motor for Centrifugal Pumps