THE

IN HIGH SPEED MOTORS AND GENERATORS

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12880 Moore Street Cerritos, CA 90703 USA Phone: +1-562-293-1660 Fax: +1-562-293-1661 Email: info@calnetix.com

HIGH SPEED MOTORS AND GENERATORS

www.calnetix.com

PRODUCTS & SERVICES

HIGH SPEED MOTORS HIGH SPEED GENERATORS MAGNETIC BEARINGS VARIABLE FREQUENCY DRIVES FOR MOTORS INVERTERS FOR GENERATORS SYSTEM INTEGRATION Calnetix is the global leader in developing and manufacturing high speed motors and generators. This leadership is recognized by the following: Large number of units operating in the field for various applications Range of power levels designed and built, from 1KW to 2MW Proven scalability up to 20MW Range of speeds designed and built, from 4000rpm to 450,000rpm Machine efficiencies of 98% achieved Low cost production Excellent track record from development to on time delivery Calnetix handles all projects in-house from design and prototype to production. A highly experienced management and engineering staff with electromechanical, mechanical, and electronic expertise and extensive experience in the turbomachinery industry make this possible. Calnetix products allow turbomachinery to operate at their optimum aerodynamic efficiency points. With Calnetixs system integration capabilities, OEMs gain many added benefits while still keeping production costs similar to conventional equipment. Some of these benefits include: Small size and footprint Light weight High system efficiency Cost effective Extended life Significant decrease in maintenance Increased reliability Less components, ie. gear box, oil lubrication system, seals, vibration monitoring, starter systems, etc Higher operating temperature capability Low life cycle cost Shorter assembly time Low noise Low vibration

APPLICATIONS
Calnetix products are utilized in various industries and applications. Calnetixs expertise in integrating high speed motors, generators and magnetic bearings enable many OEMs to bring more efficient and cost effective products to market without the higher costs and lengthy time involved with design and development. SPECIFIC APPLICATIONS Gas Turbines Auxiliary Power Units Turbo Compounders Naval Power Systems Expanders Compressors and Blowers Fuel Cell Air Management Systems Energy Storage Flywheels Pumps Industrial Laser Systems INDUSTRIES Power Generation Oil & Gas Marine Defense Aerospace Semiconductor Automotive

INDUSTRIES

THE

GLOBAL LEADER

IN HIGH SPEED MOTORS AND GENERATORS

www.calnetix.com

HIGH SPEED MOTORS & GENERATORS

Calnetix specializes in high speed permanent magnet brushless motor and generator technology to offer:
EFFICIENCY (%) 96

With acquired carbon winding process initially developed by DuPont, Calnetix offers high tip speed operation.

1. 2. 3. 4.

High tip speed capabilities for high speed operation High efficiencies compared to other machine topologies Simple construction, directly relating to low cost Simple controls compared to other machine topologies

92

88

Depending on the available cooling in the system, Calnetix can design its high speed machinery for air or liquid cooling, making the motors/generators and electronics suitable for system integration.

84

This combination makes Calnetix permanent magnet machines the optimum solution for high-speed applications.
0 20 40 60 80 100 120
60 KRPM 50 KRPM 40 KRPM

Calnetix offers a wide range of permanent magnet high speed machine design options to meet system specific needs. Calnetix integration expertise allows optimizing for the complete system rather than only meeting the needs of the high speed machine alone. With well over a million hours accumulated in the field, Calnetix has established itself as the global leader in high speed motors and generators.

OUTPUT POWER IN KILOWATTS

Calnetix proprietary carbon winding process enables high speed operation and has accumulated thousands of hours in the field.

Calnetix designs utilize proven materials and operate with very low losses. Most stators are vacuum impregnated for high voltage and meet high frequency UL certification for insulation systems.

Calnetix high speed machinery provides high efficiency throughout the operating speed and power range, offering efficient partial load operation.

Calnetix offers high power high speed metal sleeve rotor configurations. These sleeves provide stiffness as well as containment for the magnets. Metal sleeve rotors are compatible with various gases and fluids, and in most conditions, can be integrated for canned systems.

Calnetix permanent magnet designs typically range from two to eight-pole designs, although more poles are possible to meet system needs for size, torque and speed.

250.0
STATOR WINDING

200.0

STATOR TEETH STATOR CORE COMPOSITE SLEEVE

150.0

100.0
TEMPERATURE, O C

AIR

50.0

ROTOR MAGNET ROTOR SHAFT

0.0 0 5 10 15 20 25 30 35
TIME, SECONDS

Magnetic Analysis Calnetix utilizes both in house developed proprietary software along with finite element method modeling for complete electromagnetic analysis.

Stress Analysis Calnetix machines are constantly under high tensile loads. Understanding materials with proven field data assures reliable and safe operation for all designs.

Tip Speeds With continuous developments in carbon fiber winding, Calnetix has increased its tip speeds to over 1200ft/sec (365 m/s).

Thermal Analysis Calnetix is able to achieve long life and reliability by designing thermal stability into its high speed machines. This is achieved by utilizing finite difference and finite element techniques, both uniquely developed by Calnetix for high speed PM machines.

Rotordynamic Analysis Calnetix offers complete rotordynamic analysis for its high speed machines and for the complete systems. These include: undamped critical speed analysis; damped unbalanced response analysis; damped eigenvalue analysis and transient nonlinear analysis.

Manufacturability Low cost production is impossible to achieve through volume alone. Cost effectiveness is designed into Calnetix high speed machinery, from material selection to machining tolerances.

www.calnetix.com

MAGNETIC BEARINGS
Calnetix offers both patented homopolar (permanent magnets used for the bias field) and heteropolar active magnetic bearings (AMB). Utilizing the combination bearing, Calnetix provides five axis control of the rotating shaft with only two actuators and a small controller. Benefits of the homopolar and combination bearing designs are: High reliability Low rotating losses Less components for low cost Short rotor length Less complex controls Small cartridges High speed capability COMPONENTS OF MAGNETIC BEARINGS
Calnetix patented combination bearings integrate radial and axial actuators into one simple cartridge. This unique offering decreases component count while improving rotordynamic margins by shortening the shaft.

POWER ELECTRONICS
Calnetix provides power electronics customized for high speed applications. From motoring multi-pole PM machines at high frequencies to generating power to the grid, Calnetix utilizes proven state of the art technology to maximize the benefits of high speed systems. Small footprint Efficiency as high as 98% Flexible cooling schemes Scalable to all power needs Lower cost compared to others in the market Modifiable for optimal system operating conditions SOME OF THE CAPABILITIES OF CALNETIX MOTOR DRIVES AND INVERTERS INCLUDE: Hall Effect Sensored Motor Drives Encoder Feedback Motor Drives Sensorless Motor Drives Operating frequencies of over 3000Hz. Space Vector Modulation Unique DSP board design and control software

Calnetix magnetic bearing systems, particularly in turbomachinery, offer many benefits while maintaining a similar costing structure to conventional oil lubricated bearing systems. These benefits allow customers to: Eliminate physical contact between rotating and stationary components Eliminate lubrication system contamination Reduce operating costs Simplify maintenance Improve reliability Expand machine operating parameters such as speed and temperature Make applications environmentally friendly Offer real time monitoring of system performance for predictive maintenance

Similar to high speed motor/ generator stators, AMB stators are also vacuum impregnated and meet UL and CE certification for insulation system.

Low cost digital signal processors (DSPs) are utilized for many high volume applications to decrease costs. The DSP can be programmed to integrate complete system controls for turbomachinery.

Calnetix utilizes standard PWM amplifiers for high reliability and low cost. Several size ranges are available to meet the dynamic force requirements of a broad range of machines.

A dual conversion inverter system configuration capable of outputting controlled DC for power levels up to 2MW. Auxiliaries such as motor drive, black start, 110 VAC outputs are integrated as required by the system.

Flexible and low cost platform enabling high frequency switching for the IGBTs. Utilized for drive systems from 50KW to 2000KW.

www.calnetix.com

HIGH POWER
AT

HIGH SPEEDS
Calnetix high speed permanent magnet machines are scalable to the 20 MW power range while keeping the same proprietary electromagnetic topology. The speed range of Calnetix machines covers a wide array, from a few hundred rpm to over 450,000 rpm.

73" (1.85m) HIGH

28" (0.71m) HIGH

CALNETIX 2MW HIGH SPEED MACHINE

height length weight power density

CONVENTIONAL 2MW MACHINES

height length weight power density

2000KW 23,000 rpm

28" (0.71m) 53" (1.34m) 1650 lbs. (748kg) 2.67kW/kg (3770 kW/m3)

73" (1.85m) 90" (2.28m) 11,310 lbs. (5130kg) 0.39kW/kg (326 kW/m3)

100KW 60,000 rpm

10000

1000
POWER (km)

100

3KW 150,000 rpm

10

50,000

150,000

250,000

350,000

450,000

SPEED (rpm)

The above curve highlights a selection of the machines currently being produced. High speed enables small but power dense machines, which can be directly integrated into many turbomachinery applications.

www.calnetix.com

ABOUT CALNETIX
VISION With expertise in mechanical, magnetic, and electrical systems located under one roof, Calnetix supports customer integration of high speed machines. All designs, development, prototyping and testing take place at the Calnetix headquarters located in Cerritos, CA. Additionally, this facility accommodates low volume production for various applications. Calnetix assures cost-effective, reliable, and on time delivery of high speed machines with a highly experienced management and engineering staff. Calnetix is an ISO9000-2000 certified company. VYCON, a Calnetix subsidiary, is a company focused on manufacturing and marketing flywheel based energy storage systems for a wide range of applications with power levels of 125KW to 2000KW. These systems are capable of unlimited discharge and charge cycles at high power levels. For more information about VYCON, please visit the Calnetix website. Maintain leadership in the high speed motor and generator industry by continuously developing cost effective, power dense, high speed, and high power machines for the industry.

THE

IN HIGH SPEED MOTORS AND GENERATORS

GLOBAL LEADER
12880 Moore Street Cerritos, CA 90703 USA Phone: +1-562-293-1660 Fax: +1-562-293-1661 Email: info@calnetix.com

www.calnetix.com