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Power Systems Project Example
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Project Title: Design, Development & Manufacture of High-Speed
Foil Bearings
Mohawk Innovative Technology, Inc., Albany, NY
BACKGROUND
Micro and miniturbine generators offer promise for efficient, reliable,
clean distributed power. Microturbines in the 25 to 75 kW range are
in operation at commercial sites. Concurrently, several microturbine
manufacturers are developing, or have announced plans to develop, 250
to 450 kW miniturbines because of the economic benefits of scaling up,
and the growing market for this size range generators. For both size
ranges, eliminating the entire oil lubrication system is a goal that
could yield low operating and maintenance costs. Mohawk Innovative Technology,
Inc. (MiTi) is a world leader in the design and manufacture of high-performance
journal and thrust-compliant air foil bearings for use in high-speed
rotating machinery. Current air-bearing manufacturing methods were established
to meet the needs of low-volume specialty machinery. Bearing production
volumes in the 100 to 300 units per year range dictated the use of low-volume
manufacturing processes. Market projections for mini and microturbines
anticipate significant increases in production volume in the coming
years. The demand for high-quality compliant foil air bearings is also
expected to increase. Current production methods cannot economically
provide the volume of air bearings required by the expanding mini and
microturbine market. MiTi is interested in entering the potentially
high-volume air bearing market for mini and microturbines.
OBJECTIVE
Project objective is to investigate and demonstrate cost-effective,
high-volume production methods for compliant foil air bearings, and
to establish and demonstrate a cost-effective, high-volume process for
verifying assembled bearing quality.
DESCRIPTION
MiTi will investigate relevant high-volume manufacturing processes for
foil element cutting, bump foil element corrugations forming, and foil
element welding. MiTi will then design and demonstrate automated quality
control test stations for high-volume static and dynamic bearing testing.
Software will be developed to control the test instrumentation, and
to analyze inspection results for pass/fail/rework criteria.
BENEFITS
The availability of high-volume manufacturing and inspection processes
will enable compliant foil air bearing technology to compete for application
in mini and microturbine distributed generation, and expand the market
for MiTi air bearing products. Increased sales will lead to new employment
opportunities at MiTi.
SCHEDULE AND STATUS
A contract was recently executed and the project is under way.
Staff Contact
Joseph Sayer
Sr. Project Manager
ext. 3298
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17 Columbia Circle, Albany, NY 12203-6399 Toll-Free:
1-866-NYSERDA or Local: 518-862-1090 Fax: 518-862-1091
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© 2004 New York State Energy Research and Development Authority
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