Magnetic bearing systems are vital in industries that require precise, frictionless operation, especially in environments like vacuum or pressurized gasenvironments. These bearings rely on a critical internal environment to function effectively. However, one of the challenges engineers face is effectively sealing the wires and cables that pass through the bearing housing. These wires connect essential sensors like thermocouples, eddy current sensors, optical sensors, and inductive sensors to control systems that monitor and manage the bearings’ position and performance.
Traditional Sealing Methods: Compression Seals and Their Limitations
Traditionally, compression seals have been used to feed wires through the bearing housing. Compression seals work by tightly pressing the wires through a gland, creating a seal intended to prevent leaks. However, this method has its drawbacks—most notably, the risk of leakage. Over time, the compression seal may wear down or fail to maintain a perfect seal, allowing the refrigerant or other sealed media to seep through the housing. Additionally, this technology limits the user in terms of their wire and cable selections to solid core options only. This leakage can lead to performance issues, increased maintenance costs, and potential downtime.
The Importance of a Perfect Seal in Magnetic Bearing Systems
A reliable seal is crucial not just for maintaining the integrity of the bearing system but also for ensuring the long-term reliability of the sensors and instrumentation connected to it.
Our hermetic magnetic bearing feedthroughs are designed to allow power, control, and monitoring signals to flow in and out of magnetic bearings while maintaining the critical internal environment. We achieve this by using epoxy technology to create a hermetic seal that ensures liquids and gases are contained within their expected environments.
Overcoming the Challenges with Advanced Feedthroughs Solutions
One solution we offer is the use of sealed-to-suit feedthroughs, which come with customizable elements such as housing, cables, materials, and connector integration. Our feedthroughs are designed to provide a more reliable seal over the long term, reducing the risk of leaks and improving the overall durability of the bearing system. Features like direct sealing of shielded conductors help reduce noise and increase signal integrity. We also offer fully turnkey solutions, which help to streamline the procurement and manufacturing processes for the end user.
Why Our Feedthrough Technology Stands Out
Our magnetic bearing feedthroughs are versatile, allowing for direct sealing of all conductor types including those that are shielded conductors to any vacuum flange, fiber optic cables to a wide range of flanges, and even complex assemblies that combine multiple feedthroughs for power and signals into a single design. These features not only reduce potential leak paths but also save time and space, making them an efficient solution for both test and measurement scenarios as well as full OEM production volumes.
We understand that the need to connect or solder wires to our feedthroughs can be seen as a challenge. However, we believe that the long-term benefits of a leak-proof, reliable seal far outweigh the initial complexity. To further simplify integration, Douglas Electrical also offers turn-key solutions with connector terminations, making our feedthrough assemblies truly plug-and-play. We are committed to working closely with our customers to provide the technical support needed to overcome any challenges and ensure a smooth transition to our feedthrough solution.
Our feedthrough technology offers a compelling value proposition:
- Leak Prevention: A secure seal to the conductor eliminates gaps and voids, preventing oil leaks.
- Improved Reliability: By reducing the risk of leaks, our solution enhances the reliability and longevity of the magnetic bearing system.
- Customization: We can tailor our feedthroughs to meet the specific needs of your application, ensuring optimal performance.
Conclusion
While traditional compression seals have been the go-to solution for many years, they come with significant risks, particularly in high-performance applications where oil leaks can be detrimental. Our advanced feedthrough technology provides a more secure, reliable solution, ensuring the integrity of your magnetic bearing system. Although there are some challenges in adopting this technology, we believe the benefits make it a worthwhile investment for long-term performance and reliability.
