1. Magnetic Couplings Project Advisor Dr. Praveen Malali
Dr. Miltiadis Kotinis
Group Members
Carol Catoire Charles Nipp
Stacey House Mackenzie Payment

2. Project Goals Prove Flux Drive’s magnetic coupling marketing claims
Ability to tolerate shaft misalignment
Power savings at startup and during operation
Flux Drive does not have vibration data for the magnetic coupling, but expects less vibration than the mechanical coupling

3. Magnetic Coupling Installations
Flux Drive FSC-1 (0-15 hP) model was initially picked for the wind tunnel
Flux Drive FSC-2 (15-40 hP) model was initially picked for the chilled water pump.
Preliminary power readings on the chilled water pump showed that the motor was operating below 15 HP
Decision made to switch the couplings to improve energy savings in Constant Hall
Minimal energy savings for FSC-2 on Wind Tunnel
Wind Tunnel FSC-2 Installation
Chilled Water Pump FSC-1 Installation

4. Horizontal Outer Motor Bearing Testing
Vibration Testing
Misalignment in mechanical couplings introduces vibration and leads to excessive wear
Flux Drive claims SmartCOUPLINGS tolerate up to 0.1” misalignment
Vibration Analyzer
Horizontal Outer Motor Bearing Testing

5. **Wind Tunnel vertical misalignment couldn’t be performed due to axial endplay

6. Power Consumption Testing
Mechanical Coupling
Motor starts under a full load (“hard start”)
Causes a spike in power consumption at start-up
Magnetic Coupling
“Soft start” minimizes spike in power consumption at start-up
Air gap spacers reduce load speed, flow rate and power consumption
Power Logger
Air gap spacers
**Power consumption testing occurred at the Constant Hall Chilled Water Pump installation

8. Power Consumption Results
Optimum Operating Condition Options
Alternating between mechanical and magnetic coupling pumps for peak times
Obtaining another magnetic coupling and alternating air gap spacer configuration
Payback Period
Will be determined after Optimum Operating Condition is finalized

9. Future Discussion Life cycle cost analysis Design work
Magnetic coupling in contrast with mechanical coupling
Design work
Investigate potential improvements in the product design
Provide feedback to Flux Drive from testing and experience

11. Questions?