Design, manufacture and test of a magnetic encoder

An new eddy current based magnetic position encoder structure is proposed and studied in this thesis. The encoder is composed of one read head and one scale with metal plates placed periodically on a substrate. The read head contains one emitter and two receiver pairs which are all rectangular planar coils. The electromagnetic coupling between the emitter and receivers were affected by the relative position of the scale. A system level analytical model of the proposed encoder structure has been derived, from which three different encoder signals forms were generated. An amplification and synchronous demodulation circuit has been designed and fabricated. The circuit board was used successfully to process the encoder output signals in the measurement. Four PCB encoder prototypes were fabricated. These encoder structures were studied using the ANSYS MaxwellTM software package. The simulated and measured results were compared. The best accuracy performance of the PCB encoder is -15 μm to 15 μm from the simulation results and -35 μm to 25 μm from the corresponding measurement. An alternative manufacturing process of the magnetic encoder based on multilayer Low Temperature Co-fired Ceramic (LTCC) technology has also been presented. The fabrication process of the LTCC encoder and equipment used were described. Two different methods were used to characterise the LTCC encoder with good agreement between all approaches attempted. The best accuracy performance of the LTCC encoder was -30 μm to 25 μm and after lookup table correction the improved accuracy ranged from -10 μm to 10 μm

Cryogenic fibre-fed laser metrology

Cryogenic cooling is a fundamental requirement for broadband far-infrared spectroscopic instrumentation to benefit from state-of-the-art far-infrared detectors. The precision to which the moving cryogenic components of the instrument can be measured and controlled affects its ability to recover the spectrum and exacts a low power robust position metrology system. This thesis explores a number of laser-based position metrology solutions and shows that a fibre-fed range-resolved interferometer meets the stringent precision and low power requirements of a metrology system for future space missions. Two cryogenic fibre-fed range-resoled interferometers are theoretically discussed and subsequently constructed; the first using the Clarke transform to decode three-phase signals, and the second based on sinusoidal laser frequency modulation. Experimental results of room and cryogenic (<4 K) temperature testing for both systems are presented. Lessons learned, suggested improvements, and the employment of a range-resolved interferometer for cryogenic accelerometry, lunar seismology, and other applications are discussed

同心円回析格子と位相変調干渉計を用いた軸受のラジアル アキシャル アンギュラモーションの同時測定法

国立大学法人長岡技術科学大

A miniature tunable quadrature shadow oscillator with orthogonal control

This article presents a new design of a quadrature shadow oscillator. The oscillator is realized using one input and two outputs of a second-order filter cell together with external amplifiers in a feedback configuration. The oscillation characteristics are controlled via the external gain without disturbing the internal filter cell, following the concept of the shadow oscillator. The proposed circuit configuration is simple with a small component-count. It consists of, two voltage-different transconductance amplifiers (VDTAs) along with a couple of passive elements. The frequency of oscillation (FO) and the condition of oscillation (CO) are controlled orthogonally via the dc bias current and external gain. Moreover, with the addition of the external gain, the frequency range of oscillation can be further extended. The proposed work is verified by computer simulation with the use of 180 nm complementary metal–oxide–semiconductor (CMOS) model parameters. The simulation gives satisfactory results of two sinusoidal output signals in quadrature with some small total harmonic distortions (THD). In addition, a circuit experiment is performed using the commercial operational transconductance amplifiers LM13700 as the active components. The circuit experiment also demonstrates satisfactory outcome which confirms the validity of the proposed circuit

Rotary Position Sensors Comparative study of different rotary position sensors for electrical machines used in an hybrid electric vehicle application

Today, many projects about Electric Vehicles (EVs) and Hybrid Electric Vehicles (HEVs) are in progress within the automotive industry. Fuel-efficiency and reduction of carbon dioxide emissions from vehicles are the main targets. This thesis is within in one of these projects that is called electric All Wheel Drive(eAWD) at BorgWarner TorqTransfer Systems AB. A key parameter to perform an accurate and efficient control of an electric machine is the position sensor. The sensor measures the angular position of the rotor shaft and there are several ways and techniques to do this. This thesis aims to compare different common position sensors and identify ”new” sensor techniques by performing a literature study, model and simulate sensors and test an electric machine with different sensors implemented. Various enhancement methods to improve the position information and prediction are also evaluated. The electric motor prototype used in the eAWD project has different position sensors implemented and these are simulated in Matlab/Simulink together with the system model of the electric machine and control system. Tests are also performed and compared to the simulation results. The results show on best performance when using the resolver as position sensor. The Hall-effect sensor can be improved with an observer, but the observer is not suitable for this specific type of Torque Vectoring (TV) application. The Hall-effect sensor has a speed dependent torque ripple that leads to harmonics at frequencies that relates to the speed of the unit which may causes problems, such as mechanical resonances in the system. There are several ”new” sensor techniques based on the theory of eddy-currents that may be of interest since they are said to be more optimized for EV and HEV applications

Automotive Inductive Position Sensor

Inductive angular position sensors (IAPS) are widely used for high accuracy and low cost angular position sensing in harsh automotive environments, such as suspension height sensor and throttle body position sensor. These sensors ensure high resolution and long lifetime due to their contactless sensing mode and their simple structure. Furthermore, they are suitable for wider application areas. For instance, they can be miniaturized to fit into a compact packaging space, or be adopted to measure the relative angle of multiple rotating targets for the purposes of torque sensing. In this work, a detailed SIMULINK model of an IAPS is first proposed in order to study and characterize the sensor performance. The model is validated by finite element analysis and circuit simulation, which provides a powerful design tool for sensor performance analysis. The sensor error introduced by geometry imperfection is thoroughly investigated for two-phase and three-phase configurations, and a corresponding correction method to improve the accuracy is proposed. A design optimization method based on the response surface methodology is also developed and used in the sensor development. Three types of sensors are developed to demonstrate the inductive sensor technology. The first type is the miniaturized inductive sensor. To compensate for the weak signal strength and the reduced quality (Q) factor due to the scaling down effect, a resonant rotor is developed for this type of sensor. This sensor is fabricated by using the electrodeposition technique. The prototype shows an 8mm diameter sensor can function well at 1.5mm air gap. The second type is a steering torque sensor, which is designed to detect the relative torsional angle of a rotating torsional shaft. It demonstrates the mutual coupling of multiple inductive sensors. By selecting a proper layout and compensation algorithm, the torque sensor can achieve 0.1 degree accuracy. The third type is a passive inductive sensor, which is designed to reduce power consumption and electromagnetic emissions. The realization and excellent performance of these three types of sensors have shown the robustness of the inductive sensor technology and its potential applications. The research conducted in this dissertation is expected to improve understanding of the performance analysis of IAPS and provide useful guidelines for the design and performance optimization of inductive sensors

ANALYSIS AND SYNTHESIS OF PRECISION RESOLVER SYSTEM

Ph.DDOCTOR OF PHILOSOPH

Active magnetic bearing for ultra precision flexible electronics production system

Roll-to-roll printing on continuous plastic films could enable the production of flexible electronics at high speed and low cost, but the granularity of feature sizes is limited by the system accuracy. Technologies such as gravure printing and nanoimprint lithography demand a level of rotary motion precision that cannot be achieved with rolling element bearings. Manufacturing tolerances of the rotating parts, thermal drift and process forces in combination with structural compliance add up to additional error motions. In this master by research an active magnetic bearing (AMB) solution is designed for a new, super-sized roll-to-roll flexible electronics production machine, which was so far based on hydrostatic bearings. The magnetic bearing could actively compensate the accumulated synchronous error and maintain high accuracy under all conditions. However, the asynchronous error of a conventional AMB with the required size and power is a problem. In order to reduce the relatively high positioning uncertainty of active magnetic bearings an innovative radial position measurement based on linear, incremental encoders with optical conversion principle is proposed. A commercial encoder scanning head faces a round scale with concentric, coplanar lines on its face. By counting these lines the radial position can be measured. Because such a scale is not readily available, it is made by micro-machining. In experiments, different machining methods are compared. Then a magnetic bearing is built to demonstrate the efficacy of the proposed sensor. As a result, the best measurement noise is 3.5nm at 10kHz and a position uncertainty of approximately 0.25µm has been achieved for the magnetic bearing. These promising results are especially interesting for applications with high precision requirements at low speed of rotation