Intelligent instrumentation, control and monitoring of precision motion systems

Ph.DDOCTOR OF PHILOSOPH

Adaptive control system of slotless DC linear motor

Slotless DC linear motors (SDCLM) offer several benefits over traditional linear motors, including higher efficiency, smoother operation, and higher power density. These advantages make them a popular choice for a wide range of applications in various industries. One of the main benefits of a slotless DC linear motor is the absence of slot harmonics, which can cause vibration and noise in traditional slotted motors. This makes slotless motors ideal for applications that require precise and smooth motion, such as in medical equipment, robotics, and semiconductor manufacturing. However, one of the challenges of a Slotless DC linear motor is the presence of force ripple, which can limit the motor's performance, precision, and accuracy. Force ripple is caused by the mutual attraction of the translator's magnets and iron cores. It is independent of the motor current and is determined only by the relative position of the motor coils regarding the magnets. To overcome these challenges, motor redesign, magnetic field optimisation and the use of an adaptive control system. This research program focused on and investigated the above possible methods (i.e., motor redesign, magnetic field optimisation field and use of advanced control algorithms such as Sliding Mode Control SMC) to tackle the current challenges and improve the relevant industrial application performance and precision. The inquiry encompasses the analysis, design, and control of the SDCLM by proper modelling, building, and experimental validation of the modelled findings, applying both static and dynamic methodologies. Electrical, mechanical, and magnetic analyses were performed on the SDCLM design. The performance of the SDCLM was investigated using a finite element method (FEM), and the motor parameters were improved. Investigation and analysis are performed about additional difficulties such as force ripple and normal force, where the results indicated that the flux density in the airgap and the thrust force were different between the actual time and the simulation by 7.14% and 8.07%, respectively. Moreover, sliding mode control is designed to achieve desired system performance, such as reducing the power ripple of a slotless DC linear motor. where the proposed control shows experiments that it has stability despite disturbances and uncertainties. To improve the control method and reduce the steady-state error caused by the force ripple, the Bees algorithm has been used to tune the parameters of the controller. Finally, the outcomes indicate that the control method employing the disturbance observer and Bees algorithm has enhanced the performance of both position and speed, while concurrently reducing the force ripple. A comparison between simulation and experiment shows that there is a difference in the tracking performance, where the difference was around 13.6%. This error could have arisen from the omission of certain errors that cannot be accounted for within the simulation. These errors may stem from issues with the position sensor or discrepancies in the manual system design process