Levitation Performance of Two Opposed Permanent Magnet Pole-Pair Separated Conical Bearingless Motors

In standard motor applications, rotor suspension with traditional mechanical bearings represents the most economical solution. However, in certain high performance applications, rotor suspension without contacting bearings is either required or highly beneficial. Examples include applications requiring very high speed or extreme environment operation, or with limited access for maintenance. This paper expands upon a novel bearingless motor concept, in which two motors with opposing conical air-gaps are used to achieve full five-axis levitation and rotation of the rotor. Force in this motor is created by deliberately leaving the motor s pole-pairs unconnected, which allows the creation of different d-axis flux in each pole pair. This flux imbalance is used to create lateral force. This approach is different than previous bearingless motor designs, which require separate windings for levitation and rotation. This paper examines the predicted and achieved suspension performance of a fully levitated prototype bearingless system

Counteracting Rotor Imbalance in a Bearingless Motor System with Feedforward Control

In standard motor applications, traditional mechanical bearings represent the most economical approach to rotor suspension. However, in certain high performance applications, rotor suspension without bearing contact is either required or highly beneficial. Such applications include very high speed, extreme environment, or limited maintenance access applications. This paper extends upon a novel bearingless motor concept, in which full five-axis levitation and rotation of the rotor is achieved using two motors with opposing conical air-gaps. By leaving the motors' pole-pairs unconnected, different d-axis flux in each pole-pair is created, generating a flux imbalance which creates lateral force. Note this is approach is different than that used in previous bearingless motors, which use separate windings for levitation and rotation. This paper will examine the use of feedforward control to counteract synchronous whirl caused by rotor imbalance. Experimental results will be presented showing the performance of a prototype bearingless system, which was sized for a high speed flywheel energy storage application, with and without feedforward control

Design and Implementation of Modern Controls for Drive and Suspension of a High Speed Double Conical Bearingless Motor on a Real-Time System

In this work, modern control approaches for drive and suspension of a high speed double conical bearingless motor are designed. Firstly, the air gap flux density and the forces acting on the rotor are analytically calculated. Subsequently, an elaborate model of the magnetically levitated rotor is developed, which considers the non-collocation of position sensors and levitation windings as well as the presence of angular motion. Three different control approaches are designed and simulated. The first approach comprises a state controller augmented with integral action, with which the closed loop dynamics are freely defined after pole placement. The other two approaches concern Linear Quadratic Gaussian and Model Predictive control. The pole placement control approach is tested successfully on the test bench with the real motor. Sinusoidal disturbance forces, with the rotational frequency, can cause large rotor orbits and may drive the inverters to their limits. For this reason, two synchronous filtering control strategies are developed. Using Imbalance Force Compensation, the rotor can be driven with low orbits at relatively low speed and using Imbalance Force Rejection, the rotor can be driven with low levitation currents at high speed. The control performance is evaluated by measurements and the measured frequency response of the closed loop system is presented

Design of a Bearingless Permanent Magnet Synchronous Machine with a Star Point-Connected Axial Active Magnetic Bearing

The bearingless synchronous machine is considered with slotted stator, cylindrical rotor with sleeve-protected surface-mounted permanent magnets and six actively controlled degrees of freedom as high-speed drive. The focus is set on two key aspects: The machine design under consideration of size-dependent scaling effects and a novel kind of feeding the excitation winding of the axial active magnetic bearing. Since the considered bearingless PM machines typically exhibit a low degree of magnetic saturation and are equipped with distributed windings, the two-dimensional analytical calculation is used to calculate the rotor suspension force and disturbing rotor forces. These calculations are used in the subsequent electromagnetic design process. At the beginning of the design process, boundary conditions are discussed, that are derived geometrically for the combined drive and suspension winding, structural mechanically for the sleeve height and thermally for the loss and output power density. On the basis of two different machine sizes, on the one hand approximately 1.5 kW and on the other hand approximately 60 kW at 75 mm and 130 mm outer diameter, respectively, at corresponding active axial length of 40 mm and 125 mm, this work shows, how the choice of pole count, bore diameter and magnet height influences the properties relevant for the rotor position control. It is concluded that an increase in pole count, a reduction in bore diameter and an increase in magnet height reduce the undesired parasitic lateral rotor forces, caused by rotor eddy currents and armature reaction. In order to investigate scaling effects, an analytical calculation is used, where the focus is set on the two-dimensional electrodynamic field calculation. By means of a 1 kW / 60000 rpm-prototype drive, consisting of a bearingless machine and a combined active radial-axial magnetic bearing, the accuracy of the results from calculation and simulation is verified. In order to reduce the number of required power electronic half-bridges, a concept is investigated, in which the axial magnetic bearing is supplied by a current between the star points of the combined winding sections in the bearingless machine. To do so the concept of the widely used space vector pulse-width modulation for 3-phase systems is extended to a double 3-phase system in a way that the axial magnetic bearing current corresponds to the sum current in the star point of one 3-phase system. This current can be controlled by the variation of the two star point electric potentials. However, additional current oscillations in the axial bearing current and in the 3-phase current can occur if the inverter is operated close to its voltage limit or if relatively high axial bearing currents must be provided at high dynamics. Anyway, the concept is considered a promising approach, since in this application as turbo-charger drive the disturbing effects do not occur

Fourth International Symposium on Magnetic Suspension Technology

In order to examine the state of technology of all areas of magnetic suspension and to review recent developments in sensors, controls, superconducting magnet technology, and design/implementation practices, the Fourth International Symposium on Magnetic Suspension Technology was held at The Nagaragawa Convention Center in Gifu, Japan, on October 30 - November 1, 1997. The symposium included 13 sessions in which a total of 35 papers were presented. The technical sessions covered the areas of maglev, controls, high critical temperature (T(sub c)) superconductivity, bearings, magnetic suspension and balance systems (MSBS), levitation, modeling, and applications. A list of attendees is included in the document

Third International Symposium on Magnetic Suspension Technology

In order to examine the state of technology of all areas of magnetic suspension and to review recent developments in sensors, controls, superconducting magnet technology, and design/implementation practices, the Third International Symposium on Magnetic Suspension Technology was held at the Holiday Inn Capital Plaza in Tallahassee, Florida on 13-15 Dec. 1995. The symposium included 19 sessions in which a total of 55 papers were presented. The technical sessions covered the areas of bearings, superconductivity, vibration isolation, maglev, controls, space applications, general applications, bearing/actuator design, modeling, precision applications, electromagnetic launch and hypersonic maglev, applications of superconductivity, and sensors

Model Identification, Updating, and Validation of an Active Magnetic Bearing High-Speed Machining Spindle for Precision Machining Operation

High-Speed Machining (HSM) spindles equipped with Active Magnetic Bearings (AMBs) are envisioned to be capable of autonomous self-identification and performance self-optimization for stable high-speed and high quality machining operation. High-speed machining requires carefully selected parameters for reliable and optimal machining performance. For this reason, the accuracy of the spindle model in terms of physical and dynamic properties is essential to substantiate confidence in its predictive aptitude for subsequent analyses.This dissertation addresses system identification, open-loop model development and updating, and closed-loop model validation. System identification was performed in situ utilizing the existing AMB hardware. A simplified, nominal open-loop rotor model was developed based on available geometrical and material information. The nominal rotor model demonstrated poor correlation when compared with open-loop system identification data. Since considerable model error was realized, the nominal rotor model was corrected by employing optimization methodology to minimize the error of resonance and antiresonance frequencies between the modeled and experimental data.Validity of the updated open-loop model was demonstrated through successful implementation of a MIMO u-controller. Since the u-controller is generated based on the spindle model, robust levitation of the real machining spindle is achieved only when the model is of high fidelity. Spindle performance characterization was carried out at the tool location through evaluations of the dynamic stiffness as well as orbits at various rotational speeds. Updated model simulations exhibited high fidelity correspondence to experimental data confirming the predictive aptitude of the updated model. Further, a case study is presented which illustrates the improved performance of the u-controller when designed with lower uncertainty of the model\u27s accurac

Model Identification, Updating, and Validation of an Active Magnetic Bearing High-Speed Machining Spindle for Precision Machining Operation

High-Speed Machining (HSM) spindles equipped with Active Magnetic Bearings (AMBs) are envisioned to be capable of autonomous self-identification and performance self-optimization for stable high-speed and high quality machining operation. High-speed machining requires carefully selected parameters for reliable and optimal machining performance. For this reason, the accuracy of the spindle model in terms of physical and dynamic properties is essential to substantiate confidence in its predictive aptitude for subsequent analyses.This dissertation addresses system identification, open-loop model development and updating, and closed-loop model validation. System identification was performed in situ utilizing the existing AMB hardware. A simplified, nominal open-loop rotor model was developed based on available geometrical and material information. The nominal rotor model demonstrated poor correlation when compared with open-loop system identification data. Since considerable model error was realized, the nominal rotor model was corrected by employing optimization methodology to minimize the error of resonance and antiresonance frequencies between the modeled and experimental data.Validity of the updated open-loop model was demonstrated through successful implementation of a MIMO u-controller. Since the u-controller is generated based on the spindle model, robust levitation of the real machining spindle is achieved only when the model is of high fidelity. Spindle performance characterization was carried out at the tool location through evaluations of the dynamic stiffness as well as orbits at various rotational speeds. Updated model simulations exhibited high fidelity correspondence to experimental data confirming the predictive aptitude of the updated model. Further, a case study is presented which illustrates the improved performance of the u-controller when designed with lower uncertainty of the model\u27s accurac

Third International Symposium on Magnetic Suspension Technology

In order to examine the state of technology of all areas of magnetic suspension and to review recent developments in sensors, controls, superconducting magnet technology, and design/implementation practices, the Third International Symposium on Magnetic Suspension Technology was held at the Holiday Inn Capital Plaza in Tallahassee, Florida on 13-15 Dec. 1995. The symposium included 19 sessions in which a total of 55 papers were presented. The technical sessions covered the areas of bearings, superconductivity, vibration isolation, maglev, controls, space applications, general applications, bearing/actuator design, modeling, precision applications, electromagnetic launch and hypersonic maglev, applications of superconductivity, and sensors

Reducing unbalanced magnetic pull in induction machines

Induction machines are the most widely used type of electrical machines because of their robustness, simplicity, and relatively low cost. However, the small airgap in the induction machine makes them more susceptible to Unbalanced Magnetic Pull (UMP). This is because the magnitude of the UMP is a function of the degree of eccentricity, which is the ratio between the length of misalignment and the mean airgap length. The bearing-related failure accounts for approximately 41% of the total failures of induction machines; the percentages of bearing-related failure would be higher for applications in a harsher environment. In this thesis, the UMP caused by rotor eccentricity is investigated, because a small degree of rotor eccentricity is unavoidable due to the manufacturing tolerance and 80% of the mechanical faults could cause rotor eccentricity in electrical machines. When the rotor is not at the centre of the stator, the eccentric rotor causes an uneven airgap around the rotor, in which the magnetic permeance with the higher harmonics content will be created. The magnetomotive force (MMF) produces additional pole-pair ±1 magnetic flux around the airgap. The interaction between each magnetic flux with its pole pair ±1 magnetic flux produces UMP. As only the magnetic flux that crosses the airgap causes UMP, the magnetic flux is categorised into magnetising flux and airgap leakage flux, because both types of flux possess different characteristics at a different rotor slip. As the airgap leakage flux is difficult to calculate analytically, an empirical method is proposed to estimate the UMP caused by the airgap leakage flux. Then, the UMP caused by the magnetising flux can also be estimated by using the empirical method. The parameters for the empirical method can be found by using either the FEA or the experimental results. The damping effect of the magnetising flux in a parallel connected rotor bar is discussed and a damping coefficient is introduced to explain this scenario. The damping coefficient can also be used to calculate the UMP in a steady state analysis. UMP comparisons between the cage rotor and wound rotor induction machines are made. The wound rotor has a much higher UMP because the pole-specific wound rotor could not damp the additional pole pair ±1 magnetic flux. Therefore, a damper winding at the stator slot is also proposed in order to damp the UMP by producing a counteracting flux. In addition, analytical equations have also been derived for different scenarios, such as static eccentricity, dynamic eccentricity, axial-varying eccentricity, and skew rotor bars. Finite Element Analysis (FEA) and experimental work are used to demonstrate the derived analytical equation. Furthermore, the power losses caused by the rotor eccentricity are investigated. Iron losses, copper losses, and frictional loss are discussed and compared with both the analytical equation and the FEA results. In order to reduce the UMP in the induction machines, the two proposed methods are the slip control method and damper windings topology. The slip control method utilises the non-linearity characteristic of the UMP at different rotor slip. To find the optimum operating slip with the lowest UMP, the UMP/Torque ratio is introduced. The characteristics of the UMP/Torque ratio varies with the type and design of the induction machines. However, this method is only applicable when the machine is lightly loaded, because the magnetising flux is limited by the capped terminal voltage and the core saturation of the machine. For the damper winding topology, a circulating current flowing in the damper winding could produce a counteracting flux to damp the UMP. The proposed damper windings configuration is only suitable for the induction machine with an even pole pair number. Finally, comparisons between both UMP reduction methods are made