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

International Symposium on Magnetic Suspension Technology, Part 1

The goal of the symposium was to examine the state of technology of all areas of magnetic suspension and to review related recent developments in sensors and controls approaches, superconducting magnet technology, and design/implementation practices. The symposium included 17 technical sessions in which 55 papers were presented. The technical session covered the areas of bearings, sensors and controls, microgravity and vibration isolation, superconductivity, manufacturing applications, wind tunnel magnetic suspension systems, magnetically levitated trains (MAGLEV), space applications, and large gap magnetic suspension systems

Feedforward and Modal Control for a Multi Degree of Freedom High Precision Machine

High precision industrial machines suffer the presence of vibrations due to several noise sources: ground vibration, acoustic noise, direct force disturbances. In the last years the need of higher processing quality and throughput result in a continuing demand for higher accuracy. Therefore vibration isolation systems became mandatory to satisfy these requests. In general, machine supports are designed for high stiffness to obtain a robust machine alignment with respect to its surroundings. However, in the presence of significant ground vibration levels the support stiffness is commonly sacrificed to reduce their transmission to the payload stage. Efforts to go towards these issues are recorded in several applications and the solutions are different for any particular situation, depending on the nature of the vibration sources, the amount of the disturbances and the machine environment. This chapter focuses on the evaluation of a vibration isolation device on the working cell of a micro-mechanical laser center, using active electromagnetic actuators. The machine is composed by two main parts: a frame support and a payload stage where the laser cutting is performed. The machine potential in terms of accuracy and precision is reduced by the presence of two main vibration sources: the ground and the stage itself. The active device should meet two main goals: the payload vibrations damping and the reduction of the transmissibility of ground disturbances. In this work the phases followed to design, realize and validate the device are illustrated with a particular attention to the mechatronics aspects of the project and to the control strategies. The chapter starts on the description of the common solutions and of the techniques described in literature. The requirements analysis and a trade-off phase on the available opportunities for vibration isolation are described. An analysis of the plant components is reported in the second section along with an exhaustive explanation of a) actuation subsystem consisting in four voice-coils, two per axis; b) sensing subsystem aimed to measure the absolute velocities of the frame support and of the stage are measured by means of eight geophone sensors. The considerations leading to the choice of this sensing system are reported along with the signal conditioning block. The active control is performed with a digital platform based on DSP and FPGA. The core of the chapter is the description of the modeling approach and of the control strategies design. The bond-graph approach is used to represent the system behavior, in particular the interactions between the mechanical and electrical subsystems are illustrated. The realized model includes the plant, the sensing, the control and the actuation blocks. The plant is considered as a classical two mass-spring-damper system resulting on a multi-input multi-output system (MIMO), considering disturbances from the stage and the ground and the actuators action between the two masses. Time and frequency domain computations are carried out from the model to evaluate vibration levels and displacements and to identify which parameters need to be carefully designed to satisfy the requirements. The control strategy is focused on the attenuation of the effects of microvibrations on the stage caused by different sources. The technique consists in a combination of two actions, the goal being the minimization of the ground vibrations transmission and the payload vibrations damping: • A single-axis decentralized action consisting in a modal controller used to compensate the high-pass band dynamic of the geophone sensors and to control the vibrations. • A feedforward action working on the disturbances coming from the payload and from the ground. This control is not generated in on-line, but computed in advance from the data of machine responses to the direct disturbances coming from the floor and the stage and resulting in vibrations on the payload and on the frame. The first action itself is aimed to perform active isolation and vibration that nevertheless could be not sufficient for severe specifications applications. The feedforward action is hence used to face this shortcoming by suppressing direct disturbance. The controller design phases along with its performance evaluation are described. The chapter concludes on the illustration of the results obtained with the proposed modeling and control strategy

Rotors on Active Magnetic Bearings: Modeling and Control Techniques

In the last decades the deeper and more detailed understanding of rotating machinery dynamic behavior facilitated the study and the design of several devices aiming at friction reduction, vibration damping and control, rotational speed increase and mechanical design optimization. Among these devices a promising technology is represented by active magnetic actuators which found a great spread in rotordynamics and in high precision applications due to (a) the absence of all fatigue and tribology issues motivated by the absence of contact, (b) the small sensitivity to the operating conditions, (c) the wide possibility of tuning even during operation, (d) the predictability of the behavior. This technology can be classified as a typical mechatronic product due to its nature which involves mechanical, electrical and control aspects, merging them in a single system. The attractive potential of active magnetic suspensions motivated a considerable research effort for the past decade focused mostly on electrical actuation subsystem and control strategies. Examples of application areas are: (a) Turbomachinery, (b) Vibration isolation, (c) Machine tools and electric drives, (d) Energy storing flywheels, (e) Instruments in space and physics, (f) Non-contacting suspensions for micro-techniques, (g) Identification and test equipment in rotordynamics. This chapter illustrates the design, the modeling, the experimental tests and validation of all the subsystems of a rotors on a five-axes active magnetic suspension. The mechanical, electrical, electronic and control strategies aspects are explained with a mechatronic approach evaluating all the interactions between them. The main goals of the manuscript are: • Illustrate the design and the modeling phases of a five-axes active magnetic suspension; • Discuss the design steps and the practical implementation of a standard suspension control strategy; • Introduce an off-line technique of electrical centering of the actuators; • Illustrate the design steps and the practical implementation of an online rotor selfcentering control technique. The experimental test rig is a shaft (Weight: 5.3 kg. Length: 0.5 m) supported by two radial and one axial cylindrical active magnetic bearings and powered by an asynchronous high frequency electric motor. The chapter starts on an overview of the most common technologies used to support rotors with a deep analysis of their advantages and drawbacks with respect to active magnetic bearings. Furthermore a discussion on magnetic suspensions state of the art is carried out highlighting the research efforts directions and the goals reached in the last years. In the central sections, a detailed description of each subsystem is performed along with the modeling steps. In particular the rotor is modeled with a FE code while the actuators are considered in a linearized model. The last sections of the chapter are focused on the control strategies design and the experimental tests. An off-line technique of actuators electrical centering is explained and its advantages are described in the control design context. This strategy can be summarized as follows. Knowing that: a) each actuation axis is composed by two electromagnets; b) each electromagnet needs a current closed-loop control; c) the bandwidth of this control is depending on the mechanical airgap, then the technique allows to obtain the same value of the closed-loop bandwidth of the current control of both the electromagnets of the same actuation axis. This approach improves performance and gives more steadiness to the control behavior. The decentralized approach of the control strategy allowing the full suspensions on five axes is illustrated from the design steps to the practical implementation on the control unit. Furthermore a selfcentering technique is described and implemented on the experimental test rig: this technique uses a mobile notch filter synchronous with the rotational speed and allows the rotor to spin around its mass center. The actuators are not forced to counteract the unbalance excitation avoiding saturations. Finally, the experimental tests are carried out on the rotor to validate the suspension control, the off-line electrical centering and the selfcentering technique. The numerical and experimental results are superimposed and compared to prove the effectiveness of the modeling approach

Chemical spray pyrolysis of Tl-Ba-Ca-Cu-O high-T(sub c) superconductors for high-field bitter magnets

The deposition of Tl-Ba-Ca-Cu-O thick films by spray pyrolyzing a Ba-Ca-Cu-O precursor film and diffusing thallium into the film to form the superconducting phase is examined. This approach was taken to reduce exposure to thallium and its health and safety hazards. The Tl-Ba-Ca-Cu-O system was selected because it has very attractive features which make it appealing to device and manufacturing engineering. Tl-Ba-Ca-Cu-O will accommodate a number of superconducting phases. This attribute makes it very forgiving to stoichiometric fluctuations in the bulk and film. It has excellent thermal and chemical stability, and appears to be relatively insensitive to chemical impurities. Oxygen is tightly bound into the systems, consequently there is no orthorhombic (conductor) to tetragonal (insulator) transition which would affect a component's lifetime. More significantly, the thallium based superconductors appear to have harder magnetic properties than the other high-Tc oxide ceramics. Estimates using magnetoresistance measurements indicate that at 77 K Tl2Ba2CaCu2O10 will have an upper critical field, H(sub c2) fo 26 Tesla for applied fields parallel to the c-axis and approximately 1000 Tesla for fields oriented in the a-b plane. Results to date have shown that superconducting films can be reproducibly deposited on 100 oriented MgO substrates. One film had a zero resistance temperature of 111.5 K. Furthermore, x ray diffraction analysis of the films showed preferential c-axis orientation parallel to the plane of the substrate. These results have now made it possible to consider the manufacture of a superconducting tape wire which can be configured into a topology useful for high-field magnet designs. The research which leads to the preparation of these films and plans for further development are reviewed

Extended analytical charge modeling for permanent-magnet based devices : practical application to the interactions in a vibration isolation system

This thesis researches the analytical surface charge modeling technique which provides a fast, mesh-free and accurate description of complex unbound electromagnetic problems. To date, it has scarcely been used to design passive and active permanent-magnet devices, since ready-to-use equations were still limited to a few domain areas. Although publications available in the literature have demonstrated the surface-charge modeling potential, they have only scratched the surface of its application domain. The research that is presented in this thesis proposes ready-to-use novel analytical equations for force, stiffness and torque. The analytical force equations for cuboidal permanent magnets are now applicable to any magnetization vector combination and any relative position. Symbolically derived stiffness equations directly provide the analytical 3 £ 3 stiffness matrix solution. Furthermore, analytical torque equations are introduced that allow for an arbitrary reference point, hence a direct torque calculation on any assembly of cuboidal permanent magnets. Some topics, such as the analytical calculation of the force and torque for rotated magnets and extensions to the field description of unconventionally shaped magnets, are outside the scope of this thesis are recommended for further research. A worldwide first permanent-magnet-based, high-force and low-stiffness vibration isolation system has been researched and developed using this advanced modeling technique. This one-of-a-kind 6-DoF vibration isolation system consumes a minimal amount of energy (Ç 1W) and exploits its electromagnetic nature by maximizing the isolation bandwidth (> 700Hz). The resulting system has its resonance > 1Hz with a -2dB per decade acceleration slope. It behaves near-linear throughout its entire 6-DoF working range, which allows for uncomplicated control structures. Its position accuracy is around 4mum, which is in close proximity to the sensor’s theoretical noise level of 1mum. The extensively researched passive (no energy consumption) permanent-magnet based gravity compensator forms the magnetic heart of this vibration isolation system. It combines a 7.1kN vertical force with <10kN/m stiffness in all six degrees of freedom. These contradictory requirements are extremely challenging and require the extensive research into gravity compensator topologies that is presented in this thesis. The resulting cross-shaped topology with vertical airgaps has been filed as a European patent. Experiments have illustrated the influence of the ambient temperature on the magnetic behavior, 1.7h/K or 12N/K, respectively. The gravity compensator has two integrated voice coil actuators that are designed to exhibit a high force and low power consumption (a steepness of 625N2/W and a force constant of 31N/A) within the given current and voltage constraints. Three of these vibration isolators, each with a passive 6-DoF gravity compensator and integrated 2-DoF actuation, are able to stabilize the six degrees of freedom. The experimental results demonstrate the feasibility of passive magnet-based gravity compensation for an advanced, high-force vibration isolation system. Its modular topology enables an easy force and stiffness scaling. Overall, the research presented in this thesis shows the high potential of this new class of electromagnetic devices for vibration isolation purposes or other applications that are demanding in terms of force, stiffness and energy consumption. As for any new class of devices, there are still some topics that require further study before this design can be implemented in the next generation of vibration isolation systems. Examples of these topics are the tunability of the gravity compensator’s force and a reduction of magnetic flux leakage

Design and analysis of a novel eddy current damper based on three-dimensional transient analysis

With advantages of no mechanical contact, vacuum compatibility, oil-free, and high reliability, an eddy current damper has a great potential use in space. In this paper, a passive magnetic damper system is developed by using the eddy current damping effect. The proposed eddy current damper utilizes a stationary permanent magnet and two conductive plates, and has significant performance than the model with only one plate. An accurate analytical model based on the electromagnetic theory for this novel eddy current damper is proposed, and the three-dimensional transient analysis based on finite element method is carried out to predict the magnetic field and current density. To optimize the design, simulations are conducted and the design parameters are evaluated from the thickness of magnet and two plates. Simulations for the optimized eddy current damper finite element model are conducted and the damping coefficient as high as 124.079 Ns/m is achieved. The results demonstrate that this novel eddy current damper has high damping performance but simple structure, which is applicable in some vibration isolation systems of spacecraft