Abstract Active Magnetic Bearings Research Articles

Fuzzy Bang-Bang Relay Control of a Rigid Rotor Supported by Active Magnetic Bearings

Active magnetic bearings, which are open-loop and unstable, require a feedback control system to ensure stable operation of the rotating machines that they support. Proportional-integral-derivative (PID) controllers are widely used in field applications of these bearings for this purpose. PID controllers are designed to work effectively within the linear region of operation of the rotating machines. Due to the inherent nonlinearity of the active magnetic bearings, large unbalance forces that may occur in these machines result in nonlinear vibration responses. Therefore, the PID controller’s effectiveness to control the vibration of the rotating machines is considerably reduced when the unbalance forces in these machines become large. Other control strategies, such as the fuzzy logic and the sliding mode control schemes, are more apt to deal with the nonlinear responses of the rotating machines supported by active magnetic bearings. The present work proposes an integrated fuzzy bang-bang relay controller for a rigid rotor mounted on active magnetic bearings. The effectiveness of this controller to suppress rotor vibrations is examined numerically. Performance comparison of this controller with the conventional fuzzy logic and PD controllers are made for different initial conditions, rotor imbalance magnitudes, and rotor angular speeds. At extreme operating conditions due to large rotor unbalance forces, where the magnetic bearings are highly nonlinear, the proposed integrated fuzzy bang-bang relay controller proved to be more superior over the conventional fuzzy logic and PD controllers.

Analysis of a thrust magnetic bearing with rectangular wire winding

Active magnetic bearings generally use the coils made of enameled round wires, which have a low filling factor and waste plenty of slot space, resulting in large volume and weight of the machine. This paper introduces the rectangular wires to apply in magnetic bearings. The rectangular wires can be wound compactly without gaps and increase the wire filling factor, thereby reducing the size of the magnetic bearing stators, as well as the associated rotor part. These structural improvements are greatly beneficial to the high-speed rotating machinery in the aspects of windage losses, natural frequency, and material strength of the rotor, which are quantitatively analyzed. By utilizing the rectangular wire, a coil for a thrust magnetic bearing prototype is fabricated and tested, demonstrating the practical feasibility of the rectangular wires to apply in magnetic bearings.

Effect of AMB winding configurations on static and dynamic performances and power consumptions of the AMB-rotor system

Active magnetic bearings (AMBs) bring extraordinary benefits such as free of contact, elimination of lubrication, active control of rotor position, and a built-in monitoring system. In the design of AMBs, the bearing structure is of significance since it has an important impact on bearing performances. However, the effect of winding configurations of AMBs is still obscure. In this paper, the system-level implications of two radial AMB winding configurations termed the Ortho and the Cross types are investigated, including the bearing characteristics, power consumptions and rotor dynamic behaviors. The simulation results demonstrate that the Cross type contributes to larger load capacity in the direction of gravity. In condition of a heavier gravity load (−200 N), the Cross-type winding configuration saves power consumption with a percentage of 17.2% at steady state (20,000 rpm) and 12.7% considering unbalance mass during the run-up process. However, the rotor vibrations of the Cross type in case of external loads and unbalance mass are larger than the Ortho type. The proposed results of this paper provide some useful information for the AMB winding configuration design.

Application of artificial neural networks for the fault detection and diagnosis of active magnetic bearings

Active magnetic bearings (AMBs) are the class of advanced mechatronic systems. The stable operation of these depends on the normal operation of its sensors and actuators whose malfunctioning may disturb the stability of the supported rotor. Therefore, online fault detection and diagnosis (FDD) of sensors and actuators of AMB system is essential for safe and reliable operation. Model based FDD requires complex mathematical modelling and has higher chances of subjected to modelling errors. Redundant sensors and actuators based FDD incurs additional cost and also requires additional space for installation. Therefore, in the present work, simulation data driven artificial neural network (ANN) based methodology with statistical analysis is proposed for FDD of AMBs. Faults in single position-sensor or actuator as well as in multiple sensors and actuators are detected and diagnosed simultaneously. Various types of faults such as bias, multiplicative and noise addition are considered for the diagnosis.

VIBRATION INDUCED FAILURE ANALYSIS OF A HIGH SPEED ROTOR SUPPORTED BY ACTIVE MAGNETIC BEARINGS

Active Magnetic Bearings (AMBs) are increasingly used in various industries and a quick re-levitation of AMBs supported high speed flexible rotor is necessary in case of vibration induced failure. A robust fault diagnosis algorithm is presented to detect suspected saturation type of nonlinearity associated with a power amplifier. A five degree-of-freedom AMB system consisting of four opposing pair of radial magnets and a pair of axial magnets is considered. In this paper failure of an industrial grade AMB system is investigated using Sinusoidal Input Describing Function (SIDF) method. SIDF predicts the gain and frequency at which failure occurs. It is demonstrated that the predicted frequency is in agreement with the frequency at which failure occurs.

An Appraisal of Power-Minimizing Control Algorithms for Active Magnetic Bearings

Active magnetic bearings consume much less power than conventional passive bearings, especially when power-minimizing controllers are employed. Several power-minimizing controllers have been proposed, such as variable bias controllers and switching controllers. In this paper, we present an appraisal of the power-minimizing control algorithms for active magnetic bearings in an attempt to provide an objective guideline on the merits of the control algorithms. In order for the appraisal, we develop an unified and consistent model of active magnetic bearing systems. The performances of the power-minimizing controllers are assessed through this model. The results show that the power-minimizing controllers indeed save considerable power when the machine state is relatively steady. However, a simple proportional-derivative type controller is on a par with the much more complex power-minimizing controllers in terms of power consumption when the machine is experiencing transient loads.

Nonlinear Calculation of Active Magnetic Bearings Dynamic Magnetic Field by Finite Element Method

Active magnetic bearings open-loop instability makes the features of dynamic magnetic field crucial to the control performance. We presented a nonlinear calculation of AMBs dynamic magnetic field by FEM. Firstly, we constructed a AMBs dynamic field FEM model considering the magnets nonlinear permeability; Secondly, we applied a harmonic current to the coils through 160 load steps and a zero magnetic potential boundary condition; Finally the field was solved and magnetic flux lines, air gap flux density and eddy current density were retrieved and analyzed. Because of the nonlinearity of eddy current, air gap flux density is not standard harmonic and lags behind the source current,and as magnetizing energy equalizes eddy current losses, air gap flux density approaches harmonic.

DYNAMIC BEHAVIOR OF ACTIVE MAGNETIC BEARINGS IN PRESENCE OF ANGULAR MISALIGNMENT DEFECT

Active magnetic bearings (AMBs) is a device using controlled electromagnetic forces to support a shaft without mechanical contact. One of the primary techniques of condition monitoring of rotors is that of vibration control. Rotating machinery is facing some problems caused by shaft misalignment. This defect leads to a premature failure of the shaft, the coupling and the bearing because of the important vibrations and overloads generated. In this paper, the nonlinear dynamic behavior of a shaft supported by two identical AMBs with eight-pole legs is investigated in the presence of an angular misalignment defect. Thus, the electromagnetic forces, acting on the bearing in horizontal and vertical directions are computed. They are modeled by stiffness and damping matrices. The effects of air gap distance between the stator and the shaft, as well as rotor speed level on the electromagnetic forces are presented. To survey the vibratory response of a misaligned rotor, a numerical simulation of a theoretical model with an angular misalignment defect is studied. All results are presented and discussed in this work.

The Dynamic Analysis of an Energy Storage Flywheel System With Hybrid Bearing Support

Active magnetic bearings and superconducting magnetic bearings were used on a high-speed flywheel energy storage system; however, their wide industrial acceptance is still a challenging task because of the complexity in designing the elaborate active control system and the difficulty in satisfying the cryogenic condition. A hybrid bearing consisting of a permanent magnetic bearing and a pivot jewel bearing is used as the support for the rotor of the energy storage flywheel system. It is simple and has a long working life without requiring maintenance or an active control system. The two squeeze film dampers are employed in the flywheel system to suppress the lateral vibration, to enhance the rotor leaning stability, and to reduce the transmitted forces. The dynamic equation of the flywheel with four degrees of complex freedom is built by means of the Lagrange equation. In order to improve accuracy, the finite element method is utilized to solve the Reynolds equation for the dynamic characteristics of the squeeze film damper. When the calculated unbalance responses are compared with the test responses, they indicate that the dynamics model is correct. Finally, the effect of the squeeze film gap on the transmitted force is analyzed, and the appropriate gap should be selected to cut the energy loss and to control vibration of the flywheel system.

Multiharmonic Adaptive Vibration Control of Misaligned Driveline via Active Magnetic Bearings

Active magnetic bearings (AMBs) have been proposed by many researchers and engineers as an alternative to replace traditional contact bearings in rotor and driveshaft systems. Such active, noncontact bearings do not have frictional wear and can be used to suppress vibration in sub- and supercritical rotor-dynamic applications. One important issue that has not yet been addressed by previous AMB-driveline control studies is the effect of driveline misalignment. Previous research has shown that misalignment causes periodic parametric and forcing actions, which greatly impact both driveline stability and vibration levels. Therefore, in order to ensure closed-loop stability and acceptable performance of any AMB controlled driveline subjected to misalignment, these effects must be accounted for in the control system design. In this paper, a hybrid proportional derivative (PD) feedback/multiharmonic adaptive vibration control (MHAVC) feedforward law is developed for an AMB/U-joint-driveline system, which is subjected to parallel-offset misalignments, imbalance, and load-torque operating conditions. Conceptually, the PD feedback ensures closed-loop stability while the MHAVC feedforward suppresses steady-state vibration. It is found that there is a range of P and D feedback gains that ensures both MHAVC convergence and closed-loop stability robustness with respect to shaft internal damping induced whirl and misalignment effects. Finally, it is analytically and experimentally demonstrated that the hybrid PD-MHAVC law effectively adapts to and suppresses multiharmonic vibration induced by imbalance, misalignment, and load-torque effects at multiple operating speeds without explicit knowledge of the disturbance conditions.

A Multipoint Measurement Technique for the Enhancement of Force Measurement With Active Magnetic Bearings

Active magnetic bearings (AMBs) have the unique capability to act concurrently as support bearings and load cells for measuring shaft forces. Current state-of-the-art methods for force measurement rely on models with limited accuracy due to effects which are difficult to characterize such as fringing, leakage, and variations in material properties. In addition, these effects may be a function of actual air gaps which are difficult to determine in a dynamic operating environment. This paper discusses a new force measurement methodology that inherently accounts for these types of effects and other system uncertainties by utilizing multiple sets of current pairs in opposing actuators, in conjunction with a calculation algorithm, to accurately determine the force applied by the AMB. This new multipoint methodology allows for the determination of bearing forces from information on basic actuator geometry and control currents only, with no knowledge of actual operating air gaps required. The inherent nature of the methodology accounts for model uncertainties such as fringing, leakage, and other system unknowns. Initial static experimental test results are presented demonstrating 3% error in measuring the nominal determined bearing load, and a variation in calculated forces of less than 5% in most cases (8% in one case) when the location of the rotor within the bearing stator is modified. For the analogous conventional single-point measurements, the results show 15% error and 23% variation.

Two-Level Control Structure of Magnetic Bearings

Active magnetic bearings have several advantages over conventional mechanical and fluid bearings. However, when the magnetic bearings are used at high rotational speeds, whirling motions and vibrations synchronized with the rotation of the rotor should be considered. In order to suppress these unfavorable vibrations of rotor which is supported by magnetic bearings, we have developed an active vibration control system with a two-level control structure. Experimental results show that our active bearings system effectively suppresses the whirling motion.

A Comparison of Analog and Digital Controls for Rotor Dynamic Vibration Reduction Through Active Magnetic Bearings

Active magnetic bearings are implemented using analog and digital controllers to achieve vibration reduction for multimass flexible rotors. Various models are developed for the rotor-bearing system, and the first three critical speeds (resonant frequencies) are shown to be unaffected by inclusion of the higher order shaft dynamics in the model. Higher order rotor-bearing models reveal the presence of “shaft modes,” the excitation of which is a function of the position of the magnetic bearing proximity probe (these modes are effectively damped by the flexible coupling employed in the test apparatus). Rotor dynamic behavior is investigated for various analog and digital controllers. Rotor response in the presence of proportional-derivative control is similar for both analog and digital control. Higher order digital control algorithms (second derivative and integral) affect the rotor response in a frequency dependent manner: Second derivative feedback is effective at reducing third mode vibration, and integral feedback, while rejecting any steady-state rotor position error, slightly accentuates the vibration at the first critical speed. Increasing the sampling rate of the digital controller has a similar effect to increasing the amount of second derivative feedback employed.

HIGH SPEED INDUCTION MOTOR DRIVE WITH ACTIVE MAGNETIC BEARINGS AND SLIDING MODE DECENTRALIZED CONTROL

ABSTRACT Active magnetic bearings are credited with high performance in terms of low energy consumption, high speeds, increased reliability and low maintenance costs. This paper discusses a high-speed induction motor with active magnetic bearings: both radial and axial. The decentralized control system of active magnetic bearings is based on sliding mode variable structure principle to provide robustness to parameter detuning and perturbations. Test results on a laboratory model of 300 W and 25000 rpm motor designed and built for the scope are very promising for applications to high speed machine tools, vacuum pumps etc.