DEPARTMENT OF ELECTRICAL ENGINEERING

Course: INDUSTRIAL PROJECT IV Subject Code: IPR413T (6 MONTHS) IPR413R (RE-REGISTRATION) INDUSTRIAL PROJECT PROPOSAL:

ACTIVE MAGNETIC BEARINGS

by

Diakiese Ndudi Aubin 209024489 A Project Proposal Submitted as a Partial Requirement for the Bachelors Degree in Technology (BTech): Electrical Engineering

Control

In the Department of Electrical Engineering Faculty of Engineering and the Built Environment, Tshwane University of Technology

Supervisor: Professor Qi Guo-Yuan Co-Supervisor:Mr Martial Tatchum Starting Date:01/08/2013

STUDENTS DETAILS

STUDENT NUMBER: 209024489

TEL. NUMBER: 0762945738

FAX. NUMBER: N/A

CELL. NUMBER: 0762945738

E-MAIL:ndudi1989@yahoo.fr

PROPOSED TITLE OF PROJECT

ACTIVE MAGNETIC BEARING

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DETAILS OF INTERNAL PROJECT LEADER(Lecturer from TUT, if available)

SURNAME AND INITIALS: Qi G

INSTITUTE:University of Nankai (NKU) ,China

QUALIFICATION:PhD(Control

Theory

And Control (Nankai,China)

Engineering)

TELEPHONE NUMBER: +27123825385

FAX NUMBER: +27123825003

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Contents

Table of Figures

1.

ABSTRACT

The importance of Active Magnetic Bearings (AMB) is becoming more significant these days in many industrial applications. The AMB system achieves levitation (free suspension of a moving part in air without any physical contact), and therefore eliminates any friction and need for lubrication of the machine. The structure consists of a ferromagnetic rotor maintained in free space by controlled electromagnetic forces. By doing so, rotation speeds are much higher; losses and maintenance cost in the system are significantly reduced. Although Passive Magnetic Bearings (PMB) is simpler than the AMB in terms of components (no controller), two main drawbacks are noticed on that type of Bearing:

Firstly, it is impossible to achieve a six degree of freedom support due to the restriction of the Earnshaws theorem.

Secondly, the characteristics of the PMB, compared to the AMB, cannot be changed easily during the operation. Reason why this project will be entirely focused on the AMB design and control.

To achieve this purpose, the Active Magnetic Bearings (AMB) consists of an electromagnet assembly, a set of power amplifiers which supply current to the electromagnets, a controller, and gap(position) sensors which provide the feedback required to control the position of the rotor within the gap. When the process starts, the power amplifier supplies equal bias current to two pairs of electromagnets on opposite sides of a rotor. The currents supplied enable the electromagnets to exhibit their magnetic forces. As the rotor deviates from its centre position; the controller will offset the bias currents in order to balance the perturbations caused by the deviation.
FIGURE : GENERAL DESCRIPTION OF AN ACTIVE MAGNETIC BEARING SYSTEM

2.

BACKGROUND ON THE PROJECT

Nowadays, the use of energy in industrial systems is taken with much care. The modern trend is to reduce the loss as much as possible in order to optimize the utilization [2], to reduce the cost and therefore increase the performance of the systems. Traditional rotary systems were proved to be very lossy due to the friction[1] caused by the mechanical contact between the rotor(moving part ) and the electromagnets(stationary part).With the use of an AMB, frictionless structures are built, allowing most of the energy delivered to be used efficiently. A magnetic rotor is suspended by an electromagnet. In order to get an active control of the rotor, its position is measured by a position sensor. The position signal is then treated by a controller, which gives a current set point. This signal is then amplified by the power amplifier, in order to get the necessary actuator current. The actuator current is the output from a power amplifier, a Pulse Width Modulated (PWM) signal to be distributed to the actuating electromagnets for a rectifying force on the position of the levitated ferromagnetic object in free space.The concept of AMB brings a revolution in aerospace industry (turbo machinery [7], vacuum technology, machining, and airplane transportation [2]). Advantages [9]

Increased energy production As there is no friction, the operation of classical rotor bearings is maximized.

Reduced losses experienced when transferring energy from one system to another one. High energy and fuel consumption Saving of fuel resources No pollution and Fire Risk due to lubrication High circumferential speeds easily adjustable bearing characteristics low maintenance cost Enhanced ability to work at very high temperatures active vibration control and passing of critical speeds balancing and unbalance compensation

3.

PROBLEM STATEMENT

The magnetic bearings are restricted by the Earnshaws theorem which clearly states that a collection of point charges cannot be maintained in a stable stationary equilibrium configuration solely by the electrostatic interaction of the charges. Instabilities and non linearities are present because the force exhibited is a function changing with current and varying air gap as the rotor moves. Therefore, a controller needs to be designed. For contactless levitation, the AMB rotor requires position control in 3 independent directions(X, Y, Z).However, this control is complicated by the mutual coupling of the 3 displacements [1], which implies design of MIMO controller. MIMO controller implementation is very complex, and results to a more expensive system. Instead, a decoupled control using the SISO approach is much simpler to be improved and modified. The latter approach is only applicable where the rotor has small deviations from its nominal position.

Prerequisite: Modelling Since the Magnetic Bearing is a multivariable and non linear system, we need to linearize it and adapt it as a SISO system for easy control. Objective

As per request of the supervisor, the project aim is to build a digital hardware platform able to control and stabilize ferromagnetic object in free space, using two approaches:

The classical method and model free control Model free control of affine chaotic systems

Sub problem 1
Design of the AMB controller using the classical method and model free control.

Sub problem 2
Design of the same controller using the model free control of affine chaotic systems.

Sub problem 3
Simulation using MATLAB. Data acquisition and instrument control using LABVIEW
4.

PRELIMINARY LITERATURE SURVEY

Magnetic Bearings are used in various industrial applications such as electrical power generation, petroleum refinement, machine tool operation and natural gas handling, compressors, turbines, pumps. Magnetic bearings are used in watt-hour meters for home power consumption. Other applications include flywheel energy storage, artificial hearts. Two magnetic Bearing technologies are actually used, namely:

4.1 Permanent Magnetic Bearing

This method makes use of a permanent magnet to achieve the levitation of the rotor .No control is needed and therefore use of sensors and control circuit is eliminated. The system is simple, but the greatest limitation is the Earnshaws theory [3] which clearly states that group of point charges cannot be maintained in a stable stationary equilibrium configuration solely by the electrostatic interaction of the charges. This means that a rotor frequently charged will be very difficult to be stabilized in free space. The success of this approach is restricted to applications where we have a small load[4] to handle. Many researches undertaken around the world have stated that the Permanent Magnetic bearing is physically unstable as they are passive, and therefore a controlled active system would be more adapted to provide better response in terms of stiffness and damping [4]. One successful experiment of this type of bearing was achieved by the NASA Laboratory [4] for spacecraft applications in January 2008.

4.2 Active Magnetic Bearings

While the previous approach is based on a permanent magnet, the active magnetic bearing consists of electromagnets of which the magnetic force is varied by the current drawn to it. Sensors, Control circuitry and power amplifier are added to provide the necessary adjustment in case of a deviation of the rotor from its equilibrium position. A PID controller will be used for this project. The controller will calculate the error value as the difference between measured variable and the desired specification point to minimize that error by adjusting the control inputs. Based on its three terms, the PID controller can be evaluated in terms of time:(Proportional) is implemented for the present error, I(Integral)for all past errors up to present and D(Derivative) for predicting future errors on the systems. A digitally controlled system makes the process much easier, especially when it comes to modify the functionality. Analogue control systems were restricted in that sense that any change in the system requires a hardware change, while a digital one is software wise. A digital platform is very flexible to adapt various types of controllers by simply changing the software. Unfortunately, magnetic force(between the electromagnet and the rotor) is a function changing with current and varying air gap as the rotor moves ,which causes non linearities[5]. Non linearities are also due to the flattening of the magnetization curve due to saturation of the core material[6], the hysteresis of the core material depending on frequency and amplitude and the limitations of the current and slope due to power amplifiers[6,8]. As the Active Magnetic bearings have high nonlinearity and instability, design of the controller is of a great concern. Many approaches have been introduced to control magnetic bearing system and therefore to compensate for magnetic nonlinearities and maximize the performance of magnetic bearing control system.
4.2.1Mathematical and Mechanical Approaches

The big challenge in that matter is to find the right force to be exerted on the rotor .We need to estimate a simplified formula for the energy stored in the air gap between the ferromagnetic rotor and the electromagnet core. From there, we can derive a formula for the magnetic force. Energy Stored in the gap
Number of turns

Core

Air

Gap Volume

Rotor

FIGURE : ENERGY STORED IN GAP VOLUME BETWEEN THE ROTOR AND THE CORE

From electrical basics, we know that the power is determined as:

Where W is the work accomplished during a certain amount of time t. The power where V is the voltage and I the current .In case of an inductor, the voltage across an inductor is

L is the inductance, so its a constant. Since and we have two pole faces present then [1]

is the permeability of air is the spacing gap A is the sectional area of the gap N is the number of turns

Partial differentiation of work over length Keeping the current flow constant from the above formula, we can derive the force to be exerted by electromagnets. As the force is the derivative of the work over displacement, the magnitude of the force will be:

The change in the force can be calculated as:

Lets take then we have

Where and ratios.

are respectively the force/current and the force/displacement

4.2.2 Procedures to be followed in achieving the project

Its not enough to derive a formula for the force that needs to be exerted by the magnets in order to achieve the levitation. Many considerations are to be taken with care, such as:
Transfer functions designs After having the formulas for the force, the next step is to split the system in terms of block diagrams, representing each one a specific task in the whole process. The transfer functions to be designed are: a. Current and gap Control loops Because a constant control is to be done based on the gap and the current measurements, feedback loops are required. One feedback loop will be responsible for the air gap distance measurement and the other one consists of providing the input to the power amplifier to produce the necessary current for the adjustment. The air gap feedback loop will be fed to the current feedback loop.

idesired Set gap Desiredl

ADC Controller 1 ADC imeasure d Controller 2
Bias current

measured Gap Sensor

Driving Driving Circuit c

Kl

Ki

Dynamics system response

Force to be applied

FIGURE : GAP AND CURRENT FEEDBACK LOOPS

[1, 10]
The force to be applied follows the rules of a simple harmonic motion (SHM) and Newtons second law. b. Axial Coil transfer function This is to find the transfer function between the current to be measured and the
FIGURE : ELECTROMAGNET REPRESENTED AS A RL CIRCUIT

Voltage across the electromagnet coil, based on the Kirchhoffs voltage law, assuming a resistor in series with an inductor. [1] b. Controller design The controller design is of a great importance in order to meet the specification of the transient response, particularly in terms of settling time. For this project, we will decide whether a PID or a PD controller will be used. Because the system is limited to operate at certain frequencies, there is an operating range. A controller will also be used to attenuate frequencies beyond the stable range. d. Sensors transfer function Transfer function is required to scale the sensor outputs to the exact value they represent in real life. Simulation of the entire program After having all the transfer functions in place, the simulation will be follow to check whether the combined system (all the transfer functions together) responds as expected. From this point, if the performance is after review, the simulated system will then be implemented. 5.

PROJECT SCOPE , PLANNING & COST

5.1 Project Scope

TASKS Model & transfer functions design Controller(compensator) design

START

Duration(da ys) 1/8/2013 14 15/08/201 14

3

Stability Analysis(Root locus, frequency Response) Simulation Prototype Implementation Review Final Report Compilation review and completion of the whole project

29/08/201 3 09/09/201 3 1/10/2013 15/10/201 3 9/11/2013 16/11/201 3

10 22 14 25 7 10

5.2 Gantt Chart 5.3 Project Cost

Axial Position Sensor Type: SKF CMSS665 eddy current position sensor Number of sensors: 5 Unit price: 3700 Cost: 18500

Power Amplifiers PCI Card Type: NI PCI-6013, Low cost 200 kS/s, 16-Bit, 16-Analog Input Multifunction DAQ Unit price: 5910 Number: 1 Cost: 5910 Number of channels: 10 Unit Price: 4000 Number: 1 Cost: 4000

6.

REFERENCES

[1]Steyn N. 2006. Digital Control System for Active Magnetic Bearings.Tshwane University of Technology, South Africa, August 2006, page 15 [2] L. Burdet2006. Active Magnetic Bearing Design and Characterization for High Temperature Applications .Ecole Polytechnique Federale de la Lausanne.Switzerland,September 2006,page 7 [3] A.K. PilatActive Magnetic Suspension and Bearing.AGH University of Science and Technology ,Poland, page 2 [4] W.Morales and R. Fusaro, A. kasak. Permanent Magnetic Bearing for Spacecraft Applications.NASA Glenn research Center ,Cleveland,Ohio pages 5-18 [5]Jawaid I. Inayat-Hussain.Nonlinear Dynamics of aFlexible Rotor in Active Magnetic Bearings ,2007 international Symposium on Nonlinear Theory and its Applications,Monash University,Malaysia,pages 1-2 [6] L.Pust and O.Szollos, Interaction of two strong nonlinearities. [7]Jianhui Zhao,Mary E.F. Kasarda,Dewey Spangler,Robert Prins,Daniel J.Inman.Active Magnetic Bearing System Identification using current-position perturbation [8] L.Pust.Weak And Strong Nonlinearities In Magnetic Bearings,Insitute of Thermomechanics ASCRDolejskova 5 18200 Prague 8,Czech Republic,February 2004 [9]Rene Larsonneur.Design and Control of Active Magnetic Bearing Systems for High Speed Rotation.Swiss federal Institute of Technology,Zurich,Switzerland [10] Chip Rinaldi Sabirin, Andreas Binder, Dumitru Daniel Popa, Aurelian Crciunescu. Modeling and Digital Control of an Active Magnetic Bearing System