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Three areas related to the actively controlled radial magnetic bearing concepts are discussed. These areas are: (1) modification to the ac loss calculations of the 1990 report; (2) a continuous changing mechanism to compensate rotor current drop due to ac losses; and (3) design of a proof of principle experiment simulating the proposed bearing concept.
Using measured values of two-dimensional forces in a magnetic actuator, equations of motion for an active magnetic bearing are presented. The presence of geometric coupling between coordinate directions causes the equations of motion to be nonlinear. Two methods are used to examine the unbalance response of the system: simulation by direct integration in time; and determination of approximate steady state solutions by harmonic balance. For relatively large values of the derivative control coefficient, the system behaves in an essentially linear manner, but for lower values of this parameter, or for higher values of the coupling coefficient, the response shows a split of amplitudes in the two principal directions. This bifurcation is sensitive to initial conditions. The harmonic balance solution shows that the separation of amplitudes actually corresponds to a change in stability of multiple coexisting solutions.
Various disturbances that are synchronous with the shaft speed can complicate radial magnetic bearing control. These include position sensor target irregularities (runout) and shaft imbalance. The method presented here allows the controller to ignore all synchronous harmonics of the shaft position input (within the closed-loop bandwidth) and to respond only to asynchronous motions. The result is reduced control effort.
The purpose of a magnetically suspended flywheel energy storage system for electric utility load leveling is to provide a means to store energy during times when energy is inexpensive to produce and then return it to the customer during times of peak power demand when generated energy is most expensive. The design of a 20 kWh flywheel energy storage system for electric utility load leveling applications involves the successful integration of a number of advanced technologies so as to minimize the size and cost of the system without affecting its efficiency and reliability. The flywheel energy storage system uses a carbon epoxy flywheel, two specially designed low loss magnetic bearings, a high efficiency motor generator, and a 60 cycle AC power converter all integrated through a microprocessor controller. The basic design is discussed of each of the components that is used in the energy storage design.
The operating instructions for the magnetic bearings of a high-performance optical disk buffer are provided. Among the topics that are discussed are the following: front panel layout, turn-on procedure, shut-down procedure, and latch-up protection. Additionally, comprehensive engineering drawings are presented for the design.
A linear-quadratic-gaussian (LQG) regulator controller design for an acceleration-augmented active magnetic bearing (AMB) is outlined. Acceleration augmentation is a key feature in providing improved dynamic performance of the controller. The optimal control formulation provides a convenient method of trading-off fast transient response and force attenuation as control objectives.
The paper considers the development of a 500-Watt-hour magnetically suspended flywheel stack energy storage system. The work includes hardware testing results from a stack flywheel energy storage system, improvements in the area of noncontacting displacement transducers, and performance enhancements of magnetic bearings. Experimental results show that a stack flywheel energy storage system is feasible technology.
The goal of this project is to design and construct of a prototype of ultra-high temperature permanent magnet (UHT–PM), which provides the force to pull the spinning shaft towards the target position in the magnetic bearing (MB) clearance circle. This project will develop a PM biased MB system, that is actively cooled to the 550°C maximum operating temperature limit of PMs. The MB test environment will include 700°C, 40krpm and 4,000 psi requirements to advance the supercritical carbon dioxide (sCO 2 ) and other types of Brayton power cycle systems. The proposed novel MBs combine PMs for supplying the bias field and electromagnets for supplying the control field, both in UHT conditions. The choice of material is the UHT Sm-Co PMs (US patent 6,451,132) due to their significantly better thermal stability. The 6-pole homopolar design permits uninterrupted force delivery via a redundant control capability (US patent 7,429,811) even if 3 poles were to fail. The Phase I efforts was to focus on development and demonstration of component technologies and detailed design of full scale components and a demonstrator test rig for use in Phase II. UHT–PMs were produced and used in the MB actuator. The operating environment of the EEC-T550 Sm-Co magnet material could be extended by implementing active cooling. Electromagnetic coils imbedded in the MB provide forces to stabilize the shaft position at the target via sensing and control stages. Shaft position sensors enable to identify the present position of the spinning shaft relative to its desired target position in the MB clearance circle (air gap). Auxiliary bearings will be installed to provide a backup support system in the event that power to the MB fails or there is a fault in a device providing current to the MB coils. For control, reliability and safety reasons the sensors and auxiliary bearings are typically located as close as possible to the MBs, which exposes them to the same environmental conditions. Development of only the actuator for the UHT environment is an inadequate approach to complete integration of the MB system in the turbine/expander. Therefore the UHT sensor and auxiliary bearing were designed and developed along with the actively cooled, UHT-PM actuator development. Although shaft position sensors are commercially available (Kaman) they may cost up to $10k per channel, and a full 5 axis magnetic suspension is best implemented with up to 20 sensors. Once successfully completed, this project will significantly extend the operating environment capability for turbomachinery applications such as nuclear power, concentrated solar thermal, fossil fuel, geothermal, and shipboard propulsion. The further advancement of UHT-PM-MB will also strengthen the US position in PM technology, which is presently heavily dominated by China. The UHT Sm-Co magnet material that will be utilized in the proposed work has been developed exclusively by the project proposer. Many actuators, motors, generators and other MB applications will greatly benefit from the proposed work.
Lifting capacities greater than 41 N/cm(exp 2) (60 psi) at 77 K have been achieved with a new type of levitation (hybrid) using a combination of permanent magnets and high quality melt-mixtured YBa2Cu3O(7-delta) (YBCO). The key concept of the hybrid superconducting magnetic bearing (HSMB) is the use of strong magnetic repulsion and attraction from permanent magnets for high levitation or suspension forces in conjunction with a superconductor's flux pinning characteristics to counteract the inherent instabilities in a system consisting of magnets only. To illustrate this concept, radial and axial forces between magnet/superconductor, magnet/magnet, and magnet/superconductor/magnet, were measured and compared for the thrust bearing configuration
Calculations of the forces exerted on a journal by a magnetic bearing actuator are presented, along with comparisons to experimentally measured forces. The calculations are based on two-dimensional solutions for the flux distribution in the metal parts and free space, using finite but constant permeability in the metals. Above a relative permeability of 10,000 the effects of changes in permeability are negligible, but below 10,000 decreases in permeability cause significant decreases in the force. The calculated forces are shown to depend on the metal permeability more strongly when the journal is displaced from its centered position. The predicted forces in the principal attractive direction are in good agreement with experiment when a relatively low value of permeability is chosen. The forces measured normal to the axis of symmetry when the journal is displaced from that axis, however, are significantly higher than predicted by theory, even with a value of relative permeability larger than 5000. These results indicate a need for further work including nonlinear permeability distributions.
The use of an adaptive fuzzy control algorithm implemented on a VLSI chip for the control of a magnetic bearing was considered. The architecture of the adaptive fuzzy controller is similar to that of a neural network. The performance of the fuzzy controller is compared to that of a conventional controller by computer simulation.
A digital local linearization technique was used to solve a system of stiff differential equations which simulate a magnetic bearing assembly. The results prove the technique to be accurate, stable, and efficient when compared to a general purpose variable order Adams method with a stiff option.
This paper describes a modeling effort used to develop an improved type of magnetic bearing controller, called a modal controller, for use on high speed flywheel systems. The controller design is based on models of the flywheel system, is designed to directly control the natural dynamics of the spinning rotor, and is generic enough to be readily adapted to future flywheel systems. Modeling and development are described for two key controller subsystems: the modal controller subsystem, which allows direct control over the rotor rigid body modes, and the bending mode compensation subsystem, which tracks, and prevents interference from, the rotor bending modes during flywheel operation. Integration of modeling results into the final controller is described and data taken on the NASA Glenn D1 flywheel module during high speed operation are presented and discussed. The improved modal controller described in this paper has been successfully developed and implemented and has been used for regular hands-free operation of the D1 flywheel module up to its maximum operating speed of 60,000 RPM.
Five power filters and two types of power amplifiers were tested for use with active magnetic bearings for flywheel applications. Filter topologies included low pass filters and low pass filters combined with trap filters at the PWM switching frequency. Two state and three state PWM amplifiers were compared. Each system was evaluated based on current magnitude at the switching frequency, voltage magnitude at 500 kHz, and power consumption. The base line system was a two state amplifier without a power filter. The recommended system is a three state power amplifier with a 50 kHz low pass filter and a 27 kHz trap filter. This system uses 5.57 W. It reduces the switching current by an order of magnitude and the 500 kHz voltage by two orders of magnitude. The relative power consumption varied depending on the test condition between 60 to 130 percent of the baseline.
The Structural Mechanics and Dynamics Branch has successfully demonstrated a fail-safe controller for the Fault-Tolerant Magnetic Bearing rig at the NASA Glenn Research Center. The rotor is supported by two 8-pole redundant radial bearings, and coil failing situations are simulated by manually shutting down their control current commands from the controller cockpit. The effectiveness of the controller was demonstrated when only two active coils from each radial bearing could be used (that is, 14 coils failed). These remaining two coils still levitated the rotor and spun it without losing stability or desired position up to the maximum allowable speed of 20,000 rpm.
A survey is presented on the research of the Institute of Mechanics of the ETH in the field of vibration control with magnetic bearings. It shows a method for modelling an elastic rotor so that it can be represented by a low order model amenable to control techniques. It deals with the control law and spill-over effects, and it also discusses experimental results for an active resonance damper.
Finite element analysis was used to study the bandwidth of alloy hyperco50a and silicon iron laminated rotors and stators in magnetic bearings. A three dimensional model was made of a heteropolar bearing in which all the flux circulated in the plane of the rotor and stator laminate. A three dimensional model of a plate similar to the region of a pole near the gap was also studied with a very fine mesh. Nonlinear time transient solutions for the net flux carried by the plate were compared to steady state time harmonic solutions. Both linear and quasi-nonlinear steady state time harmonic solutions were calculated and compared. The finite element solutions for power loss and flux bandwidth were compared to those determined from classical analytical solutions to Maxwell's equations.
Experimental results have recently demonstrated that an adaptive open loop control strategy can be highly effective in the suppression of unbalance induced vibration on rotors supported in active magnetic bearings. This algorithm, however, relies upon a predetermined gain matrix. Typically, this matrix is determined by an optimal control formulation resulting in the choice of the pseudo-inverse of the nominal influence coefficient matrix as the gain matrix. This solution may result in problems with stability and performance robustness since the estimated influence coefficient matrix is not equal to the actual influence coefficient matrix. Recently, analysis tools have been developed to examine the robustness of this control algorithm with respect to structured uncertainty. Herein, these tools are extended to produce a design procedure for determining the adaptive law's gain matrix. The resulting control algorithm has a guaranteed convergence rate and steady state performance in spite of the uncertainty in the rotor system. Several examples are presented which demonstrate the effectiveness of this approach and its advantages over the standard optimal control formulation.