Regulation of spindle position by magnetic actuator array

A novel embedded cylindrical-array magnetic actuator (ECAMA) is proposed and verified by experiments to provide sufficient magnetic force for spindle deviation regulation of high-speed milling process. Four I-shape silicon steel columns enclosing the spindle constitute the backbone of the ECAMA. The shape of modified concave-type yokes is designed to reduce the average air gap between magnetic poles and the spindle. In contrast to the conventional AMB (active magnetic bearing) design for which coils are usually wound on the yokes, the copper wire is wound on the I-shape silicon steel columns. As a result, the overall wound coil turns can be much increased. In other words, stronger magnetic force can be induced by ECAMA. On the other hand, to reduce the cost of ECAMA, two pairs of self-sensing modules are employed to replace the gap sensors for measurement of spindle position deviation. In order to verify the efficacy of the proposed ECAMA and the self-sensing module, high-speed milling tests are undertaken. By inspection on the precision and quality of the finish surface of workpiece, the superiority of ECAMA and the self-sensing module are assured.     

Spindle vibration suppression for advanced milling process by using self-tuning feedback control

The goal of this work is to concurrently counterbalance the dynamic cutting force and regulate the spindle position deviation under various milling conditions by integrating active magnetic bearing (AMB) technique, fuzzy logic algorithm, and an adaptive self-tuning feedback loop. The experimental data, either for idle or cutting, are utilized to establish the database of milling dynamics so that the system parameters can be on-line estimated by employing the proposed fuzzy logic algorithm as the cutting mission is engaged. Based on the estimated milling system model and preset operation conditions, i.e., spindle speed, cut depth, and feed rate, the current cutting force can be numerically estimated. Once the current cutting force can be real time estimated, the corresponding compensation force can be exerted by the equipped AMB to counterbalance the cutting force, in addition to the spindle position regulation by feedback of spindle position. At the end, the experimental simulations on realistic milling are presented to verify the efficacy of the fuzzy controller for spindle position regulation and the capability of the dynamic cutting force counterbalance.     

Counterbalance of cutting force for advanced milling operations

The goal of this work is to concurrently counterbalance the dynamic cutting force and regulate the spindle position deviation under various milling conditions by integrating active magnetic bearing (AMB) technique, fuzzy logic algorithm and an adaptive self-tuning feedback loop. Since the dynamics of milling system is highly determined by a few operation conditions, such as speed of spindle, cut depth and feedrate, therefore the dynamic model for cutting process is more appropriate to be constructed by experiments, instead of using theoretical approach. The experimental data, either for idle or cutting, are utilized to establish the database of milling dynamics so that the system parameters can be on-line estimated by employing the proposed fuzzy logic algorithm as the cutting mission is engaged. Based on the estimated milling system model and preset operation conditions, i.e., spindle speed, cut depth and feedrate, the current cutting force can be numerically estimated. Once the current cutting force can be real-time estimated, the corresponding compensation force can be exerted by the equipped AMB to counterbalance the cutting force, in addition to the spindle position regulation by feedback of spindle position. On the other hand, for the magnetic force is nonlinear with respect to the applied electric current and air gap, the characteristics of the employed AMB is investigated also by experiments and a nonlinear mathematic model, in terms of air gap between spindle and electromagnetic pole and coil current, is developed. At the end, the experimental simulations on realistic milling are presented to verify the efficacy of the fuzzy controller for spindle position regulation and the capability of the dynamic cutting force counterbalance.     

A combined repetitive control for precision rotation of magnetic bearing

In this paper, we focus on improving the rotational accuracy of the magnetic bearing under the consideration of the unbalance force of the spindle and the unbalanced magnetic pull of the motor. First, the vibrations of the spindle are analyzed. Next, in order to suppress the vibrations of the spindle, a combined repetitive control method is proposed, which includes a space domain repetitive compensator and a time domain repetitive compensator. Furthermore, the experimental results show that the proposed method is effective for suppressing the vibrations of the spindle and the rotational accuracy is improved from 301.2 to 21.9 nm at 2880 min⁻¹.     

Sliding mode control with fuzzy adaptive perturbation compensator for 6-DOF parallel manipulator

This paper proposes a sliding mode controller with fuzzy adaptive perturbation compensator (FAPC) to get a good control performance and reduce the chatter. The proposed algorithm can reduce the chattering because the proposed fuzzy adaptive perturbation compensator compensates the perturbation terms. The compensator computes the control input for compensating unmodeled dynamic terms and disturbance by using the observer-based fuzzy adaptive network (FAN). The weighting parameters of the compensator are updated by on-line adaptive scheme in order to minimize the estimation error and the estimation velocity error of each actuator. Therefore, the combination of sliding mode control and fuzzy adaptive network gives the robust and intelligent routine to get a good control performance. To evaluate the control performance of the proposed approach, tracking control is experimentally carried out for the hydraulic motion platform which consists of a 6-DOF parallel manipulator.     

System modeling and robust control of an AMB spindle : part II a robust controller design and its implementation

This paper discusses an entire procedure for a robust controller design and its implementation of an AMB (active magnetic bearing) spindle, which is part II of the papers presenting details of system modeling and robust control of an AMB spindle. Since there are various uncertainties in an AMB system and reliability is the most important factor for applications, robust control naturally gains attentions in this field. However, tight evaluations of various uncertainties based on experimental data and appropriate performance weightings for an AMB spindle are still ongoing research topics. In addition, there are few publications on experimental justification of a designed robust controller. In this paper, uncertainties for the AMB spindle are classified and described based on the measurement and identification results of part I, and an appropriate performance weighting scheme for the AMB spindle is developed. Then, a robust control is designed through the mixedμ synthesis based on the validated accurate nominal model of part I, and the robust controller is reduced considering its closed loop performance. The reduced robust controller is implemented and confirmed with measurements of closed-loop responses. The AMB spindle is operated up to 57,600 rpm and performance of the designed controller is compared with a benchmark PID controller through experiments. Experiments show that the robust controller offers higher stiffness and more efficient control of rigid modes than the benchmark PID controller.     

System modeling and robust control of an AMB spindle: part I modeling and validation for robust control

This paper discusses details of modeling and robust control of an AMB (active magnetic bearing) spindle, and part I presents a modeling and validation process of the AMB spindle. There are many components in AMB spindle : electromagnetic actuator, sensor, rotor, power amplifier and digital controller. If each component is carefully modeled and evaluated, the components have tight structured uncertainty bounds and achievable performance of the system increases. However, since some unknown dynamics may exist and the augmented plant could show some discrepancy with the real plant, the validation of the augmented plant is needed through measuring overall frequency responses of the actual plant. In addition, it is necessary to combine several components and identify them with a reduced order model. First, all components of the AMB spindle are carefully modeled and identified based on experimental data, which also render valuable information in quantifying structured uncertainties. Since sensors, power amplifiers and discretization dynamics can be considered as time delay components, such dynamics are combined and identified with a reduced order. Then, frequency responses of the open-loop plant are measured through closed-loop experiments to validate the augmented plant. The whole modeling process gives an accurate nominal model of a low order for the robust control design.     

Heading tracking control with an adaptive hybrid control for under actuated underwater glider

The underwater glider changes its direction to follow the preset path in the horizontal plane only by flapping its vertical rudder. Heading tracking control plays the core role in the navigation process. To deal with non-linear flow disturbance and saturation in actuator, a new hybrid heading tracking control algorithm was presented, which integrated an adaptive fuzzy incremental PID (AFIPID) and an anti-windup (AW) compensator to improve the adaptability and robustness of underwater glider's heading control. The dynamic model of an underwater glider named as Petrel-II 200 was modeled to serve as a controlled plant. The proposed heading tracking control algorithm was described in detail, where the rudder angle, a control quantum to the controlled plant were calculated to get forces and moments required for the desired glider heading. A closed loop motion control system with desired heading angle as input and actual heading angle output was put forward, which included the dynamic model of the Petrel-II 200 and the given heading tracking control algorithm. The simulations followed three typical mathematical signals and the experimental tests were carried out by taking in the dynamic parameters of the controlled plant. And the effectiveness of the proposed control algorithm was assessed and verified.     

轴向主动磁轴承的模糊自抗扰控制

为了实现轴向主动磁轴承的准确和稳定控制,根据模糊控制理论和自抗扰控制(ADRC)理论,设计了轴向主动磁轴承模糊自抗扰控制系统,采用模糊控制器整定ADRC中非线性控制参数,并且给出了其控制算法和控制系统的结构.利用软件Matlab/Simulink对所设计的控制系统进行了仿真研究,仿真结果表明:所设计的轴向主动磁轴承模糊自抗扰控制系统具有响应速度快、超调量小、抗干扰能力强和鲁棒性好等特点.     

Non-linear compensation and displacement control of the bias-rate-dependent hysteresis of a magnetostrictive actuator

Magnetostrictive actuators invariably exhibit bias-rate-dependent hysteresis, which could cause vibration and error in the micro-positioning control. We present a methodology for linearization control for the hysteresis of a magnetostrictive actuator with a wide range of input rates and biases. The hysteresis compensation is attained through application of a dynamic Bouc-Wen model and experimental measured hysteresis properties of the magnetostrictive actuator under inputs with different frequencies and biases. The effectiveness of the compensator for hysteresis is demonstrated through experimental results of the magnetostrictive actuator under inputs at different frequencies and bias levels. Based on the proposed compensator, a displacement PID controller is applied to force the output displacement of the magnetostrictive actuator to track the desired displacement accurately thereafter. The maximum absolute tracking errors is 0.052 μm. Compared to the control results without the compensator, the compensator can reduce the control error by about 85%. The results indicate that this study provides an effective method which can compensate the hysteresis of the magnetostrictive actuator under different frequencies and biases of inputs.     

Adaptive control of an active magnetic bearing with external disturbance

Adaptive back stepping control (ABC) is originally applied to a linearized model of an active magnetic bearing (AMB) system. Our control goal is to regulate the deviation of the magnetic bearing from its equilibrium position in the presence of an external disturbance and system uncertainties. Two types of ABC methods are developed on the AMB system. One is based on full state feedback, for which displacement, velocity, and current states are assumed available. The other one is adaptive observer based back stepping controller (AOBC) where only displacement output is measurable. An observer is designed for AOBC to estimate velocity and current states of AMB. Lyapunov approach proves the stabilities of both regular ABC and AOBC. Simulation results demonstrate the effectiveness and robustness of two controllers.     

基于FPGA的磁悬浮飞轮用自修复磁轴承控制器的设计

磁悬浮飞轮是卫星等航天器高精度姿态控制的执行机构,磁悬浮飞轮的空间应用需要可靠性高、适应性好的实时控制器。FPGA可靠性高、接口灵活,非常适合空间系统的开发应用。本文利用片上软硬件系统设计的思想,提出了一种基于FPGA和LEON软处理器的磁轴承数字控制器,并搭建了实验平台验证了系统实际性能。然后,又提出了一种基于PFGA的自修复磁轴承控制器,这种控制器可以理论上可以大大提高系统的可靠性。     

Spindle position regulation for wind power generators

The three-time-scale plant model of a wind power generator, including a wind turbine, a flexible vertical shaft, a variable inertia flywheel (VIF) module, an active magnetic bearing (AMB) unit and the applied wind sequence, is constructed. In order to make the wind power generator be still able to operate as the spindle speed exceeds its rated speed, the VIF is equipped so that the spindle speed can be appropriately slowed down once any stronger wind field is exerted. Currently, most of wind energy input is, as a matter of fact, a waste since the commercially available wind power generators only operate for fairly mild or low-speed wind field. To prevent any potential damage due to collision by shaft against conventional bearings, the AMB unit is proposed to replace the traditional bearings and regulate the shaft position deviation. By singular perturbation order-reduction technique, a lower-order plant model can be established for the synthesis of feedback controller. It is found that two major system parameter uncertainties, an additive uncertainty and a multiplicative uncertainty, are constituted by the wind turbine and the VIF, respectively. The upper bounds of system parameters variation can be therefore estimated and the frequency shaping sliding mode control (FSSMC) loop is proposed to account for these uncertainties and suppress the unmodeled higher-order plant dynamics. At last, the efficacy of the FSSMC is verified by intensive computer and experimental simulations for regulation on position deviation of the shaft and counter-balance of unpredictable wind disturbance.     

A self-sensing technology of active magnetic bearings using a phase modulation algorithm based on a high frequency voltage injection method

Conventional AMB(active magnetic bearings) systems consist of electromagnetic coils, position sensors, power amplifiers and a feedback controller. This hardware configuration can lead to a structural complexity, problems of space limitations for the installation, and position control difficulties due to the non-collocation of actuators and sensors. In this paper, a self-sensing mechanism is proposed to resolve such limitations of the general AMB system. The proposed self-sensing scheme uses a phase difference of the injected current of two opposite electromagnetic actuators while an object is levitating between the actuators. The relationship between the phase difference of injected currents and the position of a levitated object was theoretically derived and linearized. In order to realize the proposed self-sensing scheme, a signal processing algorithm was developed. The frequency response of the estimator was measured to verify the performance of the proposed self-sensing scheme. In addition, a magnetic levitation and a disturbance rejection response were experimentally obtained to verify the feasibility of the proposed self-sensing mechanism. Experimental results showed that the developed self-sensing technique has similar performance as a practical gap sensor.     

磁轴承磨床电主轴全局线性化研究

由于电磁力与电流和位移关系的非线性,当主轴工作点改变时,建立在局部线性化基础之上的主动磁轴承(AMB)系统的性能会产生很大的变化。AMB用于磨削主轴,特别是用于非圆工件的磨削加工,要求具有不随工作点改变的刚度性能和位移跟踪性能。在理论上给出了AMB系统工作点改变对系统性能的影响,并通过试验得到了验证。考虑到线性补偿方法的简单性,采用了线性补偿方法进行AMB系统的全局线性化。针对功率损耗和动态性能,比较了3种线性补偿方法：最小磁通(MIF)、磁通和不变(CFS)及磁通积不变(CFP),结果表明,MIF具有最小的功率损耗,而CFS具有最好的动态性能。测量了建立在全局线性化基础上的AMB系统的性能,结果表明,工作点改变时,AMB系统的性能几乎不随之而改变。     

电磁轴承功率放大器参数设计

由于功率放大器处于电磁轴承系统的执行环节,其动态性能将直接影响系统的性能。为了提高电磁轴承系统的性能,针对电流响应速度、力的响应速度、同频允许的最大振幅和不平衡量控制等指标,以采用最小脉宽开关功率放大器的电磁轴承系统为例,从系统的频响角度出发,分析了满足实际工况下功率放大器参数设计要求。从而在保证系统运行性的同时,通过合理设计功率放大器的主要个数,节省设备制造成本。在经过理论分析和仿真试验之后,给出一些设计的实例,从而对实际电磁轴承功率放大器的设计提供了指导依据。     

Design and control of a new linear magnetic actuator for squeeze film damper

A new model of a linear magnetic actuator (LMA) that can be applied to the controllable squeeze film damper (CSFD) was proposed, designed, and fabricated. To validate the operation of the proposed actuator, a mathematical model of the proposed LMA was derived through experiments. From the experimental results it was verified that the electromagnetic force depends upon the position of the mover (the outer damper ring of the CSFD) and the applied current. Also, the electromagnetic force varies symmetrically with the position of the mover within the working region. A self-tuning fuzzy PID controller was applied to control the position of the novel LMA. Further, the proposed LMA was assembled in the squeeze film damper (SFD), where the clearance can be controlled by LMA. To investigate the damping effect of the damper under various clearances by controlling the LMA, experiments on the rotor test-rig were conducted. From the experimental results, the proposed device, which is composed of SFD and LMA, was verified to be very effective for attenuation of the vibration of the rotor system. This paper was recommended for publication in revised form by Associate Editor Dong Hwan Kim Kyoung Kwan Ahn received the B.S. degree in the department of Mechanical Engineering from Seoul National University in 1990, the M. Sc. degree in Mechanical Engineering from Korea Advanced Institute of Science and Technology (KAIST) in 1992 and the Ph.D. degree with the title “A study on the automation of out-door tasks using 2 link electro-hydraulic manipulator” from Tokyo Institute of Technology in 1999. He is currently a Professor in the School of Mechanical and Automotive Engineering, University of Ulsan, Ulsan, Korea. His research interests are design and control of smart actuator using smart material, fluid power control and active damping control. He is a Member of IEEE, ASME, SICE, RSJ, JSME, KSME, KSPE, KSAE, KFPS, and JFPS. Truong Quoc Thanh received the B.S degree in the department of Mechanical Engineering from Hochiminh City University of Technology in 1998, and the M.Sc. degree with title “Dynamic stiffness method in calculation vibration of structure” from the master program of mechanics under Inter-University Cooperation Program between Liege University (Belgium) and HCMUT (Vietnam) in 2000. From 2000 to 2004, he worked as a lecturer in the mechanical department of Hochiminh City University of Technology. His teaching subjects are relevant in Advanced Manufacturing Methods, Measuring Technique and Manufacturing Technique. He is currently a Ph.D. candidate at the University of Ulsan. His research interests focus on designing and manufacturing of new actuators, vibration control theory and application theories.     

Fixed structure compensator design using a constrained hybrid evolutionary optimization approach

This paper presents an efficient technique for designing a fixed order compensator for compensating current mode control architecture of DC−DC converters. The compensator design is formulated as an optimization problem, which seeks to attain a set of frequency domain specifications. The highly nonlinear nature of the optimization problem demands the use of an initial parameterization independent global search technique. In this regard, the optimization problem is solved using a hybrid evolutionary optimization approach, because of its simple structure, faster execution time and greater probability in achieving the global solution. The proposed algorithm involves the combination of a population search based optimization approach i.e. Particle Swarm Optimization (PSO) and local search based method. The op-amp dynamics have been incorporated during the design process. Considering the limitations of fixed structure compensator in achieving loop bandwidth higher than a certain threshold, the proposed approach also determines the op-amp bandwidth, which would be able to achieve the same. The effectiveness of the proposed approach in meeting the desired frequency domain specifications is experimentally tested on a peak current mode control dc−dc buck converter.     

Regulation on radial position deviation for vertical AMB systems

As a source of model uncertainty, gyroscopic effect, depending on rotor speed, is studied for the vertical active magnetic bearing (VAMB) systems which are increasingly used in various industries such as clean rooms, compressors and satellites. This research applies H^∞ controller to regulate the rotor position deviations of the VAMB systems in four degrees of freedom. The performance of H^∞ controller is examined by experimental simulations to inspect its closed-loop stiffness, rise time and capability to suppress the high frequency disturbances. Although the H^∞ is inferior to the LQR in position deviation regulation, the required control current in the electromagnetic bearings is much less than that for LQR or PID and the performance robustness is well retained. In order to ensure the stability robustness of H^∞ controller, two approaches, by Kharitonov polynomials and TITO (two inputs & two outputs) Nyquist Stability Criterion, are employed to synthesize the control feedback loop. A test rig is built to further verify the efficacy of the proposed H^∞ controller experimentally. Two Eddy-current types of gap sensors, perpendicular to each other, are included to the realistic rotor-bearing system. A four-pole magnetic bearing is used as the actuator for generation of control force. The commercial I/O module unit with A/D and D/A converters, dSPACE DS1104, is integrated to the VAMB, gap sensors, power amplifiers and signal processing circuits. The H^∞ is designed on the basis of rotor speed 10 K rpm but in fact it is significantly robust with respect to the rotor speed, varying from 6.5 to 13.5 K rpm.