Modelling and Control of Stepper Motors for High Accuracy Positioning Systems Used in Radioactive Environments

Hybrid Stepper Motors are widely used in open-loop position applications. They are the choice of actuation for the collimators in the Large Hadron Collider, the largest particle accelerator at CERN. In this case the positioning requirements and the highly radioactive operating environment are unique. The latter forces both the use of long cables to connect the motors to the drives which act as transmission lines and also prevents the use of standard position sensors. However, reliable and precise operation of the collimators is critical for the machine, requiring the prevention of step loss in the motors and maintenance to be foreseen in case of mechanical degradation. In order to make the above possible, an approach is proposed for the application of an Extended Kalman Filter to a sensorless stepper motor drive, when the motor is separated from its drive by long cables. When the long cables and high frequency pulse width modulated control voltage signals are used together, the electrical signals difer greatly between the motor and drive-side of the cable. Since in the considered case only drive-side data is available, it is therefore necessary to estimate the motor-side signals. Modelling the entire cable and motor system in an Extended Kalman Filter is too computationally intensive for standard embedded real-time platforms. It is, in consequence, proposed to divide the problem into an Extended Kalman Filter, based only on the motor model, and separated motor-side signal estimators, the combination of which is less demanding computationally. The efectiveness of this approach is shown in simulation. Then its validity is experimentally demonstrated via implementation in a DSP based drive. A testbench to test its performance when driving an axis of a Large Hadron Collider collimator is presented along with the results achieved. It is shown that the proposed method is capable of achieving position and load torque estimates which allow step loss to be detected and mechanical degradation to be evaluated without the need for physical sensors. These estimation algorithms often require a precise model of the motor, but the standard electrical model used for hybrid stepper motors is limited when currents, which are high enough to produce saturation of the magnetic circuit, are present. New model extensions are proposed in order to have a more precise model of the motor independently of the current level, whilst maintaining a low computational cost. It is shown that a significant improvement in the model It is achieved with these extensions, and their computational performance is compared to study the cost of model improvement versus computation cost. The applicability of the proposed model extensions is demonstrated via their use in an Extended Kalman Filter running in real-time for closed-loop current control and mechanical state estimation. An additional problem arises from the use of stepper motors. The mechanics of the collimators can wear due to the abrupt motion and torque profiles that are applied by them when used in the standard way, i.e. stepping in open-loop. Closed-loop position control, more specifically Field Oriented Control, would allow smoother profiles, more respectful to the mechanics, to be applied but requires position feedback. As mentioned already, the use of sensors in radioactive environments is very limited for reliability reasons. Sensorless control is a known option but when the speed is very low or zero, as is the case most of the time for the motors used in the LHC collimator, the loss of observability prevents its use. In order to allow the use of position sensors without reducing the long term reliability of the whole system, the possibility to switch from closed to open loop is proposed and validated, allowing the use of closed-loop control when the position sensors function correctly and open-loop when there is a sensor failure. A different approach to deal with the switched drive working with long cables is also presented. Switched mode stepper motor drives tend to have poor performance or even fail completely when the motor is fed through a long cable due to the high oscillations in the drive-side current. The design of a stepper motor output fillter which solves this problem is thus proposed. A two stage filter, one devoted to dealing with the diferential mode and the other with the common mode, is designed and validated experimentally. With this ?lter the drive performance is greatly improved, achieving a positioning repeatability even better than with the drive working without a long cable, the radiated emissions are reduced and the overvoltages at the motor terminals are eliminated.

Evaluation of preisach model of hysteresis to model superconductors

The Large Hadron Collider is the world’s largest and most powerful particle accelerator. The project is divided in phases. The first one goes from 2009 until 2020. The second phase will consist of the implementation of upgrades. One of the upgrades is to increase the ratio of collision, the luminosity. This objective is the main of one of the most important projects which is carrying out the upgrades: Hi-Lumi LHC project. Increasing luminosity could be done by using a new material in the superconductor magnets placed at the interaction points: Nb3Sn, instead of NbTi, the one being used right now. Before implementing it many aspects should be analysed. One of them is the induction magnetic field quality. The tool used so far has been ROXIE, software developed at CERN by S. Russenschuck. One of the main features of the programme is the time-transient analysis, which is based on three mathematical models. It is quite precise for fields above 1.5 Tesla. However, they are not very accurate for lower fields. Therefore the aim of this project is to evaluate a more accurate model: Classical Preisach Model of Hysteresis, in order to better analyse induced field quality in the new material Nb3Sn. Resumen: El Gran Colisionador de Hadrones es el mayor acelerador de partículas circular del mundo. Se trata de uno de los mayores proyectos de investigación. La primera fase de funcionamiento comprende desde 2009 a 2020, cuando comenzará la siguiente fase. Durante el primer periodo se han pensado mejoras para que puedan ser implementadas en la segunda fase. Una de ellas es el aumento del ratio de las colisiones entre protones por choque. Este es el principal objetivo de uno de los proyectos que está llevando a cabo las mejoras a ser implementadas en 2020: Hi- Lumi LHC. Se cambiarán los imanes superconductores de NbTi de las dos zonas principales de interacción, y se sustituirán por imanes de Nb3Sn. Esta sustituciónn conlleva un profundo estudio previo. Entre otros, uno de los factores a analizar es la calidad del campo magnético. La herramienta utilizada es el software desarrollado por S. Russenschuck en el CERN llamado ROXIE. Está basado en tres modelos de magnetización, los cuales son precisos para campos mayores de 1.5 T. Sin embargo, no lo son tanto para campos menores. Con este proyecto se pretende evaluar la implementación de un cuarto modelo, el modelo clásico de histéresis de Preisach que permita llevar a cabo un mejor análisis de la calidad del campo inducido por el futuro material a utilizar en algunos de los imanes.