Methodology for an AMB system commissioning

This master’s thesis is focused on the active magnetic bearings system commissioning. The scope of the work is to test the existent procedures with old and new prototypes of an AMB system and additionally automate necessary steps instead of their hand tuning, because determination of rotor clearances and finding effective rotor-origins are time consuming and error prone. The final goal is to get a documented and mostly automated step by step methodology for end efficient system’s commissioning.

AMB system for high-speed motors using automatic commissioning

The general trend towards increasing e ciency and energy density drives the industry to high-speed technologies. Active Magnetic Bearings (AMBs) are one of the technologies that allow contactless support of a rotating body. Theoretically, there are no limitations on the rotational speed. The absence of friction, low maintenance cost, micrometer precision, and programmable sti ness have made AMBs a viable choice for highdemanding applications. Along with the advances in power electronics, such as signi cantly improved reliability and cost, AMB systems have gained a wide adoption in the industry. The AMB system is a complex, open-loop unstable system with multiple inputs and outputs. For normal operation, such a system requires a feedback control. To meet the high demands for performance and robustness, model-based control techniques should be applied. These techniques require an accurate plant model description and uncertainty estimations. The advanced control methods require more e ort at the commissioning stage. In this work, a methodology is developed for an automatic commissioning of a subcritical, rigid gas blower machine. The commissioning process includes open-loop tuning of separate parts such as sensors and actuators. The next step is to apply a system identi cation procedure to obtain a model for the controller synthesis. Finally, a robust model-based controller is synthesized and experimentally evaluated in the full operating range of the system. The commissioning procedure is developed by applying only the system components available and a priori knowledge without any additional hardware. Thus, the work provides an intelligent system with a self-diagnostics feature and an automatic commissioning.

Sähkömekaanisen turvalaakerirakenteen suunnittelu

Turvalaakereita käytetään suojaamaan aktiivisia magneettilaakereita vikatilanteiden tapahtuessa. Tässä kandidaatintyössä suunniteltiin erilaisia ratkaisuja toteuttaa turvalaakerin toiminta sähkömekaanisella toimilaitteella. Työn tarkoituksena oli löytää uusia tapoja toteuttaa turvalaakerin rakenne. Uusilla ratkaisuilla poistettiin turvalaakereille ominaisia ongelmia. Suunnittelussa käytettiin perinteisiä koneensuunnittelun menetelmiä. Menetelmien tarkoitus oli mahdollistaa järjestelmällinen suunnittelu. Tässä työssä myös kirjallisuuskatsaus toimi yhtenä suunnittelun vaiheena. Tuloksiksi saatiin hahmotelmia ja 3D-malleja. Tulokset poikkesivat tavanomaisista turvalaakereiden rakenteista. Tuloksissa huomioitiin, että tässä työssä ei suunnitella valmista tuotetta. Suunniteltujen turvalaakereiden toiminta perustui mekanismeihin, jotka toivat mukanaan uusia ominaisuuksia. Sähkömekaanisen toimilaitteen sijoittaminen mekanismeihin oli kuitenkin vaikeaa. Työn tulokset avasivat uusia näkökulmia turvalaakerirakenteiden jatkokehittämiseen.

Multibody models for examination of touchdown bearing systems

Increased rotational speed brings many advantages to an electric motor. One of the benefits is that when the desired power is generated at increased rotational speed, the torque demanded from the rotor decreases linearly, and as a consequence, a motor of smaller size can be used. Using a rotor with high rotational speed in a system with mechanical bearings can, however, create undesirable vibrations, and therefore active magnetic bearings (AMBs) are often considered a good option for the main bearings, as the rotor then has no mechanical contact with other parts of the system but levitates on the magnetic forces. On the other hand, such systems can experience overloading or a sudden shutdown of the electrical system, whereupon the magnetic field becomes extinct, and as a result of rotor delevitation, mechanical contact occurs. To manage such nonstandard operations, AMB-systems require mechanical touchdown bearings with an oversized bore diameter. The need for touchdown bearings seems to be one of the barriers preventing greater adoption of AMB technology, because in the event of an uncontrolled touchdown, failure may occur, for example, in the bearing’s cage or balls, or in the rotor. This dissertation consists of two parts: First, touchdown bearing misalignment in the contact event is studied. It is found that misalignment increases the likelihood of a potentially damaging whirling motion of the rotor. A model for analysis of the stresses occurring in the rotor is proposed. In the studies of misalignment and stresses, a flexible rotor using a finite element approach is applied. Simplified models of cageless and caged bearings are used for the description of touchdown bearings. The results indicate that an increase in misalignment can have a direct influence on the bending and shear stresses occurring in the rotor during the contact event. Thus, it was concluded that analysis of stresses arising in the contact event is essential to guarantee appropriate system dimensioning for possible contact events with misaligned touchdown bearings. One of the conclusions drawn from the first part of the study is that knowledge of the forces affecting the balls and cage of the touchdown bearings can enable a more reliable estimation of the service life of the bearing. Therefore, the second part of the dissertation investigates the forces occurring in the cage and balls of touchdown bearings and introduces two detailed models of touchdown bearings in which all bearing parts are modelled as independent bodies. Two multibody-based two-dimensional models of touchdown bearings are introduced for dynamic analysis of the contact event. All parts of the bearings are modelled with geometrical surfaces, and the bodies interact with each other through elastic contact forces. To assist in identification of the forces affecting the balls and cage in the contact event, the first model describes a touchdown bearing without a cage, and the second model describes a touchdown bearing with a cage. The introduced models are compared with the simplified models used in the first part of the dissertation through parametric study. Damages to the rotor, cage and balls are some of the main reasons for failures of AMB-systems. The stresses in the rotor in the contact event are defined in this work. Furthermore, the forces affecting key bodies of the bearings, cage and balls can be studied using the models of touchdown bearings introduced in this dissertation. Knowledge obtained from the introduced models is valuable since it can enable an optimum structure for a rotor and touchdown bearings to be designed.

Neuartige Verfahren für die Überwachung und Diagnose von aktiv magnetgelagerten rotierenden Maschinen

Mit aktiven Magnetlagern ist es möglich, rotierende Körper durch magnetische Felder berührungsfrei zu lagern. Systembedingt sind bei aktiv magnetgelagerten Maschinen wesentliche Signale ohne zusätzlichen Aufwand an Messtechnik für Diagnoseaufgaben verfügbar. In der Arbeit wird ein Konzept entwickelt, das durch Verwendung der systeminhärenten Signale eine Diagnose magnetgelagerter rotierender Maschinen ermöglicht und somit neben einer kontinuierlichen Anlagenüberwachung eine schnelle Bewertung des Anlagenzustandes gestattet. Fehler können rechtzeitig und ursächlich in Art und Größe erkannt und entsprechende Gegenmaßnahmen eingeleitet werden. Anhand der erfassten Signale geschieht die Gewinnung von Merkmalen mit signal- und modellgestützten Verfahren. Für den Magnetlagerregelkreis erfolgen Untersuchungen zum Einsatz modellgestützter Parameteridentifikationsverfahren, deren Verwendbarkeit wird bei der Diagnose am Regler und Leistungsverstärker nachgewiesen. Unter Nutzung von Simulationsmodellen sowie durch Experimente an Versuchsständen werden die Merkmalsverläufe im normalen Referenzzustand und bei auftretenden Fehlern aufgenommen und die Ergebnisse in einer Wissensbasis abgelegt. Diese dient als Grundlage zur Festlegung von Grenzwerten und Regeln für die Überwachung des Systems und zur Erstellung wissensbasierter Diagnosemodelle. Bei der Überwachung werden die Merkmalsausprägungen auf das Überschreiten von Grenzwerten überprüft, Informationen über erkannte Fehler und Betriebszustände gebildet sowie gegebenenfalls Alarmmeldungen ausgegeben. Sich langsam anbahnende Fehler können durch die Berechnung der Merkmalstrends mit Hilfe der Regressionsanalyse erkannt werden. Über die bisher bei aktiven Magnetlagern übliche Überwachung von Grenzwerten hinaus erfolgt bei der Fehlerdiagnose eine Verknüpfung der extrahierten Merkmale zur Identifizierung und Lokalisierung auftretender Fehler. Die Diagnose geschieht mittels regelbasierter Fuzzy-Logik, dies gestattet die Einbeziehung von linguistischen Aussagen in Form von Expertenwissen sowie die Berücksichtigung von Unbestimmtheiten und ermöglicht damit eine Diagnose komplexer Systeme. Für Aktor-, Sensor- und Reglerfehler im Magnetlagerregelkreis sowie Fehler durch externe Kräfte und Unwuchten werden Diagnosemodelle erstellt und verifiziert. Es erfolgt der Nachweis, dass das entwickelte Diagnosekonzept mit beherrschbarem Rechenaufwand korrekte Diagnoseaussagen liefert. Durch Kaskadierung von Fuzzy-Logik-Modulen wird die Transparenz des Regelwerks gewahrt und die Abarbeitung der Regeln optimiert. Endresultat ist ein neuartiges hybrides Diagnosekonzept, welches signal- und modellgestützte Verfahren der Merkmalsgewinnung mit wissensbasierten Methoden der Fehlerdiagnose kombiniert. Das entwickelte Diagnosekonzept ist für die Anpassung an unterschiedliche Anforderungen und Anwendungen bei rotierenden Maschinen konzipiert.

Mancais magnéticos ativos para atenuação de vibrações em eixos rotativos

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Controle ativo de vibrações de rotores com mancais magnéticos: influência dos parâmetros do controlador PID

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Single Axis Controlled Hybrid Magnetic Bearing for Left Ventricular Assist Device: Hybrid Core and Closed Magnetic Circuit

In previous studies, we presented main strategies for suspending the rotor of a mixed-flow type (centrifugal and axial) ventricular assist device (VAD), originally presented by the Institute Dante Pazzanese of Cardiology (IDPC), Brazil. Magnetic suspension is achieved by the use of a magnetic bearing architecture in which the active control is executed in only one degree of freedom, in the axial direction of the rotor. Remaining degrees of freedom, excepting the rotation, are restricted only by the attraction force between pairs of permanent magnets. This study is part of a joint project in development by IDPC and Escola Politecnica of Sao Paulo University, Brazil. This article shows advances in that project, presenting two promising solutions for magnetic bearings. One solution uses hybrid cores as electromagnetic actuators, that is, cores that combine iron and permanent magnets. The other solution uses actuators, also of hybrid type, but with the magnetic circuit closed by an iron core. After preliminary analysis, a pump prototype has been developed for each solution and has been tested. For each prototype, a brushless DC motor has been developed as the rotor driver. Each solution was evaluated by in vitro experiments and guidelines are extracted for future improvements. Tests have shown good results and demonstrated that one solution is not isolated from the other. One complements the other for the development of a single-axis-controlled, hybrid-type magnetic bearing for a mixed-flow type VAD.

Redução de vibrações de rotores utilizando atuadores magnéticos e sistema de controle feedforward

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Controle ativo de vibração de rotores com mancais magnéticos: influência da flexibilidade dos rotores

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Magnetic Attitude Control System for a Small Satellite. Impact on the Thermal Performance

El principal objetivo de la tesis es estudiar el acoplamiento entre los subsistemas de control de actitud y de control térmico de un pequeño satélite, con el fin de buscar la solución a los problemas relacionados con la determinación de los parámetros de diseño. Se considera la evolución de la actitud y de las temperaturas del satélite bajo la influencia de dos estrategias de orientación diferentes: 1) estabilización magnética pasiva de la orientación (PMAS, passive magnetic attitude stabilization), y 2) control de actitud magnético activo (AMAC, active magnetic attitude control). En primer lugar se presenta el modelo matemático del problema, que incluye la dinámica rotacional y el modelo térmico. En el problema térmico se considera un satélite cúbico modelizado por medio de siete nodos (seis externos y uno interno) aplicando la ecuación del balance térmico. Una vez establecido el modelo matemático del problema, se estudia la evolución que corresponde a las dos estrategias mencionadas. La estrategia PMAS se ha seleccionado por su simplicidad, fiabilidad, bajo coste, ahorrando consumo de potencia, masa coste y complejidad, comparado con otras estrategias. Se ha considerado otra estrategia de control que consigue que el satélite gire a una velocidad requerida alrededor de un eje deseado de giro, pudiendo controlar su dirección en un sistema inercial de referencia, ya que frecuentemente el subsistema térmico establece requisitos de giro alrededor de un eje del satélite orientado en una dirección perpendicular a la radiación solar incidente. En relación con el problema térmico, para estudiar la influencia de la velocidad de giro en la evolución de las temperaturas en diversos puntos del satélite, se ha empleado un modelo térmico linealizado, obtenido a partir de la formulación no lineal aplicando un método de perturbaciones. El resultado del estudio muestra que el tiempo de estabilización de la temperatura y la influencia de las cargas periódicas externas disminuye cuando aumenta la velocidad de giro. Los cambios de temperatura se reducen hasta ser muy pequeños para velocidades de rotación altas. En relación con la estrategia PMAC se ha observado que a pesar de su uso extendido entre los micro y nano satélites todavía presenta problemas que resolver. Estos problemas están relacionados con el dimensionamiento de los parámetros del sistema y la predicción del funcionamiento en órbita. Los problemas aparecen debido a la dificultad en la determinación de las características magnéticas de los cuerpos ferromagnéticos (varillas de histéresis) que se utilizan como amortiguadores de oscilaciones en los satélites. Para estudiar este problema se presenta un modelo analítico que permite estimar la eficiencia del amortiguamiento, y que se ha aplicado al estudio del comportamiento en vuelo de varios satélites, y que se ha empleado para comparar los resultados del modelo con los obtenidos en vuelo, observándose que el modelo permite explicar satisfactoriamente el comportamiento registrado. ABSTRACT The main objective of this thesis is to study the coupling between the attitude control and thermal control subsystems of a small satellite, and address the solution to some existing issues concerning the determination of their parameters. Through the thesis the attitude and temperature evolution of the satellite is studied under the influence of two independent attitude stabilization and control strategies: (1) passive magnetic attitude stabilization (PMAS), and (2) active magnetic attitude control (AMAC). In this regard the mathematical model of the problem is explained and presented. The mathematical model includes both the rotational dynamics and the thermal model. The thermal model is derived for a cubic satellite by solving the heat balance equation for 6 external and 1 internal nodes. Once established the mathematical model of the problem, the above mentioned attitude strategies were applied to the system and the temperature evolution of the 7 nodes of the satellite was studied. The PMAS technique has been selected to be studied due to its prevalent use, simplicity, reliability, and cost, as this strategy significantly saves the overall power, weight, cost, and reduces the complexity of the system compared to other attitude control strategies. In addition to that, another control law that provides the satellite with a desired spin rate along a desired axis of the satellite, whose direction can be controlled with respect to the inertial reference frame is considered, as the thermal subsystem of a satellite usually demands a spin requirement around an axis of the satellite which is positioned perpendicular to the direction of the coming solar radiation. Concerning the thermal problem, to study the influence of spin rate on temperature evolution of the satellite a linear approach of the thermal model is used, which is based on perturbation theory applied to the nonlinear differential equations of the thermal model of a spacecraft moving in a closed orbit. The results of this study showed that the temperature stabilization time and the periodic influence of the external thermal loads decreases by increasing the spin rate. However, the changes become insignificant for higher values of spin rate. Concerning the PMAS strategy, it was observed that in spite of its extended application to micro and nano satellites, still there are some issues to be solved regarding this strategy. These issues are related to the sizing of its system parameters and predicting the in-orbit performance. The problems were found to be rooted in the difficulties that exist in determining the magnetic characteristics of the ferromagnetic bodies (hysteresis rods) that are applied as damping devices on-board satellites. To address these issues an analytic model for estimating their damping efficiency is proposed and applied to several existing satellites in order to compare the results with their respective in-flight data. This model can explain the behavior showed by these satellites.

Optimal Controller Designs for Rotating Machines - Penalising the Rate of Change of Control Forcing

In the context of active control of rotating machines, standard optimal controller methods enable a trade-off to be made between (weighted) mean-square vibrations and (weighted) mean-square currents injected into magnetic bearings. One shortcoming of such controllers is that no concern is devoted to the voltages required. In practice, the voltage available imposes a strict limitation on the maximum possible rate of change of control force (force slew rate). This paper removes the aforementioned existing shortcomings of traditional optimal control.

Modelização de um mecanismo de levitação supercondutor para um sistema de volante de inércia comercial

Este trabalho teve como objectivo o estudo de um sistema de levitação magnética com chumaceiras supercondutoras, para utilização numa fonte de alimentação de energia eléctrica ininterrupta, que usa um volante de inércia como sistema de armazenamento de energia. Partindo de um modelo comercial existente, foi modelizada a substituição do sistema de levitação por um sistema com chumaceiras supercondutoras. Foi feito o dimensionamento do magnete permanente e do supercondutor de forma a atingir-se a força de levitação magnética necessária para elevar o rotor da máquina, garantindo simultaneamente a máxima estabilidade do sistema. Os perfis de distribuição do campo magnético no volante de inércia foram modelizados recorrendo ao método dos elementos finitos, através da utilização do software Ansys. O cálculo da força de levitação foi efectuado recorrendo ao software MATHEMATICA.

Modellbildung und Untersuchung eines magnetisch gelagerten Rundtisches

Active magnetic bearing, round table, multi-body system, state-control

Experimental and Numerical Analysis of Different Volutes in a Centrifugal Compressor

In a centrifugal compressor the flow around the diffuser is collected and led to the pipe system by a spiral-shaped volute. In this study a single-stage centrifugal compressor with three different volutes is investigated. The compressorwas first equipped with the original volute, the cross-section of which was a combination of a rectangle and semi-circle. Next a new volute with a fully circular cross-section was designed and manufactured. Finally, the circular volute wasmodified by rounding the tongue and smoothing the tongue area. The overall performance of the compressor as well as the static pressure distribution after the impeller and on the volute surface were measured. The flow entering the volute was measured using a three-hole Cobra-probe, and flow visualisations were carriedout in the exit cone of the volute. In addition, the radial force acting on theimpeller was measured using magnetic bearings. The complete compressor with thecircular volute (inlet pipe, full impeller, diffuser, volute and outlet pipe) was also modelled using computational fluid dynamics (CFD). A fully 3-D viscous flow was solved using a Navier-Stokes solver, Finflo, developed at Helsinki University of Technology. Chien's k-e model was used to take account of the turbulence. The differences observed in the performance of the different volutes were quite small. The biggest differences were at low speeds and high volume flows,i.e. when the flow entered the volute most radially. In this operating regime the efficiency of the compressor with the modified circular volute was about two percentage points higher than with the other volutes. Also, according to the Cobra-probe measurements and flow visualisations, the modified circular volute performed better than the other volutes in this operating area. The circumferential static pressure distribution in the volute showed increases at low flow, constant distribution at the design flow and decrease at high flow. The non-uniform static pressure distribution of the volute was transmitted backwards across the vaneless diffuser and observed at the impeller exit. At low volume flow a strong two-wave pattern developed into the static pressure distribution at the impeller exit due to the response of the impeller to the non-uniformity of pressure. The radial force of the impeller was the greatest at the choke limit, the smallest atthe design flow, and moderate at low flow. At low flow the force increase was quite mild, whereas the increase at high flow was rapid. Thus, the non-uniformityof pressure and the force related to it are strong especially at high flow. Theforce caused by the modified circular volute was weaker at choke and more symmetric as a function of the volume flow than the force caused by the other volutes.