McTronX:Proudly South African magnetic bearing solutions

McTronX:Proudly South African magnetic bearing solutions

G van SchoorG van Schoor

OverviewOverview

Present Past Vision

1. Present ... who we are

2. Past ... where we come from

3. Future ... our vision

McTronX @ presentMcTronX @ present

Research group in the Engineering faculty at the North-West University

Research focus: Self-sensing AMBs AMB retainer bearings Advanced modelling and control PMSM machines

Industrial focus: High-speed AMB systems: flywheels and blowers

Present Past Vision

Structure, support & collaborationStructure, support & collaboration

Industry sponsor

Collaboration

McTronX

Permanent personnel

Postgraduate students

Research division

Industrial division

•AMBs, power electronics•Electrical machines & drives•Modelling & control•Signal processing•High level software•Analogue systems•Mechanical systems

•AMBs, power electronics•Embedded control•Analogue systems•Mechanical systems

•Ph.D.•Masters

Present Past Vision

Current expertiseCurrent expertise

Power electronics

AMB design

Modelling & control

Embedded systems

Sensors & self-sensing

Retainer bearings

PMSM design & control

Artificial intelligence

Permanent personnel ...

Students ...

PhD

PhD

PhDPhD

PhDcandidate

M (2)

PhDcandidate

PhDcandidate (2)

PhDcandidate

PhDcandidate

M

M (4)

M (2)

M (2)M (2)

7

16

Present Past

Current expertiseCurrent expertise

Power electronics

AMB design

Modelling & control

Embedded systems

Sensors & self-sensing

Retainer bearings

PMSM design & control

Artificial intelligencePresent Past

Mechanica

l

design

Vibration analysis

Rot

or-

dyna

mic

s

Strength analysis

Therm

al

analysis

Summary: 2003 - 2009Summary: 2003 - 2009

Year

Cost: students

Cost:

personnel

Costs:

laboratory

Costs:

projects

Total costs

Completed Masters

Completed PhDs

Present Past Vision

2003

0

0

R 0.4 M

R 0 M

R 0.1 M

R 0.1 M

R 0.6 M

4

0

2004

R 0.88 M

R 0 M

R 0.4 M

R 0.1 M

R 1.38 M

6

0

2005

R 1.15 M

R 0.2 M

R 0.4 M

R 0.1 M

R 1.85 M

2006

7

0

R 1.35 M

R 0.25 M

R 0.35 M

R 0.15 M

R 2.1 M

2007

5

3

R 1.6 M

R 0.4 M

R 0.15 M

R 0.15 M

R 2.3 M

2008

4

2

R 1.4 M

R 1.1 M

R 0.17 M

R 0.5 M

R 3.17 M

2009

n/a

n/a

R 1.6 M

R 1.6 M

R 0.05 M

R 1.6 M

R 4.85 M

Total

R 3.55 M

R 8.38 M

R 1.62 M

R 2.7 M

R 16.25 M

26

5

Power Amplifiers

Single AMBs

Fly-UPS Twins

ADES: Analog Drive Electronic System

100 kW blower system + retainer bearing test-bed

Double AMB

Condition monitoring on AMB-suspended systems

Fault classification of main power system in PBMR

Self-sensing

Modelling of coupled thermo-hydraulic systems

Self-sensing

2003: 1-DOF axial AMB2003: 1-DOF axial AMB

2003 2004 2005 2006 2007 2008 2009*1-DOF AMBs

2010

Leve

l of e

xper

tise

Present Past Vision

• 1-DOF axial AMB• PA: linear• Sensor: inductive• Control: dSpace

• 2 kg disk• 3 mm gap• 250 N force

2003: 2-DOF radial AMB2003: 2-DOF radial AMB

2003 2004 2005 2006 2007 2008 2009*1-DOF AMBs

2010

Leve

l of e

xper

tise

Present Past Vision

• 2-DOF radial AMB (homopolar)• PA: linear• Sensor: inductive• Control: dSpace

• 2 kg shaft• 1 mm gap• 100 N force

2004: Double radial AMB2004: Double radial AMB

2003 2004 2005 2006 2007 2008 2009*1-DOF AMBs *

Double AMB

2010

Leve

l of e

xper

tise

Present Past Vision

• 7.7 / 14 kg shaft (rigid / flexible)• 0.6 mm gap• 500 N force

2004• 4-DOF radial AMBs (heteropolar)• PA: switch-mode• Sensor: eddy current• Control: dSpace

2003 • 2-DOF radial AMB (homopolar)• PA: linear• Sensor: inductive• Control: dSpace

2007: Flywheel system (Fly-UPS)2007: Flywheel system (Fly-UPS)

2003 2004 2005 2006 2007 2008 2009

*

*1-DOF AMBs *

Double AMB *

Power amplifiers

*

Fly-UPS

Integrated controller

2010

Leve

l of e

xper

tise

Present Past Vision

Specifications:• 600 kJ• 18 kg• 30 000 rpm• 0.5 mm• 150 N radial, 520 N axial• 2 kW PMSM• 300 W for 30 min

Progression: 2005 - 2007Progression: 2005 - 2007

2003 2004 2005 2006 2007 2008 2009

*

*1-DOF AMBs *

Double AMB *

Power amplifiers

*Fly-UPS

Integrated controller

2010

Leve

l of e

xper

tise

Present Past Vision

2007• 5-DOF AMB system• Control: dSpace (stand-alone) Single-board computer• PMSM

2005 • 4-DOF radial AMBs• Control: dSpace

• Air-turbine

Rotor/flywheelPMSM

2007: Integrated controller2007: Integrated controller

2003 2004 2005 2006 2007 2008 2009

*

*1-DOF AMBs *

Double AMB *

Power amplifiers

2010

Leve

l of e

xper

tise

Present Past Vision

• Purpose:• AMB drive• Self-sensing• AMB embedded control

• 3-level piggy backed system consisting of:• Analogue interface circuitry• FPGA and DSP• Power amplifiers

2008: Twins2008: Twins

2003 2004 2005 2006 2007 2008 2009

*

*1-DOF AMBs *

Double AMB *

Power amplifiers

*

Fly-UPS

Integrated controller *Twins

Blower support

Self-sensing

2010

Leve

l of e

xper

tise

Present Past Vision

Summary:• Two in-house designed 2-pole, 3-phase PMSMs• Mechanically coupled• Both motor/generator modes• Versatile platform for testing advanced motor control strategies• Roller element bearings• Tested up to 30,000 rpm in a specially built test chamber.

2008: Blower support2008: Blower support

2003 2004 2005 2006 2007 2008 2009

*

*1-DOF AMBs *

Double AMB *

Power amplifiers

*

Fly-UPS

Integrated controller *Twins

Blower support

Self-sensing

2010

Leve

l of e

xper

tise

Present Past Vision

•Successful re-commissioning of AMB suspended HTF blower •AMB system support:

•On-site fault finding•Analysis of AMB system•Recommendations•System tested to within

specifications•Valuable support to

local industry

2008: Self-sensing2008: Self-sensing

2003 2004 2005 2006 2007 2008 2009

*

*1-DOF AMBs *

Double AMB *

Power amplifiers

*

Fly-UPS

Integrated controller *Twins

Blower support

Self-sensing

2010

Leve

l of e

xper

tise

Present Past Vision

• Definition: self-sensing estimates the rotor position by monitoring the electrical impedance of the actuator (the stator magnet coils).

• Hardware implementationvia in-house developedintegrated controller card.

Current projectsCurrent projects

2003 2004 2005 2006 2007 2008 2009

*

*1-DOF AMBs *

Double AMB *

Power amplifiers

*

Fly-UPS

Integrated controller *Twins

Blower support

Self-sensing

*ADES

RDS

2010

Leve

l of e

xper

tise

Present Past Vision

ADES: AMB and Drive Electronics SystemADES: AMB and Drive Electronics System

Present Past Vision

Main functions:•Actively control an AMB system•AMB condition monitoring•Drive a 3-phase Permanent Magnet

Synchronous Motor (PMSM)•Provide comprehensive user interfacing

Purpose: to develop an AMB control system that meets industrial standards

cPCI cardSBC

PMC cardFPGA

PMC cardProfibus DP

RS485 & CMOS I/O

Sensor driver unitPA unitsMotor DriveAdditional I/OPower conditioning UnitRemote access/

Maintenance port

SCADA

cPC

I bac

kpla

ne

Ethernet

cPCI connectors

DifferentialRS485 link

ProfibusRS485

PM

CS

ites

(PC

I)

PM

CS

ites

(PC

I)

RDS: Rotor Delevitation SystemRDS: Rotor Delevitation System

In-house software for the analysis (and selection) of retainer bearings.

Test-bench for delevitation tests

Modelling of advancedback-up bearings

Present Past Vision

Our VisionOur Vision

Medium term:Support of existing AMB systems in local

industry

Longer term:Development of proudly South African high-

speed AMB solutions

Present Past Vision

Based on our current expertiseBased on our current expertise

Power electronics

AMB design

Modelling & control

Embedded systems

Sensors & self-sensing

Retainer bearings

PMSM design & control

Artificial intelligence

Permanent personnel ...

Students ...

PhD

PhD

PhDPhD

candidate

PhDcandidate

M (2)

PhDcandidate

PhDcandidate (2)

PhDcandidate

PhDcandidate

M

M (4)

M (2)

M (2)M (2)

7

16

The next step is ...The next step is ...

2003 2004 2005 2006 2007 2008 2009

*

*1-DOF AMBs *

Double AMB *

Power amplifiers

*

Fly-UPS

Integrated controller *Twins

Blower support

Self-sensing

*ADES

RDS

2010

*Industrial

Leve

l of e

xper

tise

Present Past Vision

To demonstrate our expertise in an industrial

setting, typically high-speed blowers.

Thank youThank you

What is an AMB?What is an AMB?

AMB = Active Magnetic Bearing

Controllers Rotor

Power Amplifiers& Drives

Electromagnet

Sensors

Motor