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Active magnetic bearings (AMBs) provide reliable solution for high-speed rotors, where oil-free and reliable operation are crucial. In high-power applications benefits of AMBs, compared to traditional rolling element bearings or fluid film bearings, are highly valued. Typical AMB rotors comprise two radial AMBs, which are designed with compressor or generator wheels integrated on the rotor. AMB dimensions and locations are carefully selected for each new application. The system design is being iterated such that the nodes of the lowest frequency rotor bending modes are sufficiently far away from the AMB and sensor nodes to ensure robust AMB control. The design is very challenging and cost sensitive. This work focuses on electromagnetic design, modeling, and control of fully levitated AMB-rotor with three radial AMBs. The additional bearing ensures that the same design can be reused with different applications and regardless of the changes in locations of nodes of the first bending mode. The control plant is modeled based on flexible rotor dynamics; while bearing inductances and forces are modeled with 2-D and 3-D finite element method (FEM) electromagnetic simulations. The presented multi-input multi-output (MIMO) model-based control is coupled and centralized with three actuator-sensor pairs for radial suspension. The control design is verified in simulations using nonlinear engineering models. Additionally, experimental identification results are included. [ABSTRACT FROM AUTHOR]

The article addresses coupled loss and thermal analyses of a bearingless drive with an operating speed range of 17 000–32 000 rpm. The drive is a part of a high-temperature heat pump system integrated in a high-speed compressor. This drive system comprises two bearingless motor units and an axial active magnetic bearing. The drive can be positioned horizontally or vertically. The positioning is directly related to the force necessary to raise and suspend the rotor. Furthermore, the amplitude of the suspension current has a significant effect on the motor winding and iron losses. The iron losses, eddy current losses in the magnets, and losses in the bandage are investigated by three-dimensional (3-D) and 2-D finite-element analysis. The influence of segmentation of the magnets on losses is analyzed. Friction losses of the coolant are calculated analytically, and all the losses obtained from the electromagnetic analysis are represented as distributed heat sources and coupled with the 3-D thermal field analysis. The temperature fields are modeled under different motoring and suspension current conditions and evaluated for horizontal and vertical positions of the motor. As a precaution, demagnetization of the magnets is also considered. [ABSTRACT FROM AUTHOR]

High-speed solid-rotor induction machines (HSIMs) are popular within high-speed (HS) applications because of their high rotor structural integrity and their fairly well-established manufacturing process guaranteeing high quality series products. Designing a new HS electric machine requires a multidisciplinary team to accomplish the machine performance desired. In case of a HS machine design, the components and applied materials often reach their physical limits at the rated operating condition. Therefore, the design process is highly iterative and, thus, a systematic approach has a high potential to reduce the time of the design phase significantly. In this article, a systematic design process is proposed for a modular, multimegawatt (MMW) HSIM with three radial active magnetic bearings. The process includes a traditional multidisciplinary design flow with extra critical aspects of MMW HS machines: manufacturability, bearing system, housing, and operating unit. In addition, the manufactured machine is reported. The proposed systematic design process is described, including several multidisciplinary critical design aspects of HS machinery. [ABSTRACT FROM AUTHOR]

High-speed (HS) electrical machines provide high system efficiency, compact design, and low material consumption. Active magnetic bearings (AMBs) bring additional benefits to the HS system, such as elimination of the friction losses, reduced wear and maintenance, and a built-in monitoring system. HS drivetrains are usually designed for specific applications and require a high level of integration. This paper describes a design method of the HS electrical machine supported by AMBs, considering their mutual influence on the system performance. The optimization procedure, which takes into account both the electrical machine and bearing designs, is developed. The optimization is based on a multiobjective genetic algorithm. The selected optimization parameters include the AMB and machine dimensions. The optimization objectives cover the electrical machine performance and the rotordynamics. The results of the proposed optimization algorithm are implemented in the constructed 350-kW, 15 000-r/min induction machine with a solid rotor supported by AMBs. The prototype tests verify the design and optimization results. [ABSTRACT FROM AUTHOR]

A method is presented for tooltip tracking in active magnetic bearing (AMB) spindle applications. The proposed tool tracking approach uses control of the AMB air gap to achieve the desired tool position. A μ-synthesis-based controller is designed for the AMBs with the goal of robustly minimizing the difference between the tool reference and estimated tool position. In such a way, the model-based control approach concurrently addresses the tracking problem and the inability to directly measure real-time tool position in the presence of machining disturbances. To ensure the tractability of the control problem, a model of the desired tracking dynamics is included in the plant. The method is demonstrated on a high-speed AMB boring spindle. To confirm the tool tracking capability, characteristic part geometries are traced including stepped, tapered, and convex profiles. Tool tracking is demonstrated for the rotating AMB spindle in the range of 90 μm. Also, static and dynamic external loading is applied to the spindle tool location to confirm the disturbance rejection ability of the closed-loop system. [ABSTRACT FROM PUBLISHER]

Accurate and updated knowledge of the electric machine parameters provides benefits in many applications, such as model-based control methods. This paper presents an online parameter estimation method for double-star interior permanent-magnet (IPM) machines supplied with voltage-source inverters (VSI). The estimation method is based on a decoupled D–Q model of the machine and a recursive least-squares (RLS) algorithm. Initial machine parameters are estimated at a standstill. Then, in the rotating operating state, the inductances and the flux linkage produced by the PMs are updated. The estimation in the operating state is performed with a flux-linkage-based approach. The experimental results are compared with the corresponding values obtained from finite-element analyses. The results show an acceptable agreement and demonstrate the feasibility of the estimation scheme to estimate the parameters of double-star PM machines. The parameters are validated by comparing experimental and simulated open-loop responses and steady-state torques. [ABSTRACT FROM PUBLISHER]