Professional Documents
Culture Documents
Levitation Capabilities
A. Abdel-Khalik, A. Massoud, A. Elserougi, and S. Ahmed
Abstract – Magnetic gearboxes (MGBs) are now a
powerful alternative to their conventional mechanical II. INTRODUCTION
counterparts in terms of reduced maintenance requirements,
improved reliability, tolerance to mechanical inaccuracies,
and inherent overload protection. MGBs have been proposed C OMPARED to a mechanical gearbox, the magnetic
gearbox offers reduced maintenance and improved
for numerous applications especially compact harsh reliability, lack of lubrication requirements, precise peak
environments subjected to severe shocks and vibrations. torque transmission, inherent overload protection,
MGB designed with high gear ratio for only one transmission physically isolated input and output shafts, misalignment
stage is an appropriate candidate for high speed applications.
tolerance, and low acoustic noise and vibration [1,2]. A
In this paper, the conventional planetary magnetic gearbox is
equipped with a three-phase winding to provide additional number of linear and rotary magnetic gears have been
magnetic levitation capabilities besides torque transmission. introduced over the years [1, 3, 4]. One of the promising
This can be tackled by adding a three-phase winding in the configurations is the rotary planetary configuration
space between the ferromagnetic pieces. The current in this initially proposed in [5]. A detailed comparison between
additional winding is controlled to provide decoupled axial this configuration and a mechanical planetary gearbox is
forces irrespective to the transmitted mechanical power. This addressed in [6]. It was shown that the magnetic gearbox
feature is important to reduce the mechanical losses
especially for high speed rotor and can be a viable method for can achieve comparable performance to its mechanical
vibration suppression. counterpart with the obvious benefits inherent in its
noncontact magnetic structure. On the other hand, torque
Index Terms-- Gearbox, magnetic planetary gear, density of this configuration falls significantly for gear
bearingless machines, permanent magnets, finite elements, ratios higher than about 20:1. In [3], a novel magnetic
speed reduction ratio, electric machines, AC machines. harmonic gearbox, which is similar to a mechanical
harmonic gearbox, was introduced to address the higher
I. NOMENCLATURE gear ratio limitations of the planetary magnetic gearbox.
pl Number of pole-pairs of the low-speed rotor An active torque density reaching 150 kN.m/m3 per stage
ph Number of pole-pairs of the high-speed rotor can be achieved when rare-earth permanent magnets are
ns Number of ferromagnetic pole pieces used in this configuration. Moreover, ripple free
F Force transmitted torque was obtained. The origin for this
Nl Speed of the low-speed rotor cycloid/harmonic gear concept is described in [7]. Despite
Nh Speed of the high-speed rotor their advantages, magnetic gears have received minimal
Nseg Speed of ferromagnetic pole-pieces industrial attention, mainly due to the perceived initial cost
Gr Gear ratio added by permanent magnets. However, their advantages
CT Cogging torque factor may warrant their application, especially when combined
I Current with a high-speed electrical machine resulting in a
J Current density desirable size/weight and cost effective solution. Hence,
As Slot area MGBs were proposed in applications as wind energy with
ac Conductor cross sectional area high speed generators [8] and a contra-rotating tidal
Ac Total conductor area turbine [9].
kfill Slot filling factor In high-speed electrical machines, the critical speed is a
Tcoil Number of conductors per slot main serious problem due to the significant induced
x, y xy radial displacements vibration on the rotor structure at that speed [10]. The self-
Peripheral angle bearing or bearingless machine is an electromagnetic
α, β Winding stationary frame device that supports its own rotor by magnetic forces
generated from windings on its stator [11]. The application
of bearingless motor in vibration suppression is proved to
be effective because the magnetic force is generated within
the motor itself [10]. The concept of bearingless motors
This work was supported by a National Priorities Research Program
(NPRP) grant from the Qatar National Research Fund (QNRF).
has been developed theoretically in [11]. Since then, the
A. S. Abdel-Khalik and A. Elserougi are with the Department of concept has been applied to synchronous reluctance,
Electrical Engineering, Faculty of Engineering, Alexandria University, induction, permanent magnet, disc-type bearingless,
Alexandria 21544, Egypt (e-mail:ayman@spiretronic.com; ahmed.abbas
@spiretronic.com). homopolar, hybrid, and consequent-pole bearingless drives
A. M. Massoud is with the Department of Electrical Engineering, [12-14]. Bearingless motors also represent the recent trend
Faculty of Engineering, Qatar University, Doha 2713, Qatar (e-mail: for miniaturization and the increasing cleanness
ahmed.massoud@qu.edu.qa).
S. Ahmed is with Texas A&M University at Qatar, Doha, Qatar (e-mail: specifications in chemical, pharmaceutical, biotechnology,
shehab.ahmed@qatar.tamu.edu). and semiconductor industry applications demand for high-
543
Slot Number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
A A A A C- C- C- B B B B A- A- A- C C C C B- B- B-
A A A C- C- C- C- B B B A- A- A- A- C C C B- B- B- B-
Fig. 2. Suspension winding layout
pl Nl ph N h ns N seg (1) ripple on performance. The higher the factor, the higher
For stationary ferromagnetic pole-pieces, the relationship the cogging torque is. This factor is defined as (4);
between the high speed and the low speed rotors is given 2p n
CT h s (4)
by (2), and the corresponding gear ratio is given by (3) Nc
ph N h pl N l (2) where Nc is the smallest common multiple between the
Nh pl ns ph number of poles on the high-speed rotor, 2ph, and the
Gr (3) number of ferromagnetic pole-pieces, ns. The minimum
Nl ph ph
value for such factor is unity, which constitutes a possible
good selection.
B. Electrical Port Circuit Design
The number of turns per coil is determined based on the
available slot area, As, and the allowable load current.
Depending on the recommended current density, J, and the
maximum load current, I, the conductor cross sectional
area is found from (5).
ac I J (5)
For a certain fill factor, the conductor area is given by (6).
Ac k fill As (6)
Hence, the available number of turns is given by (7).
Tcoil Ac ac (7)
The design parameters for the prototype gearbox are
given in Table I. Both the high and low speed rotors are
equipped with NdFeB permanent magnets with radial
(a) magnetization. The prototype is designed to obtain a gear
ratio of 9.5. For the selected 19/2 pole-pairs combination,
the required number of pole-pieces is 21. For this pole-
pairs combination, the cogging torque factor is found to be
unity, which is the minimum value for this factor [2].
Hence, a low torque ripple magnitude is expected for this
design, as will be shown form the FE simulation.
544
rotor. The required suspension will be much similar to that A. Flux Density Distribution
of conventional bearingless PM motor [26] and is shown in Fig. 5 shows the flux density distribution of the
Fig. 4. The differences between the detected displacements proposed gear for two values of the reference x- current
and the commands x* and y* are amplified by a PID component of the suspension winding, namely 0A and 2A.
controller to produce the required suspension winding It is evident that for Ix equals zero, the flux distribution f
current components Ix* and Iy*. Generally, the high speed the high speed rotor has a 4-pole distribution with
rotor radial position commands are set to be the center symmetrical distribution around the core periphery.
position in x- and y-axes, i.e., x* = 0, y* = 0. However, the 2-pole levitation winding current causes a
Hence, the radial suspension current commands are distortion in the flux distribution resulting in a radial force
transformed to the radial suspension winding current in the positive x direction. It is worthy to mention that the
commands iα* and iβ* based on the rotor angular and using back iron of the low speed rotor should be selected to avoid
(8). core saturation with Ix set to its maximum value.
i* cos 2 sin 2 ix* Fig. 6 shows the variation of the radial component of
* (8)
cos 2 i *y
flux density in the air gaps adjacent to the high speed and
i sin 2 low speed rotors as well as the flux density in the
Eventually, the three-phase currents are determined using ferromagnetic pole pieces, corresponding to the high speed
2- to 3-phase transformation. As depicted from (8) and as and the low speed pole-pair magnets respectively. It is
concluded from Fig. 3, the angular frequency of the evident that the two north poles in the inner airgap and in
suspension winding current is double the mechanical the x-direction are affected by the suspension winding
angular speed of the high speed rotor to ensure an average current, as shown in Fig. 6a. The flux density under the
radial force in the required direction. first pole is slightly increased while it decreases under the
second pole. However, the effect on the two south-poles in
VI. SIMULATION STUDIES the y-direction in neglected. The same effect on the flux
A two-dimensional magneto static finite element method density in the ferromagnetic pole pieces is also shown in
is employed for the simulation studies using JMAG- Fig. 6b. Finally, the effect on the air gap flux of the outer
Studio10. The transient module is used to simulate the air gap is much small.
performance with time of the proposed gear with magnetic
levitation assuming a negligible core loss for simplicity.
Rotary Encoder
Eddy current
Ix* Iα* Iu2* sensors
x* PID
i* cos 2 *
sin 2 i x Iv2* Current x
* 2Φ/3Φ hysteresis
Iy* i* sin 2
cos 2 i y Iβ* Iw2* controller
y* PID
Force
producing y
Current
winding
feedback
(a) (b)
Fig. 5. Flux density distribution (a) Ix = 0 and (b) Ix = 2A
545
1
low speed rotor, a corresponding x- component of the
radial force and a small y- component are generated. Since,
I = 2A
x
0.5
Finally, the unbalance pull force, which represents a
relation between the generated radial force and with the
0 radial displacement, is calculated. The unbalance pull force
is important because it is the cause of inherently unstable
-0.5 characteristics for magnetic suspension systems. This
relation is found by introducing a certain radial
displacement in the rotation axis of the high speed rotor
-1
0 60 120 180 240 300 360 while the winding suspension current is set to zero. FEA is
Peripheral angle, deg
(b)
then used to calculate the average induced pull force
caused by this eccentricity. This relation is plotted in Fig.
1.5
10b. This relation is approximately linear and its slope is
called the force-displacement factor. Because this factor is
FLux density (Outer air gap), T
546
23 200
Ix = 0
20
-100
19
-200
18
-300
17
0 0.002 0.004 0.006 0.008 0.01
-400
Time, s 0 0.002 0.004 0.006 0.008 0.01
(a) Time, s
(b)
186 Fig. 9. Radial force on low speed rotor (a) Ix = 0A and (b) Ix = 2A.
Low speed rotor torque, Nm
185.8 600
500
185.6
Radial Force, N
400
185.4
300
185.2 I=0
I=2 200
185
0 0.005 0.01 0.015 0.02
100
Time, s
(b)
0
Fig. 7. Transmitted mechanical torque for different suspension current 0 0.5 1 1.5 2 2.5 3
component Ix (a) high speed rotor and (b) low speed rotor. Ix , A
150 (a)
F
x 80
100 F
F , N (High speed rotor)
50
60
Radial Force, N
-50 40
xy
-100
20
-150
0 0.002 0.004 0.006 0.008 0.01
Time, s
0
(a) 0 0.1 0.2 0.3 0.4 0.5
500 Radial displacement, mm
(b)
400
Fig. 10. (a) Relation between Ix current component and radial force and
Fxy, N (High speed rotor)
300 (b) relation between radial displacement and radial force generated in high
speed rotor.
200
50
“Development of a high performance magnetic gear,” IEEE Trans. Ind.
Appl., vol. 41, no. 3, pp. 764–770, May/Jun. 2005.
0 [3] J. Rens, K. Atallah, S. D. Calverley, and D. Howe, “A Novel Magnetic
Harmonic Gear,” IEEE Trans. Ind. Appl., vol. 46, no. 1, pp. 206-212,
Jan./Feb. 2010.
-50 [4] R. Holehouse, K. Atallah, and J. Wang, “Design and Realization of a
Linear Magnetic Gear, ” IEEE Trans. Magn., vol. 47, no. 10, pp.
4171-4174, Oct. 2011.
-100 [5] K. Atallah and D. Howe, “A novel high-performance magnetic gear,”
0 0.002 0.004 0.006 0.008 0.01
Time, s IEEE Trans. Magn., vol. 37, no. 4, pp. 2844–2846, Jul. 2001.
(a)
547
[6] E. Gouda, S. Mezani, L. Baghli, and A. Rezzoug, “Comparative Study Bearing on a Two-Axis Actively Regulated Low-Speed Bearingless
Between Mechanical and Magnetic Planetary Gears,” IEEE Trans. Motor,” IEEE Trans. Energy Conv., vol. 26, no. 1, pp. 46-54, Mar.
Magn., vol. 47, no. 2, pp. 439–450, Feb. 2011. 2011.
[7] F. Jørgensen, T. Andersen, and P. Rasmussen, “The Cycloid Permanent [25] A. Chiba, T. Fukao, and M. Azizur Rahman, “Vibration Suppression of
Magnetic Gear,” IEEE Trans. Ind. Appl., vol. 44, no. 6, pp. 1659- a Flexible Shaft With a Simplified Bearingless Induction Motor Drive,”
1665, Nov./Dec. 2008. IEEE Trans. Ind. Appl., vol. 44, no. 3, pp. 745-752, May/Jun. 2008.
[8] N. W. Frank and H. Toliyat, “Gearing Ratios of a Magnetic Gear for [26] A. Chiba, T. Fukao, O. Ichikawa, M. Oshima, M. Takemoto and D.
Wind Turbines, ” in Conf. IEMDC 2009, pp. 1224-1230. Dorrell, “ Magnetic bearings and bearingless drives,” Newnes, An
[9] L. Shah, A. Cruden, and B. W. Williams, “A Variable Speed Magnetic imprint of Elsevier, 2005.
Gear Box Using Contra-Rotating Input Shafts, ” IEEE Trans. Magn., [27] Z.Q . Zhu, and D. Howe, “Influence of design parameters on cogging
vol. 47, no. 2, pp. 439–450, Feb. 2011. torque in permanent magnet machines, ” IEEE Trans. Energy Conv.,
[10] A. Chiba, K. Sotome, Y. Iiyama, and M. Azizur Rahman, “A Novel vol. 15, no. 5, pp. 407–412, Dec. 2000.
Middle-Point-Current-Injection-Type Bearingless PM Synchronous
Motor for Vibration Suppression,” IEEE Trans. Ind. Appl., vol. 47, no.
4, pp. 1700-1706, Jul./Aug. 2011.
X. BIOGRAPHIES
[11] A. Chiba, T. Deido, T. Fukao and M. A. Rahman, “An Analysis of
Bearingless AC Motors”, IEEE Trans. Energy Conv., vol. 9, no. 1, pp. Ayman S. Abdel-Khalik (SM’12) was born in Alexandria-Egypt in July
61–68, Mar. 1994. 1979. He received his B.Sc, and M.Sc. degrees in Electrical Engineering
[12] J. Asama, et. al, “Evaluation of a Bearingless PM Motor With Wide from Alexandria University, Egypt in 2001 and 2004 respectively. He
Magnetic Gaps,” IEEE Trans. Energy Conv., vol. 25, no. 4, pp. 957- received his Ph.D degree in May 2009 under a dual channel program
964, Dec. 2010. between Alexandria University and Strathclyde University, Glasgow, UK.
[13] A. Laiho, A. Sinervo , J. Orivuori, K. Tammi, A. Arkkio, and K. Dr. Abdel-khalik is currently a lecturer in Electrical Engineering
Zenger, “Attenuation of Harmonic Rotor Vibration in a Cage Rotor Department, Faculty of Engineering, Alexandria University. In 2009, he also
Induction Machine by a Self-Bearing Force Actuator,” IEEE Trans. joined Spiretronic LLC as a senior research scientist. His research interests
Magn., vol. 45, no. 12, pp. 5388-5398, Dec. 2009. are electrical machine design, electric machine simulation, mathematical
[14] Y. Asano, et. al, “Development of a Four-Axis Actively Controlled modeling and electric drives.
Consequent-Pole-Type Bearingless Motor,” IEEE Trans. Ind. Appl.,
vol. 45, no. 4, pp. 1378-1386, Jul./Aug. 2009.
[15] T. Nussbaumer, P. Karutz, F. Zurcher, and J. W. Kolar, “Magnetically Ahmed Massoud (SM’11) received the B.Sc. (first class honors) and M.Sc.
Levitated Slice Motors—An Overview, ” IEEE Trans. Ind. Appl., vol. degrees from the Faculty of Engineering, Alexandria University, Egypt, in
47, no. 2, pp. 754-766, Mar./Apr. 2011. 1997 and 2000, respectively, and the Ph.D. degree in electrical engineering
[16] B. Warberger, R. Kaelin, T. Nussbaumer, and J.W. Kolar, “50 Nm / from the Computing and Electrical Department, Heriot-Watt University,
2500 W Bearingless Motor for High-Purity Pharmaceutical Mixing,” Edinburgh, U.K., in 2004. From 2005 to 2008, he was a Research Fellow at
IEEE Trans. Ind. Electron., vol. 59, no. 5, pp. 2236-2247, May 2012. Strathclyde University, Glasgow, U.K. From 2008 to 2009, he was a
[17] L. Chen and W. Hofmann, “Speed Regulation Technique of One Research Fellow at Texas A&M at Qatar, Doha, Qatar. From 2009 to 2012,
Bearingless 8/6 Switched Reluctance Motor with Simpler Single,” he was an Assistant Professor at the Department of Electrical Engineering,
IEEE Trans. Ind. Electron., vol. 59, no. 6, pp. 2592-2600, Jun. 2012. College of Engineering, Qatar University, where he is currently an Associate
[18] F. Zurcher, T. Nussbaumer, and J. W. Kolar “Motor Torque and Professor in the same department. His research interests include Power
Magnetic Levitation Force Generation in Bearingless Brushless Electronics, Energy Conversion, Renewable Energy and Power Quality.
Multipole Motors, ” Accepted for future publication in IEEE/ASME
Trans. Mechatronics. Ahmed A. Elserougi received the B.Sc. , M.Sc. and Ph.D. degrees in
[19] X. L. Wang, Q.-C. Zhong, Z. Q. Deng and S. Z. Yue, “Current- electrical engineering from the Faculty of Engineering, Alexandria
controlled Multi-phase Slice Permanent Magnetic Bearingless Motors University, Egypt, in 2004, 2006 and 2011, respectively. He is currently a
with Open-circuited Phases: Fault-Tolerant Controllability and its lecturer at the Electrical Department, Faculty of Engineering, Alexandria
Verification,” IEEE Trans Ind. Electron., vol. 5, no. 5, pp. 2059-2072, University, Egypt. His research interests include Power Quality, HVDC and
May 2012. FACTS, Renewable Energy and Electric power utility.
[20] T. Reichert, T. Nussbaumer, and J. W. Kolar, “Bearingless 300-W
PMSM for Bioreactor Mixing,” IEEE Trans. Ind. Electron., vol. 59, Shehab Ahmed (SM'12) was born in Kuwait City, Kuwait in July 1976. He
no. 3, pp. 1376-1388, Mar. 2012. received the B.Sc. degree in Electrical Engineering from Alexandria
[21] E. F. Rodriguez and J. A. Santisteban, “An Improved Control System University, Alexandria, Egypt, in 1999; the M.Sc. and Ph.D. degrees from
for a Split Winding Bearingless Induction Motor,” IEEE Trans. Ind. the Department of Electrical & Computer Engineering, Texas A&M
Electron., vol. 58, no. 8, pp. 3401-3408, Aug. 2011. University, College Station, TX in 2000 and 2007, respectively. From 2001
[22] M. Ooshima and C. Takeuchi, “Magnetic Suspension Performance of a to 2007, he was with Schlumberger Technology Corporation working on
Bearingless Brushless DC Motor for Small Liquid Pumps,” IEEE downhole mechatronic systems. He is currently an Assistant Professor with
Trans. Ind. Appl., vol. 47, no. 1, pp. 72-78, Jan./Feb. 2011. Texas A&M University at Qatar, Doha, Qatar. His research interests include
[23] M. T. Bartholet, T. Nussbaumer, and J. W. Kolar, “Comparison of mechatronics, solid-state power conversion, electric machines, and drives.
Voltage-Source Inverter Topologies for Two-Phase Bearingless Slice
Motors,” IEEE Trans. Ind. Electron., vol. 58, no. 5, pp.1921-1925,
May 2011.
[24] J. Asama, T. Asami, T. Imakawa, A. Chiba, A. Nakajima, and M.
Azizur Rahman, “Effects of Permanent-Magnet Passive Magnetic
548