2011 Third International Conference on Measuring Technology and Mechatronics Automation

Integrated Design and Research of Active Magnetic Bearing-Sensor

Zhang Gang, Jiang Dede, Ruan Juan, Yin Qingzhen, Zhang Xue, Wang Chunlan
Bearing Research Institute, School of Mechatronics Engineering and Automation, Shanghai University, Shanghai, 200072, China zg@shu.edu.cn; gzhang@mail.shu.edu.cn
AbstractBecause of shortages when the conventional Eddy Current Sensor used in the Active Magnetic Bearing (AMB) system, a new kind of Differential Eddy Current Displacement Sensor (DECDS) which is integrated with the AMB is designed in this thesis. And the characteristics of the DECDS for AMB system has been studied. A correction instrument of static characteristics has been designed. During the experiments of static characteristics of the DECDS, the sensitivity, linearity, hysteresis and repeatability are researched. Keywords-Active Magnetic Bearing (AMB); Differential Eddy Current Displacement Sensor (DECDS); Sensitivity

distance from the conductor to the coils. What need to be said is that the two coils need to be the same in electrical specifications and geometric dimensions. Figure 1(b) shows the simplified diagram for schematic of DECDS.
Coil 1

Measured Conductor

I. INTRODUCTION Eddy Current Sensor (ECS) is described which operates on the induction principle of eddy current. It is widely used in the system of Active Magnetic Bearing (AMB)[1]. The performance of the ECS affects the control precision of AMB system directly. The traditional ECS used in AMB always set one sensor at a degree of freedom and have single probe structure. Probe is installed inside of magnetic bearing while preamplifier is placed outside of it. They are connected by shielded cable[2]. This paper presents a new differential structure of the eddy current displacement sensor which is different from the traditional one. It set two sensor probe at one degree of freedom. The two probe inductance coils are connected in a signal processing circuit. And the sensor probes and signal processing circuits are integrated within the magnetic bearings[3]. The sensor can work to achieve differential operation, overcome the impact of measurement error E0, achieve large-signal transmission, and avoid shielded cable. The sensor can make the entire volume of magnetic bearing system more compact, more convenient to use and install. The number of cables can also be reduced, which lays good foundation for cost reduction and productization of the magnetic bearing system. II. WORKING PRINCIPLE OF NEW DIFFERENTIAL STRUCTURE OF THE EDDY CURRENT SENSOR Figure 1(a) shows the schematic of DECDS structure. The two identical high-frequency detection inductors share one measured conductor, which constitutes differential structure of the eddy current sensor. The two probe inductance coils of DECDS are connected to the AC bridge arms. Suppose the equivalent inductance of the coil 1 is set to L1, equivalent resistance of the coil 1 is set to RL1, the equivalent inductance of the coil 2 is set to L2, equivalent resistance of the coil 2 is set to RL2. The other two resistance are R1 and R2, and here R1=R2. x1 x2 respectively show the
978-0-7695-4296-6/11 $26.00 2011 IEEE DOI 10.1109/ICMTMA.2011.395 433
Coil 2

1(a)

1(b) Figure 1. Schematic of DECDS and its simplified diagram

The input voltage of the bridge is set to U i , and the x output voltage of the bridge is set to U O , then we can know
x

UO

x x R2 R L 2  jZ L 2 Ui Ui R1  R 2 R L 1  R L 2  j Z ( L1  L 2 ) ( R 2 R L 1  R 1 R L 2 )  j Z ( L1 R 2  L 2 R 1 ) x Ui ( R 1  R 2 )[ R L 1  R L 2  j Z ( L1  L 2 )]

When the measured conductor is in equilibrium position, x1=x2. Because of the symmetry of DECDS, we can know that L1=L2=L RL1 RL2 R , then the output voltage
x

When the measured conductor is not in equilibrium position, move upward 'x ( 'x is very small) it leads to variation 'L of the coil inductance

L1 L2

L  'L L  'L

At this point, the output voltage of sensor changes x x ( R . L 1  R L 2 )  j Z ( L1  L 2 ) UO xU i 2 ( R L 1  R L 2 )  2 j Z ( L1  L 2 )

( R .L1  R L 2 )  2 jZ ' L 2 ( R L1  R L 2  2 jZ L ) xU
x i

Preamplifier

Probe

III. INTEGRATED DESIGN OF ACTIVE MAGNETIC BEARINGSENSOR Figure 2 shows the structure diagram of the integrated design sensor inside of the magnetic bearings.

3(a) External coil type of probe framework

3(b) Internal coil type of probe framework Figure 3. Three-dimensional diagram of the DECDS structure

Figure 2. Integrated structure diagram of magnetic bearing-sensor

To more clearly demonstrate the DECDS structure and its location in the magnetic bearing, the figure omits the front cover of magnetic bearing. Shown in Figure 2, the sensor consists of two parts, namely the probe coil framework (including coil) and preamplifier (sensor signal conversion circuit). In the figure, "1" is the differential sensor coil probe, a total of four. They are evenly distributed in the sensor probe framework 2. Each of the two coils is in a group, what is to say that a degree of freedom has two probe coils for the differential test. The down-leads of the probe coils solder directly to the sensor signal conversion circuit. As the distance from the probe coil to the signal conversion circuit is very short and the transmission signal is large enough, so there is no need to use shielded cable then. The probe use non-metallic materials and interference fit with the preamplifier"3". In the figure, "4,5,6" are magnetic bearing jacket, a iron core made from silicon steel and the back cover. A. Design of the Probe The probe of DECDS consists of two parts: probe framework and probe coil. Just as the name implies probe framework is for fixing probe coil. There are two ways to connect them, shown in Figure 3.

Figure 3(a) shows the external coil type of probe framework. The coil winds on a small slot from the probe framework. Then the framework is connected with the screw. Figure 3(b) shows the external coil type of probe framework. The coil is directly buried inside the probe framework. External coil type one would be better at the development phase in the sensor experiments. B. Structure of Coil Framework and Technology and Process of Coil Manufacturing Figure 4 shows the schematic diagram of the coil framework. The front of the small slot is used for probe coil winding. The down-leads of the probe coil would go across from the two oblique holes and be soldered directly to the sensor conversion circuit. The thread part at the back end is used to fix the coil framework to the probe framework.

Figure 4. The structural diagram of the probe coil

The performance of DECDS is influenced by the coil structure parameters. During the experiment, to test the sensor performance is to better meet the requirements of magnetic bearings. Sensor probe coils need to update and re-

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winding, which would easy be resulting in longer design cycle, waste and make costs. The new way introduced in this article could eliminate the need for a large number of custom-made for the experimental probe by changing the diameter of the small slot. Shown from figure 5(a), the diameter of the small slot is added up from 2mm to 3mm. Or by changing the width of the slot we can change the height of the coil. Figure 5(b) shows width of the slot is reduced from 1.8mm to 0.8mm. Figure 6 is the experimental probe coil.
Thickening
Rubber G k t

The instrument is composed of the base of the statics, test disk, spiral micrometer, left and right probe, etc. It is worked mainly through changing the inputs of the screw micrometer to change the inputs of the sensor. Then it is matched with the conversion circuit to test the static characteristics. As it is shown in Figure 8~10.

5(a)

5(b) Figure 8. Sensor static characteristics test rig

Figure 5. Diagram of two ways to change coil diameter or height

Figure 6. The experimental probe coil

IV. THE EXPERIMENTAL STUDY OF DECDS A. Design of Correction Instrument of Static Characteristics Static characteristics are the basic characteristics of sensor. As this developed DECDS has two probes for each degree of freedom, traditional single-probe eddy current sensor apparatus can not be used in the experiment study. A two-probe DECDS static characteristics test apparatus has been designed. Its structure is shown in Figure 7.
Test Disk Spiral Micrometer

Figure 9. The Differential Eddy Current Displacement Sensor (DECDS)

Probe Framework

Circuit Board

Left Probe Right Probe

Figure 10. The Picture of DECDS

Base

Figure 7. Correction instrument of static characteristics for DECDS

B. Sensitivity and Linearity of DECDS According to the experimental data measured in Table 1 and Table 2, static calibration curve can be drawn by using Matlab software. According to the experimental data and

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calibration curves we can have the static characteristics of sensor sensitivity, linearity, repeatability, hysteresis, etc.
Table 1 Experimental data of different coil groups

Repeatability of the sensor are discussed below:

Table 2 Repeatability of experimental data (coil group 2 #)

Group No. Distance (mm) (

Positive Negative Positive Negative Positive Negative Route 1 Route 1 Route 2 Route 2 Route 3 Route 3 -12.38
Group1# Group 2# Group 3# Group 4# Group 5#

-12.44 -9.73 -7.47 -4.8 -2.5 0.1 2.01 4.23 6.47 8.95 11.33

-12.44 -9.76 -7.43 -4.76 -2.5 0.04 2.1 4.21 6.55 9.1 11.39

-12.47 -9.68 -7.45 -4.81 -2.56 0.06 2.05 4.19 6.57 8.97 11.39

-12.47 -9.69 -7.41 -4.75 -2.49 0.05 2.09 4.19 6.5 9.05 11.4

-12.41 -9.66 -7.46 -4.78 -2.55 0.08 2.07 4.23 6.51 9.02 11.4

-9.72 -7.42

0 0.15 0.3 0.45 0.6 0.75 0.9 1.05 1.2 1.35 1.5

-14.01 -10.98 -7.63 -4.85 -2.55 0.33 2.47 5.09 7.81 10.52 13.05

-12.38 -9.72 -7.42 -4.71 -2.43 0.12 2.07 4.29 6.45 9.03 11.33

-11.37 -9.58 -7.35 -4.88 -2.88 -0.03 2.27 4.21 6.89 9.19 11.02

-8.22 -6.35 -4.83 -3.39 -1.88 -0.09 1.15 2.72 4.07 5.51 7.58

-7.21 -5.89 -4.59 -3.12 -1.55 -0.19 1.33 2.95 4.31 5.66 6.71

-4.71 -2.43 0.12 2.07 4.29 6.45 9.03 11.33

Figure 11 shows the coil group 1# static experimental data line graph.
Raw Data ___Fitting Curve Output Voltage (V)

According to the experimental study of DECDS, the analysis of the data shows that the developed differential eddy current sensor has great static characteristics. Especially when we choose the proper coil, the sensor can get a high sensitivity and large linearity. The experiment inevitably have some errors, these errors may come from the coil winding process, human error and other visual error, the performance of sensor have been affected. But generally speaking, the static performance index can meet theoretically the requirements of magnetic bearing system. V. CONCLUSIONS

Distance

Figure 11. Line graph of group 1#

C. Hysteresis and Repeatability of DECDS Figure 12 shows the hysteresis characteristics:

Sensor is a key component of the active magnetic bearing system. Its performance will directly affect the entire control precision of the system. Because of shortages when the conventional Eddy Current Sensor used in the AMB system, DECDS is designed that the probes and signal processing circuits are integrated within the magnetic bearing. It lays good foundation for cost reduction and productization of the magnetic bearing system. REFERENCES
[1] [2] J.Boehm,R.Gerber,N.R.C.Kiley.Sensors for Magnetic Bearings [J]. IEEE Transactions on Magnetics, Vol.29, No.6, November, 1993 Liu Chunyan. Developmental Research Eddy Current Sensor used in Active Magnetic Bearing.[D]: [Master's Thesis]. Xian: Xian Jiaotong University, 2003 Wang Chunlan. Structure Design and Characteristic Research of Differential Eddy Current Sensor used in AMB. [D]: [Master's Thesis].Shanghai: Shanghai University, 2006

Output Voltage (V)

Positive Route Data Negative Route Data

[3]

Distance Distance

Figure 12. Hysteresis characteristics

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