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Design and Implementation of a Low-Cost Active Magnetic Bearing

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Abstract

Background

This work presents the design and experimental data results of a functional rotating machine prototype supported by active magnetic bearings (AMBs), whose digital data acquisition and control system were entirely designed using a digital signal processing (DSP) microcontroller and other low-cost electronic components.

Situating the case

From studies on rotordynamics, AMBs, and control engineering, a computer code devoted to the design of AMBs was implemented.

Methodology

Subsequently, the characterization of the electronic components with the potential of application to the development and integration of the submodules of the control electronic system was carried out. Then, the three-dimensional mechanical design was performed to get the manufacturing plans and to allow for the rotordynamic analysis. Then, the design of the analog power control signal processing submodule was performed, as required to develop the digital-to-analog converter–serial peripheral interface (DAC-SPI) submodule (hardware and firmware) due to the limitation of the number of DAC outputs available on the microcontroller unit (MCU) with DSP features.

About the case

Experimental tests were performed with the rotor system based on the proportional–integral–derivative (PID) control parameters calculated in the numerical/computational model implemented in the MATLAB®/Simulink environment. The obtained results demonstrated that the AMB was able to support the shaft operating at two different rotation speeds, namely 1500 and 1800 RPM. Under these conditions, the maximum vibration amplitude of the shaft reached 450 µm and 300 µm, respectively. Additionally, it was demonstrated that the design and construction of a functional rotating machine supported by AMBs using low-cost electronic hardware are feasible and constitute the main contribution of the present paper. The detailed discussion on the design of the associated hardware and firmware can be also considered as an important contribution of the present contribution.

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Acknowledgements

The authors would like to thank Petrobras, CNPq, FAPEMIG, and CAPES (INCT-EIE) for the financial support of the present contribution. The authors also would like to thank the companies Foz do Chapecó, Baesa, Enercan and Ceran for technical and financial support, through the Research and Development project PD-02949-3007/2022 with fundings from ANEEL's R&D program.

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Authors and Affiliations

  1. LMEst-Structural Mechanics Laboratory, School of Mechanical Engineering, Federal University of Uberlândia, Av. João Naves de Ávila, 2121, MG, 38408-100, Uberlândia, Brazil

    M. V. Mancuzo, R. M. Finzi Neto, A. A. Cavallini Jr. & V. Steffen Jr.

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  1. M. V. Mancuzo
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  2. R. M. Finzi Neto
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  3. A. A. Cavallini Jr.
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  4. V. Steffen Jr.
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Correspondence to A. A. Cavallini Jr..

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Mancuzo, M.V., Finzi Neto, R.M., Cavallini, A.A. et al. Design and Implementation of a Low-Cost Active Magnetic Bearing. J. Vib. Eng. Technol. 12, 2851–2864 (2024). https://doi.org/10.1007/s42417-023-01018-z

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