MAGNETIC SUSPENSION WITH FLUX FEEDBACK LINEARIZATION

Abstract: A magnetic actuator for providing a single-axis, non-contacting force capability with unconstrained cross-axis mobility utilises flux feedback force linearisation. Electromagnets (20, 22, 24 to 31) cooperating with an armature (24) suspended therebetween are energised by a bias flux and a signal derived from flux densities sensed in the air gaps. The bias flux density may be optimised to minimise the peak power required by the actuator. The flux density signals are applied in a closed force loop to provide a net force directly proportional to the commanded flux.

Description: This invention relates generally to magnetic suspensions or levitations for movable members. More specifically, the invention pertains to suspensions with unconstrained mobility in linear translation and a circuit using flux feedback for linearizing the net output armature force of a magnetic actuator adaptable to pointing and isolating instruments. A differential magnetic actuator provides a single-axis, non-contacting force capability which is insensitive to cross-axis translations (i.e. those axes perpendicular to the direction of the force field). It is comprised of at least two diametrically opposing electromagnets or half-stations acting on a movable armature disposed therebetween. Force is exerted on the armature when a closed magnetic field is established around each half-station core and the movable armature due to input coil current excitation Force exerted by each half-station is unidirectional and acts only in a direction to decrease the gap between itself and the armature. By using two half-stations in a diametrically opposing configuration, the net armature force is equal to the algebraic sum of the force components contributed by each half-station. The magnetic actuator exerts force on the armature along the axis perpendicular to the pole face. Armature motion along this axis is limited by the gap distance between each half-station. Translation along this axis would eventually result in the armature coming in contact with the actuator. However, in the cross-axes (i.e. those axes perpendicular to the axis of force) armature motion or translation is not physically limited by the magnetic actuator. The only requirement is that the armature maintains a magnetic path between the half-station pole faces. It is known to those skilled in the art that the net armature force of a differential magnetic actuator is inherently non-linear, being related to the squared functions of magnetising currents and gaps for the co-energy relationship, and to a squared function of gap flux densities for the energy relationship. Because of these inherent squared non-linearities, a significant problem arises in linearising the net output armature force of the differential magnetic actuator in response to an applied force command, i.e. to obtain an armature force proportional to the input signal. In providing linear force control on the armature of a differential magnetic actuator, previous control techniques have included force feedback and current/gap feedback. See, for example, EP-A-0,218,318. Force feedback incorporates a force sensor in a closed-loop configuration to linearise the net forces on the armature. The armature is physically tied to the payload through the force sensor. Any force exerted on the armature is transmitted through the force sensor to the payload. The sensor itself is typically a quartz crystal which varies an oscillator frequency in response to a tensile or compressive force. Force on the armature is controlled by modulating the magnetic flux density produced by each half-station. In this approach the force sensor, located between the suspended payload and armature, transmits a force signal across the magnetic gap which, through appropriate compensation, drives the flux producing coil current in each half-station. One drawback to this approach is that a harness assembly or a complex non-contacting telemetry system must be employed across the magnetic gap. The use of a harness assembly is undesirable since it can degrade actuator performance by acting as a shunt spring. Other drawbacks to this approach are that force sensors capable of a high bandwidth and resolution required for low level force control are costly, fragile, and require sophisticated support electronics. Further, because of their fragility, these sensors often require elaborate holding fixtures to protect them from damage during non-operational conditions. As another approach, current gap feedback force linearisation has been used. This technique is more common and utilises the relationship between magnetising current and air gap for a linear medium in an open force loop configuration. In this method, force is controlled through the co-energy relationship that armature force is proportional to the square of the magntising current and inversely proportional to the square of the gap distance. Any sensor capable of providing a signal proportional to gap position can be used. Previous applications have incorporated eddy current, capacitive, and inductive sensors. By employing both current and gap position sensors, the requirement for and disadvantages of a force sensor are eliminated. To remove the current squared non-linearity a bias current technique has been utilised. This consists of adding a flux producing bias current to one half-station and subtracting the same flux producing bias current from the diametrically opposite half-station. However, because of the open force loop configuration and square law relationships, both the position and current sensing signals, as well as squaring compensation circuitry, must be very accurate and linear over full operational conditions. Because of the squaring relationship percentage, force errors can be greater than twice the percentage position and gap errors that cause them. To implement the necessary gap feedback, position sensors are employed as described above. These sensors, because of their high accuracy requirements, are expensive and often require sophisticated compensation circuitry to achieve the necessary linearity over full operating conditions. Such an arrangement is disclosed in FR-A-2,417,797 in which a feedback circuit is employed for controlling current in a magnetic bearing, together with flux sensing means for providing a correction circuit. Additionally, because the applied armature force is related to the magnetic field established in the gap due to the input coil currents, a linear relationship between the input coil current and magnetic flux is required. Therefore non-linearities due to hysteresis and saturation between the magnetic flux and input coil current can seriously impact actuator performance. To attain the required linearity between the magnetic field and input coil current, core materials with low hysteresis properties are used. These materials however often require specialised processing and are-difficult to machine, which increases the actuator cost. Also, these low hysteresis materials tend to saturate at relatively low flux densities. As a result, a larger volume of core material is required to avoid saturation non-linearities, increasing the actuator weight. Finally, the current gap feedback force linearisation requires multiplication circuitry which is often undesirable because of errors introduced due to temperature variations. The present invention avoids the limitations of the prior art by utilising the energy relationship between force and magnetic flux density in the gaps between the halfstations and armature to linearise the net force. Flux density is measured by a Hall effect device. The present invention is defined in the appended claims and comprises apparatus for applying a force linearly proportional to an input command signal to the armature of a differential magnetic actuator. While the displacement of the armature is limited along an axis perpendicular to the plane of the armature, the armature is free for translation normal to the axial force. A force command signal representative of a desired armature force is applied to derive a flux command signal for providing control currents to electromagnetic coils of the magnetic actuator. A flux sensor is coupled to the core of each half-station for providing control signals corresponding to the actual flux density. The flux control signals and the flux command signals are applied to provide modified control currents in the half-station coils, thereby to provide a magnetic flux density which is linearly proportional to the force command signal. The flux command signals are applied to amplifier means via an opto-isolator. In a preferred embodiment, the apparatus includes compensation circuitry for gain scaling the force command signals, means for applying a predetermined bias flux, and gain correction means for augmenting the frequency bandwidth of the compensation amplifier. The present invention will now be described in greater detail, by way of example, with reference to the accompanying drawings, in which :- Figure 1 is a conceptual block diagram showing a flux feedback linearisation loop of the present invention, Figure 2 is a schematic diagram in cross section of an electromagnetic actuator suitable for use with the present invention, Figure 3 is an electrical schematic diagram in block form of circuitry for utilising a Hall effect device as a flux density sensor, Figure 4 is a block diagram showing a biasing and compensation circuitry of the present invention, Figure 5 is an electrical schematic diagram of a compensating amplifier, Figure 6 is an electrical schematic diagram of a pulsewidth modulator utilising an opto-isolator, and Figure 7 is a gain characteristic curve of a compensating amplifier as shown in Figure 5. In the present invention, armature force is controlled by implementing a closed flux loop around each half station. These flux loops ensure that the magnetic flux density in the gaps is linearly proportinal to a commanded input. To linearise the flux-squared term a bias technique is used. This consists of maintaining a constant bias flux in each half-station gap. The net force on the armature due to this bias flux is zero since both sides are equal in magnitude and diametrically opposing. Force on the armature is controlled by adding a flux command of a predetermined magnitude to one half-station and subtracting the same flux command magnitude from the diametrically opposite half station. The result is that the net armature force is proportional to the product of the bias flux and commanded flux as shown below: Let: B₁ = B BIAS + B CMD (1) B₂ = B BIAS - B CMD (2) where B BIAS = The applied bias flux and B CMD = The commanded flux. For a linear medium, force is proportinal to the square of the magnetic flux densities in the gaps between the half-stations and armature, as given in equation (3): where F NET = Net force exerted on armature (Newtons) A = Cross-sectional area of magnetic actuator pole face (square meters) µo= Permeability of free space (4πl0⁻⁷ Henries/meter) B₁,B₂ = Magnetic flux density at each half-station pole face (Tesla) Then Since the bias flux is held constant, the net force is directly proportional to the commanded flux. Therefore, the force produced by the differential electromagnet can be measured and controlled in a closed flux feedback loop by sensing the magnetic flux density produced by each half-station. Referring first to Figure l, a conceptual block diagram is shown of one feedback loop for driving a half-station. It will be appreciated that two such loops will be required for energising two half-stations comprising a magentic actuator. The magnetic actuator is comprised of four major components: a differential electromagnet l0, a flux sensor l2, compensation electronics l4, and an amplifier l6, all of which are described in further detail below with respect to Figure 4. Referring next to Figure 2, the differential magnetic actuator is comprised of an electromagnet having two identical stator pieces 20, 22 and a soft iron armature 24. The stator pieces 20, 22 are each made up of two identical coils 26, 27 and 28, 29 connected in series and wound around a magnetic core 30, 3l respectively. The armature 24 is an essentially planar piece of soft iron or other magnetic material placed between the pole faces 32-35. The flux density is preferably sensed by a Hall effect device 36, 37 placed on one pole face of each stator. A block diagram of the electronics required to drive the Hall effect device and obtain an output is shown in Figure 3. A current source 40 establishes a constant current in two leads 42, 43 of a Hall effect device 44. The voltage across the output terminals 45, 46 of the device 44 is proportional to the magnetic flux density. This voltage is amplified by a high gain differential amplifier 48 to produce a suitable signal 49 proportional to the flux density for processing by the control circuitry. Figure 4 shows the system of Figure l with details of scaling, bias and frequency compensating networks for driving the electromagnets of an opposing pair of half-stations. The function of this circuitry is to accept a voltage proportional to the desired force output F C , convert this voltage into two voltage B 1C , B 2C proportional to the flux density levels required to produce this force, compare the required flux density levels with the measured flux density levels at sensors 77, 79 to provide resultant outputs 62, 64, and through compensation amplifiers 66, 68 command the drive amplifiers 70, 72 to apply current to coils 74, 76 to produce the required flux density. The force command F C is converted to flux density commands by a gain scaling block 50 and adding bias flux density commands 52. The function of the bias command is to force the actuator to respond linearly to the force command. In operation, the unidirectional force exerted by each half station on the armature is given by: where F₁, F₂ = the forces exerted by each half station (Newtons) A = the actuator pole face area (square meters) µo = the permeability of free space (4πl0⁻⁷ Henries/metre) B₁,B₂ = the flux densities at the half-station pole faces (Tesla) Since each half-station is diametrically opposing with respect to the armature, the net armature force is the difference of the forces exerted by each half-station and can be described by The closed flux loops 78, 80 around each half-station of the magnetic actuator ensure a flux density level in the magnetic gaps equal to a referenced input B 1C , B 2C . This input is obtained by applying the sum and difference of a flux density bias 52 and scaled command input B CMD to summing junctions 54 and 58, respectively: B 1C = B BIAS + B CMD (9) B 2C = B BIAS - B CMD (10) Substituting these relationships into force equation (8) and simplifying yields. By holding B BIAS at a predetermined value, the scaling factor 50 between the force command (F C ) and the flux density command (B CMD ) is: Thus, the bias flux density added to the scaled force command produces flux density commands which energise the compensation and power amplifiers to produce a force equal to the commanded force. The bias flux density may be selected to minimise the peak power required by the actuator. Peak power occurs when the maximum force is commanded, therefore: which, assuming a linear actuator, is also given by where, g = the magnetic gap (metres) Thus, the peak powers is:- Taking the derivative of PMAX gives:- Setting the derivative equal to zero yields:- Therefore, the above value of B BIAS will minimise the peak actuator power. Referring now to Figure 5, the compensation amplifier U₁ comprises an integrator and a lead-lag network C₁R₂C₂. The integrator is used to reduce the dc force error and the lead-lag network is used to obtain increased bandwidth. The lead frequency is selected to cancel the low frequency pole produced by the resistance and inductance of the electromagnet, and the lag frequency is selected to assure control loop stability. The compensation network parameters chosen for the flux loops around each half station are dependent on the desired frequency response. Typically the closed loop response chosen is of the form: where ω O = the open loop crossover frequency δ = the damping coefficient S = the Laplace operator To design compensation circuitry for the desired closed loop response the frequency characteristics of the magnetic actuator must be known. These characteristics are dependent upon the geometry of the actuator and are in the form shown below for each half-station: where B OUT = the flux density at the pole face for a given output coil voltage V COIL = voltage applied across coil windings K p = is a gain constant with units of (Tesla/Volt) P₁,P₂ = are poles associated with the transfer function. For most actuator designs P₂ occurs at sufficiently high frequencies (typically > 2KHz) that it can be neglected; whereas P₁ occurs at low frequencies (typically < 10Hz) and must be compensated for. Thus each half station is conveniently viewed as having a freqeuncy characteristic in form To obtain the closed loop response identified in equation (18), the compensation design would be in the form: where the zero (Z₁) is chosen to cancel the low frequency pole (P₁) of the actuator and compensation gain (K C ) and compensation pole (P C ) are chosen for the desired open loop crossover bandwidth (ω O ) and damping coefficient (δ). A typical compensation amplifier frequency characteristic curve is shown in Figure 7. From equation (18) for unity gain of the power amplifier and flux sensing blocks, the closed loop characteristics would be: One possible operational amplifier realisation of this compensation design is shown in Figure 5. The output of the compensation amplifier 66, 68 is preferably connected to an optically coupled pulse-width modulated driver (Figure 6) to produce the desired fluxes and provide isolation between the low level command signals and the high current power amplifier. As current in either direction in the coil produces force in the same direction, since the force is a function of the square of the current, the amplifiers may by unipolar. The pulse width modulation results in high efficiency. The pulse width modulator is simply a comparator referenced to a triangle wave as shown in Figure 6. The output pulse widths of the comparator are a function of the input signal level. A suitable component for the comparator would be an integrated circuit LMlll as manufactured by National Semiconductor Corp., Santa Clara, CA 9505l, U.S.A. A suitable component for the opto-isolator would be the type 4N24, as made by Texas Instruments, Inc., Dallas TX 75265, U.S.A. The operation of the system is shown most clearly in Figure 4. A desired force F C is applied to block 50, where it is gain scaled and applied to two summing junctions 54, 58. A bias voltage from source 52 is added in junction 54 to scaled signal B CMD , and subtracted at junction 58 to provide force command signals B 1C and B 2C , respectively. Signals B 1C and B 2C energise the coils 74 and 76 and the flux densities produced thereby are sensed by the flux sensors 77, 79. The flux density signals are combined in junctions 56 and 60 with the corresponding force command signals B 1C and B 2C to drive the power amplifiers 70, 72 through compensation amplifiers 66, 68. The sensed flux values are thereby compared with the commanded flux density to increase or decrease the driving signal to the power amplifier, thereby producing the desired force level in linear relationship to the output force command signal. In summary, the present invention offers the following advantages over previous linearisation techniques: l) No requirement for sensitive, fragile, and costly force sensors. 2) No requirement for transmitting feedback information across the magnetic gap by the use of harness assemblies or complicated non-contacting telemetry systems. 3) No requirement for position sensors or multiplication circuitry in force linearisation. 4) The ability to use core materials exhibiting hysteresis and high saturation levels to realise smaller, lighter and less costly actuators. 5) High level power and low-level signal power are easily isolated using pulse width modulation techniques and optical couplers.

Claims: Apparatus for magnetic suspension of an armature (24) relative to a magnetic actuator, the actuator comprising a pair of opposing half-stations, each of which further comprise a magnetically permeable core having cooperable pole pieces (33,36; 34,35), the core carrying a pair of electromagnetic coils (26,27; 28,29) adapted, when energised, for conducting magnetic lines of flux between faces of the pole pieces and the armature (24), the pole pieces being spaced apart from the armature by an air gap, and the core being positioned to apply force along an axis perpendicular to the pole pieces for displacement of the armature, relative thereto, characterised in that the apparatus further comprises : a) means for providing a force command signal representative of a desired armature force, b) means (50,52,54,58) responsive to the force command signal for providing a flux command signal representative of a desired flux density, the flux command signal being coupled to supply control currents to said electromagnetic coils, c) means (77,79) coupled to each core for sensing the lines of flux and providing flux control signals representative of an actual flux density, d) means (48) coupled to receive the flux control signals and the flux command signals for modifying the control currents of the electromagnetic coils (26,27; 28,29), so as to produce a magnetic flux density linearly corresponding to the force command signal, and e ) amplifier means (66,68) for supplying the control currents, the amplifier means comprising e1) isolation means (81) for coupling the flux command signals to the amplifier means, e2) differential comparator means (82) having a first input for receiving a reference signal waveform, and a second input for receiving the flux command signals, and providing an output pulse having a pulse width proportional to the magnitude of the flux command signal, e3) light source means (84) coupled to receive the output pulse and to provide light pulse emissions, and e4) light sensor means (86) coupled to receive pulse emissions from the light source means and to provide a signal output proportional to the flux command signal, the signal output being electrically isolated from the flux command signal. Apparatus according to claim 1, characterized in that the means for providing a flux command signal comprises : a) means (50) for providing a corresponding gain scaled flux density command signal representative of a desired flux density at the armature (24), b) bias means (52) for providing a predetermined flux density command signal for maintaining a predetermined bias flux in said gap, c) means (54,58) for providing algebraic sums and differences of the desired flux density command signal and the predetermined flux density signal, and d) means (62,64) for providing the sums and differences to the means for receiving the flux control and flux command signals. Apparatus according to claim 1 or 2, characterised in that it further comprises gain compensating means (U1) for augmenting the frequency bandwidth of the means for deriving a flux command signal, the gain compensating means having a gain characteristic proportional to the ratio : where K C = the compensation amplifier gain; Z₁ = a predetermined impedance characterising a low frequency pole of a transfer function of the electromagnetic coil corresponding to the developed flux density as a function of voltage applied to the coil; P C = is a predetermined value representative of a desired bandwidth and damping coefficient; S = Laplace transform operator. Apparatus according to claim 2, or to claim 3 when appended to claim 2, characterised in that the bias means (52) further comprise means for supplying bias signals of opposite senses for energizing first and second ones of the pair of half-stations. Apparatus according to any of the preceding claims, characterised in that the flux sensor means further comprises a Hall effect device means (36,37). Apparatus according to any of the preceding claims, characterised in that the predetermined flux density command signal is selected to provide a magnitude corresponding to a predetermined force command signal. Apparatus according to claim 6, characterised in that the predetermined flux density command signal is selected to minimize the peak power required by the actuator in accordance with the expression : where B BIAS is the applied bias flux density in said gap in Teslas, N is the number of turns comprising the coil winding of the actuator, F MAX is the maximum force commanded, and µ0 is the permeability of free space (4π 10⁻⁷ Henries/metre). A method of driving an electromagnetic actuator of the type comprising a magnetically permeable armature (24) suspended between pairs of cooperating electromagnetic half-stations, characterised in that it comprises the steps of : a) applying a force command signal representative of a desired force to be applied to the armature. b) applying predetermined bias signals corresponding to a predetermined maximum force command. c) applying algebraic sums of the force command and bias signals to provide energisation to the half-stations, d) sensing the flux densities of air gaps between the armature and the half-stations, e) providing control signals from the sensed flux densities, f) providing an algebraic sum of the derived signals and the summed force command and bias signals to modify the energisation, the signals being applied in ratios such that the applied force is linearly proportional to the force command signal, g) providing amplifier means for supplying the control currents, and h) providing opto-isolation for coupling the flux command signals to the amplifier means.

Inventors: HAVENHILL, DOUGLAS DEAN, KRAL, KEVIN DALE
Applicants: HONEYWELL INC.
Application year: 1986
Main classification: F16C39
IPC codes: F16C39, B60L13