At present, the range of CNC machine tools has become quite comprehensive, with a wide variety of specifications. According to incomplete data, there are over 400 different types available. The classification of these machines can be based on various criteria, but in general, four main methods are commonly used. This article introduces the magnetic levitation technology, focusing on its application in spindle systems.
The paper discusses the composition and working principle of the magnetic suspension spindle system, and presents a new digital controller design that enhances the traditional PID control. The core component is TI's TMS320LF2407A microcontroller, and the system includes a five-degree-of-freedom magnetic suspension structure. Using the C2000 platform, an intelligent PID controller is developed. Theoretical analysis shows that this intelligent controller improves control performance and achieves higher precision.
Active magnetic suspension bearings (AMBs) are a multidisciplinary technology, representing advanced mechatronics. Compared to conventional bearings, they offer advantages such as no contact, no friction, high speed, and high precision. Traditional bearings suffer from wear and require replacement, while oil-lubricated bearings may leak over time, causing environmental issues. Magnetic bearings avoid these problems, making them eco-friendly. They have broad applications in aerospace, transportation, medical, and manufacturing industries, with many examples abroad.
A magnetic suspension bearing system consists of a controller, rotor, electromagnet, sensor, and power amplifier. The controller is the most critical part, determining the system's overall performance. It affects dynamic behavior, stiffness, damping, and stability. There are two types: analog and digital controllers. While analog controllers are widely used in China and provide some stability, they have limitations compared to digital ones: they are hard to adjust, difficult to implement complex control, cannot handle multiple degrees of freedom simultaneously, lack interchangeability, and consume more power and space. These drawbacks limit their use, making digital control the future trend.
Over the past three decades, control theory has advanced significantly. Recent research on magnetic bearing control laws has made notable progress. Foreign countries employ techniques like conventional PID, PD, adaptive control, and H∞ control. In China, the main approaches are PID, PD, and H∞, though no reports confirm successful H∞ application in magnetic bearings.
Globally, foreign companies and research centers, such as SKF and NASA, lead in magnetic bearing development. SKF uses adaptive control, suitable for loads of 50–2500N and speeds up to 100,000 rpm. NASA has been researching magnetic levitation for aerospace applications, including rocket engines and propulsion systems. In contrast, China lacks domestic manufacturers, highlighting the need for increased investment to catch up.
Domestically, research on magnetic bearing control began later. Most systems still use conventional PID or PD control, with limited accuracy and difficulty in tuning. Adjusting parameters like KP, KI, and KD is cumbersome. To make magnetic bearings user-friendly, the controller must be intelligent, combining hardware and software advancements. Making it simple to use, like a "fool-proof" device, is essential for broader adoption.
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