At present, the variety of CNC machine tools is nearly complete, with a wide range of specifications. According to incomplete statistics, there are over 400 different types available. Classification can be performed using various principles, but in general, four common methods are widely used. This article focuses on the main aspects of magnetic levitation technology.
The paper introduces the structure and working principle of the magnetic suspension spindle system, and proposes an improved digital controller design based on traditional PID control. The core component is TI's TMS320LF2407A, and a hardware block diagram for a five-degree-of-freedom magnetic suspension spindle system is presented. Using the C2000 platform as a development base, an intelligent PID controller was designed. Theoretical analysis shows that this intelligent PID controller achieves better control performance and meets higher precision requirements.
Active magnetic suspension bearings (AMB) are a multidisciplinary technology, representing a key example of mechatronic systems. Compared to conventional bearings, magnetic suspension bearings offer several advantages: they are contactless, frictionless, capable of high-speed operation, and provide high precision. Traditional bearings suffer from wear over time, requiring frequent replacement, while oil-lubricated bearings may leak, causing environmental issues. Magnetic bearings eliminate these problems, making them an eco-friendly option. Additionally, they have broad applications in aerospace, transportation, medical equipment, and manufacturing.
The magnetic suspension bearing system consists of five key components: the controller, rotor, electromagnet, sensor, and power amplifier. Among these, the controller is the most critical, as it determines the overall performance of the system. The control algorithm affects dynamic behavior, stiffness, damping, and stability. There are two types of controllers: analog and digital. While analog controllers are still commonly used in China, they have several disadvantages compared to digital controllers, such as difficulty in adjustment, limited complexity in control algorithms, inability to manage multiple degrees of freedom simultaneously, poor interchangeability, and higher power consumption and size. These limitations hinder the widespread adoption of magnetic bearings, making digital control the future trend.
In recent decades, control theory has advanced rapidly and been widely applied. Research on magnetic suspension bearing control laws has made significant progress. In foreign countries, control strategies include conventional PID, PD, adaptive control, and H∞ control. In China, the main approaches are PID, PD, and H∞, although no successful application of H∞ control in magnetic suspension systems has been reported yet.
Looking at current developments, foreign countries lead in both research and commercialization. Companies like SKF and NASA have been actively involved in magnetic bearing R&D for many years. For instance, SKF uses adaptive control in its products, which operate within a range of 50–2500N, speeds up to 100,000r/min, and temperatures below 220°C. NASA has conducted long-term research on magnetic levitation, particularly in aerospace applications, including rocket engines and propulsion systems. Their achievements include a rocket reaching 643–965km/h on a magnetic levitation track. In contrast, China lacks domestic manufacturers of magnetic suspension bearings, highlighting the need for increased investment in research and development.
Domestic research on magnetic bearing control systems started later, and most current systems rely on conventional PID or PD control. PIDD is also used in some circuits, but the control accuracy remains relatively low. Each system requires individual tuning of KP, KI, and KD, which is cumbersome and inconvenient for users. To make magnetic bearings more accessible and user-friendly, they must be developed into "fool-proof" devices. This requires intelligent controllers, combining both hardware and software improvements to enhance flexibility, reduce size, and lower power consumption. Ultimately, the goal is to achieve smarter, more reliable, and more widely applicable magnetic suspension systems.
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