Redesign of Rotary Inductrack for Magnetic Train Levitation

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Redesign of Rotary Inductrack for 

Magnetic Train Levitation 

Bradley University 

Department of Electrical and Computer Engineering 

Senior Capstone Project 

Student: 

Glenn Zomchek 

Advisor: 

Dr. Anakwa


Overview 

– Background information 

– Purpose of Maglev System 

– Previous Work 

– Project Summary 

– Physical Design 

– Controls 

– Parts & Equipment


Overview (cont’d) 

– Specifications for New Maglev System 

– Issues Addressed 

– Tentative Schedule 

– References 

– Patents 

– Questions


Background Information 

The inductrack was first developed by Richard F. Post in 

the late 1990’s at Lawrence Livermore National 

Laboratory. 

– 20 meter test track for propulsion


Purpose of Maglev System 

Life-size Life size track and train propulsion system 

Low Speed Urban Maglev Program


Previous Work at Bradley University 

2003-2004 2003 2004 

– Paul Friend 

Initial research 

Equations developed 

Graphical User Interface (GUI) created in MATLAB 

Circular wire-rung wire rung inductrack attempted 

– Tony Pederson and Toby Miller 

Linear wire-rung wire rung inductrack attempted 

2005-2006 2005 2006 

– Dusty Funk and Kyle Getsla 

New support structure created 

Laminated sheets inductrack attempted

s 

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Small-Scale Small Scale Maglev System 

1 st 

goal 

st goal 

Project Summary 

– To demonstrate levitation 

2 nd 

goal 

nd goal 

– To use a position sensor to measure the 

displacement in height created by the train levitation. 

– Use the signal created as feedback to the DC motor 

to control the motor speed, creating a closed-loop 

closed loop 

system. 

– To use a digital force gauge to measure the force 

needed to levitate the train to a desired height.


Inductrack: Inductrack 

Physical Design 

Thin sheets of laminated aluminum 

wrapped around a wheel 

Slots cut every 2.2 cm to guide 

eddy currents 

Eddy currents created due 

to moving magnetic field


Machine Shop 

Tri-City Tri City Machine Products, Inc. 

– Joseph Richey 

President 

Tri-City Tri City Machine Products, Inc. 

1506 SW Washington Street 

Peoria, IL 61602 

Phone: 309 673-5589 673 5589 

Fax: 309 673-5592 673 5592

Wheel Design 

Wheel Design 



Levitation Speed 

– Levitation will occur at the “breakpoint 

velocity” 

– This breakpoint velocity is defined as the 

velocity when the levitation force is great 

enough to levitate the train off its rolling 

clearance height. 

– According to previous research, this 

breakpoint velocity = 23.2038 meters/second 

= 697.89 rpm


Maglev Train 

Mass = 0.375 kg 

Halbach array of magnets 

Magnet Strength: 1.21 Tesla 

Halbach wavelength, λ = 5.5 cm


Halbach Array 

When the Halbach array passes over the track, current is 

induced. The current induced in the track creates the 

magnetic field.


Support Structure 

Support structure used in 2005 

I will be dealing with the 

fabrication of the new 

support structure


Controls 

Overall System Block Diagram 

The Maglev System block consists of the train, Halbach array array 

of 

magnets, rotary wheel, drive unit, and DC motor.


Rotary Subsystem Block Diagram 

The rotary subsystem consists of AC power coming directly from from 

the 

wall into a drive unit which will control the DC motor. The DC motor 

will be connected to the rotary wheel to accelerate the wheel to a 

specified velocity.


Levitation Subsytem Block Diagram 

The levitation subsystem consists of the velocity of the wheel wheel 

creating an 

induced current which in turn creates an induced magnetic force to levitate 

the train. The feedback path will consist of a levitation constant. constant.


Motor 

Parts & Equipment 

– Model: 2Z846A 

115 VAC 

180 VDC 

Single Phase 

¾ HP 

Rated Speed: 2500 RPM 

Torque 18.9 lb. in. 

Motor provided by Bradley University


Parts & Equipment (cont’d) 

Position Transducer 

– Model: MLT002N3000B5C 

$234.36 

Max. Applied Voltage: 30 Vdc 

Electrical travel in inches: 2” 

Will measure the displacement of the train due to 

levitation



Digital Force Gauge 

– Model 475040 

$329 

5 digit LCD with reversible 

display to match any viewing angle 

Zero Adjust push-button 

push button 

Peak Hold switch 

Range: 176 oz, 5000 g, 49 Newtons 

(train begins levitating at ~4 Newtons) Newtons 

Will be used to measure the 

levitation force felt by the train



3M Hi-Strength Hi Strength 90 Spray Adhesive 

– $18 

Bonds most wood, particle board, 

metal, laminate, SBR rubber and 

many plastics including 

polyethylene and polypropylene. 

Various spray widths, from 1 inch 

to 12 inches can be achieved

Parts & Equipment Costs 

Parts & Equipment Costs 



Specifications for New Maglev System


Issues Addressed 

Adverse effect of steel rivets on bicycle wheel to 

the attraction of the Halbach array of magnets. 

Material selection for gap creation between steel 

rivets and inductrack. 

Wheel rotation with load must exceed ~700 rpm 

Stability of support structure to withstand fast 

rotational speeds of the wheel with little vibration 

Proper sensor placement on the Maglev system


Fall Semester Schedule 

Weeks 1-2 1 

Development of functional description 

deliverable. Research on previous 

Maglev work along with personal 

verification measurements. 

Weeks 3-5 3 

Development of specifications 

deliverable. Parts research for motors, 

position sensors, and force sensors. 

Development ideas for new Maglev 

system. 

Weeks 6-7 6 

Preparation for project proposal and 

oral presentation. Collaboration with 

mechanical technician for rebuilding of 

support structure.


Spring Semester Tentative Schedule 

Weeks 1-2 1 

Collaboration with mechanical 

technician for rebuilding of 

support structure. 

Weeks 3-5 3 

Complete Maglev system 

construction. 

Weeks 6-10 6 10 Train levitation. Experimental 

tests and measurements. 

Weeks 11-14 11 14 Development of feedback 

signals to create a closed-loop 

closed loop 

system. Preparation for oral 

presentation and final project 

report.


References 

[1] Paul Friend’s Senior Project Magnetic Levitation Technology 1 Final Report, 

12 May, 2004. 

[2] Paul Friend’s Senior Project Proposal, 12 December, 2003. 

[3] Paul Friend’s Project Proposal Presentation, 9 December, 2003. 2003. 

[4] Dusty Funk & Kyle Getsla’s Senior Project Magnetic Levitation Levitation 

Train 

Final Report, 2005. 

[5] Halbach, K., “Applications of permanent magnets in accelerators accelerators 

and electron 

storage rings,” Journal of Applied Physics, Physics, 

vol. 57, p. 3605, 1985. 

[6] Post, Richard F., Ryutov, Dmitri D., “The Inductrack Approach Approach 

to 

Magnetic Levitation,” Lawrence Livermore National Laboratory. 

[7] Yaskawa Electric Corporation. “User’s Manual,” Servo Selection and Data 

Sheets, Sheets, 

October, 2000.


Patents 

Richard F. Post 

Magnetic Levitation System for Moving Objects 

U.S. Patent 5,722,326 

March 3, 1998 


Inductrack Magnet Configuration 

U.S. Patent 6,633,217 B2 

October 14, 2003 


Inductrack Configuration 

U.S. Patent 629,503 B2 



Laminated Track Design for Inductrack Maglev System 

U.S. Patent Pending US 2003/0112105 A1 

June 19, 2003 

Coffey; Howard T. 

Propulsion and stabilization for magnetically levitated vehicles 

U.S. Patent 5,222,436 

June 29, 2003 

Coffey; Howard T. 

Magnetic Levitation configuration incorporating levitation, 

guidance and linear synchronous motor 

U.S. Patent 5,253,592 


Levi;Enrico; Zabar;Zivan; 

Air cored, linear induction motor for magnetically levitated 

systems 

U.S. Patent 5,270,593 

November 10, 1992 

Lamb; Karl J. ; Merrill; Toby ; Gossage; Scott D. ; Sparks; 

Michael T. ;Barrett; Michael S. 

U.S. Patent 6,510,799 

January 28, 2003

Questions?

Redesign of Rotary Inductrack for Magnetic Train Levitation

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