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Novel High-Speed, Lorentz-Type, Slotless Self-Bearing Motor

Novel High-Speed, Lorentz-Type, Slotless Self-Bearing Motor

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<strong>Novel</strong> <strong>High</strong>-<strong>Speed</strong>, <strong>Lorentz</strong>-<strong>Type</strong>, <strong>Slotless</strong> <strong>Self</strong>-<br />

<strong>Bearing</strong> <strong>Motor</strong><br />

T.I. Baumgartner, A. Looser, C. Zwyssig, and J.W. Kolar<br />

Power Electronic Systems Laboratory<br />

ETH Zurich<br />

CH-8092 Zurich, Switzerland<br />

baumgartner@lem.ee.ethz.ch<br />

Abstract — Active magnetic bearings are a preferred choice for<br />

supporting rotors spinning at high-speed due to low friction<br />

losses and no wear. However, the rotational speed in previous<br />

bearing topologies has been limited by complex rotor<br />

constructions, high rotor losses, or position control instabilities at<br />

high speed. This paper presents a novel <strong>Lorentz</strong>-type, slotless<br />

self-bearing motor concept which overcomes most limitations of<br />

previously presented high-speed AMBs. An analytical model for<br />

motor torque and bearing forces is presented and a design for<br />

500 000 rpm is verified with FE simulations, showing<br />

exceptionally low negative stiffness cross coupling. Finally, a<br />

prototype system is described.<br />

I. INTRODUCTION<br />

Ultra-high-speed electrical drive systems are developed for<br />

new emerging applications, such as generators/starters for<br />

micro gas turbines, turbo-compressor systems, drills for medical<br />

applications, and spindles for machining and optical<br />

applications. Typically, the power ratings of these applications<br />

range from a few watts to a few kilowatts, and the speeds from<br />

a few tens of thousands of rpm up to a million rpm, which<br />

results in machine rotor diameters in the Millimeter area [1].<br />

The biggest remaining challenge is a bearing that can support<br />

such rotors with low losses and a long lifetime. The active<br />

magnetic bearing (AMB) is a preferred choice due to the<br />

contactless operation which leads to low friction losses and no<br />

wear, the ability to operate in vacuum, and the controllability<br />

which allows for cancellation or damping of instabilities.<br />

There are several feasibility studies and theoretical designs<br />

for high-speed magnetic bearings, such as a 500 000 rpm<br />

homopolar AMB concept in [2] and a comparison of long and<br />

short AMB rotors in [3]. However, there are only few<br />

publications with experimental results. [4] achieved a speed of<br />

64 000 rpm with a heteropolar bearing and a homopolar<br />

bearing in [5] ran at 120 000 rpm.<br />

To the authors knowledge no AMB presented in literature<br />

has achieved rotational speeds above 120 000 rpm, the biggest<br />

challenges are the high rotor losses, the disintegration of the<br />

rotor due to a complex rotor structure, and instabilities due to<br />

high frequency excitation and limited controller bandwidth.<br />

Therefore, in this paper, a novel slotless self-bearing motor<br />

topology (Figure 1) is presented allowing for ultra-high speed<br />

operation. It overcomes most of the limitations of previously<br />

presented high-speed AMBs, which are usually due to the<br />

bearing topology. The novel bearing is analyzed analytically,<br />

and a design for 500 000 rpm is verified with FE simulations.<br />

II. NOVEL SELF-BEARING MOTOR<br />

The basic concept of a self-bearing (also called<br />

bearingless) motor has been presented in 0 for a reluctance<br />

motor and has been adopted for slotted permanent-magnet<br />

motors in [7] and for a slice motor in [8]. There have been a<br />

few attempts for high-speed self-bearing motors, and in [9] a<br />

speed of 60 000 rpm has been achieved.<br />

An early reference to a <strong>Lorentz</strong>-type bearing can be found<br />

in [10], slotless <strong>Lorentz</strong>-type bearing prototypes have been<br />

presented in [11] for positioning applications and in [12] for<br />

mirrors in laser applications. [13] is the first to mention the<br />

high-speed potential of a slotless self-bearing motor, although<br />

the prototype presented rotates at only 5 000 rpm.<br />

The magnetic bearing concept presented in this paper is<br />

based on the electric machine concept presented in [14]. With<br />

a different winding design, forces in x and y direction can be<br />

generated beside the torque in direction of the z-axis. In order<br />

to levitate a long rotor, two separate bearing windings<br />

separated in z direction are required.<br />

y<br />

<strong>Motor</strong> winding<br />

<strong>Bearing</strong> winding<br />

Stator core<br />

Air gap<br />

Permanent magnet<br />

r<br />

θ<br />

R 1<br />

R Fw1<br />

R Fw2<br />

R 2<br />

R 4<br />

R 5<br />

Sleeve<br />

Figure 1. Machine cross-section and symbol definitions: diametrically<br />

magnetized cylindrical permanent magnet rotor inside a slotless stator with<br />

separate bearing and motor winding.<br />

x<br />

978-1-4244-5287-3/10/$26.00 ©2010 IEEE 3971


This concept has several advantages for high-speed<br />

operation. The rotor consists of a diametrically magnetized,<br />

two-pole ( p M = 1) cylindrical permanent magnet encased in a<br />

nonmagnetic sleeve. Mechanically, this rotor construction<br />

allows for highest rotational speeds even with large rotor<br />

diameters. Furthermore, the slotless air-gap winding has<br />

several advantages for high-speed operation: no slotting<br />

harmonics in the air-gap field, which in other AMB topologies<br />

lead to large eddy-current losses in the rotor, a constant<br />

magnetic air-gap and a high rotational symmetry leading to<br />

linear forces. With a thick winding the magnetic air-gap<br />

between rotor magnet and stator iron can be made large such<br />

that a very low negative stiffness results, which reduces the<br />

position control complexity. Furthermore, a large magnetic<br />

air-gap leads to a low inductivity, which allows for high<br />

dynamics in current control which is required at high<br />

rotational speeds. Finally, the magnetic flux density in the<br />

stator iron will be low and therefore also the iron losses.<br />

The motor winding for the torque generation has the same<br />

number of pole-pairs ( pT = pM<br />

) as the rotor, whereas the<br />

bearing winding has to be pF<br />

= pM<br />

+ / − 1 according to [15].<br />

In the concept presented here the pole-pair of the bearing<br />

winding is chosen to be p F = 2 in order to achieve the lowest<br />

possible fundamental frequency. The two windings can be<br />

combined or separated as shown in Figure 1. In electric<br />

machines the large stray fields in a slotless machine not<br />

entering the stator iron are a disadvantage. This changes to an<br />

advantage in the self-bearing motor as these stray fields add to<br />

the bearing force. Due to that, if the windings are separated,<br />

the bearing winding should be placed on the inner side where<br />

the stray field is larger, and the torque winding should be<br />

placed on the outer side where the moment arm is longer.<br />

Beside the many advantages, there are also a few<br />

drawbacks of the presented topology. As in all self-bearing<br />

motors the bearing currents are depending on the rotor angle<br />

for a constant force in one direction. Therefore, firstly the<br />

rotor angle is required and secondly, the bearing currents show<br />

a fundamental frequency depending on the rotational speed n,<br />

in this topology ( pT<br />

= pM<br />

= 1 p 2 , F = ) it is n /60. This<br />

leads to the requirement of high inverter dynamics, a fast<br />

transformation between stationary and rotating reference<br />

frames, and angle and current measurements with a high<br />

accuracy and a bandwidth depending on the rotational<br />

frequency. Furthermore, the achievable bearing forces are<br />

small compared to other AMBs with the same rotor radius and<br />

length. However, the limited force is not degrading the control<br />

stability, as it comes along with a very low negative stiffness<br />

as mentioned before. A further disadvantage is that the bearing<br />

forces are applied in the axial center of the bearing winding,<br />

penalizing the rotor dynamic design, ideally they should act on<br />

each end of the rotor.<br />

III. ANALYTICAL CALCULATIONS<br />

The following discussion of the magnetic field is based on<br />

the magnetostatic analytic field solution as in [16] and [14] for<br />

a permanent magnet with pole-pair number p M = 1. In<br />

cylindrical coordinates ( r, θ , z)<br />

the magnetic field in the nonferromagnetic<br />

region ( R1 < r < R4)<br />

is given by<br />

B<br />

⎡<br />

2<br />

4<br />

2 1 ⎛R<br />

⎞<br />

r = KB ⎢ + ⎥ cos − M<br />

⎢⎣<br />

⎜<br />

⎝<br />

⎤<br />

r<br />

⎟<br />

⎠ ⎥⎦<br />

( θ ϕ )<br />

, (1)<br />

⎡ 2<br />

4<br />

2 1 ⎛R<br />

⎞ ⎤<br />

Bθ =−KB<br />

⎢ −⎜<br />

⎥ sin ( θ −ϕM<br />

)<br />

r<br />

⎟<br />

⎢ ⎝ ⎠ ⎥<br />

. (2)<br />

⎣ ⎦<br />

The constants K B2<br />

and R 4 are defined according to [14]. ϕ M<br />

is the pole orientation of the permanent magnet. It is assumed<br />

that the axial component of the magnetic flux density B z is<br />

very small and can therefore be neglected. This assumption is<br />

valid when the active length of the motor L is large compared<br />

to its diameter. Furthermore, it is assumed that the magnetic<br />

field resulting from winding currents is small compared to the<br />

permanent-magnet field and can be omitted as well. The<br />

<strong>Lorentz</strong>-force and the torque density are given by<br />

dFk<br />

jk<br />

B<br />

dV = × <br />

, (3)<br />

dM<br />

k ⎛dFk<br />

⎞<br />

= a ×<br />

dV<br />

⎜<br />

dV<br />

⎟ , (4)<br />

⎝ ⎠<br />

<br />

where j k is the winding current density in z direction The<br />

current density is constant over a winding segment k . a is the<br />

local position vector. The total <strong>Lorentz</strong>-force and torque on the<br />

rotor can be calculated by integration of the densities over the<br />

volume of each winding segment and summation over all<br />

segments as shown in (5) and (6).<br />

K L/2<br />

Rw2<br />

θk,2<br />

<br />

⎛dFk<br />

⎞<br />

F = ∑ ∫ ∫ ∫ ⎜ rdθ<br />

drdz<br />

dV<br />

⎟<br />

⎝ ⎠<br />

k = 1 z=− L/2<br />

r= Rw1 θ=<br />

θk,1<br />

K L/2<br />

Rw2<br />

θk<br />

,2<br />

<br />

⎛dM<br />

k ⎞<br />

M = ∑ ∫ ∫ ∫ ⎜ rdθ<br />

drdz<br />

dV<br />

⎟<br />

⎝ ⎠<br />

k = 1 z=− L/2<br />

r= Rw1 θ=<br />

θk,1<br />

A. <strong>Motor</strong> winding<br />

In order to generate a motor torque on the rotor, a one<br />

pole-pair, three-phase air-gap winding ( p T = 1, K = 6 ) is<br />

considered. The winding has an inner radius R Tw1<br />

and an<br />

outer radius RTw2<br />

and a copper filling factor k w . A<br />

symmetrical three phase current is defined with a current<br />

density amplitude ˆT j and a phase ϕ T . The force and torque<br />

of this winding can be obtained by solving (5) and (6) in<br />

Cartesian coordinates leading to<br />

⎡0⎤<br />

⎡ 0 ⎤<br />

<br />

F<br />

⎢<br />

T 0<br />

⎥ ⎢<br />

⎥<br />

=<br />

⎢ ⎥<br />

, MT = MT<br />

⎢<br />

0<br />

⎥<br />

, (7)<br />

⎢⎣0⎥⎦ ⎢<br />

⎣cos( ϕT<br />

−ϕM<br />

) ⎥<br />

⎦<br />

M ˆ<br />

T = Lkw jT KB2( RTw2 −RTw1)<br />

⋅<br />

(8)<br />

2 2 2<br />

3 R + R + R R + R .<br />

( 4 Tw1 Tw1 Tw2 Tw2)<br />

B. <strong>Bearing</strong> winding<br />

Radial bearing forces are generated by a two pole-pair,<br />

three-phase winding ( p F = 2 K = 12 ). The winding has an<br />

inner radius of R Fw1<br />

and an outer radius of R Fw2<br />

and a<br />

copper filling factor k w . A symmetrical three phase current is<br />

(5)<br />

(6)<br />

3972


defined with a current density amplitude ˆF j and a phase ϕ F .<br />

The resulting torque and <strong>Lorentz</strong> force is given by<br />

⎡ sin ( ϕF<br />

−ϕM<br />

) ⎤ ⎡0⎤<br />

⎢ ⎥ <br />

FF = FF cos ( ϕF ϕM ) , M<br />

⎢<br />

F 0<br />

⎥<br />

⎢− − ⎥ =<br />

⎢ ⎥<br />

, (9)<br />

⎢<br />

⎣ 0 ⎥<br />

⎦<br />

⎢⎣0<br />

⎥⎦<br />

ˆ 2 ⎛ RFw2<br />

⎞<br />

FF = 3Lkw jF KB2 R4<br />

ln ⎜ ⎟.<br />

(10)<br />

⎝ RFw1<br />

⎠<br />

This result indicates that the bearing force is linearly<br />

dependent on the magnitude of the bearing current ˆF j . Its<br />

direction is given by the angleϕ<br />

F − ϕ M . Thus, the bearing<br />

force can be controlled with a standard three phase inverter<br />

when a good estimation of the angular position of the rotor is<br />

available to the controller.<br />

C. Negative stiffness<br />

In this section the sensitivity of small rotor eccentricities is<br />

examined. When the rotor is displaced radially, a reluctance<br />

force dragging the rotor away from the centered position<br />

occurs. This is due to the unsymmetrical field distribution at<br />

the inner side of the iron core. This negative stiffness<br />

dFx<br />

kx<br />

= (11)<br />

dx<br />

is defined similar to a spring constant. Due to the rotational<br />

symmetry of the cross section k x = k y can be assumed. The<br />

negative stiffness is determined with evaluating Maxwell<br />

stress tensors in FEM field simulations.<br />

D. Winding inductances<br />

A major advantage of the proposed self-bearing motor is<br />

the low winding inductances. Therefore, reactive power is<br />

small and there is no need for high inverter dc link voltages to<br />

achieve high current control dynamics as in other AMBs.<br />

Contrariwise, an inverter topology and modulation has to be<br />

chosen that allows for lowest inductances. The inductance<br />

values given in Table I are calculated by means of magnetic<br />

energy integration in FEM field simulations.<br />

IV. WINDING OPTIMIZATION<br />

<strong>Lorentz</strong>-force based force and torque generation is<br />

primarily proportional to the winding currents and therefore<br />

limited by the resulting copper losses [12]. Therefore, for a<br />

given force and torque the minimization of the copper losses<br />

P π ˆ2 2 2<br />

Cu = w ( w2 w1)<br />

2<br />

Lk j R −<br />

σ<br />

R<br />

(12)<br />

cu<br />

is desired. For the following optimization considerations an<br />

approximate field solution<br />

2<br />

⎡ ⎤ Brem<br />

R1<br />

B2 = lim ⎢ lim KB2⎥<br />

=<br />

μ<br />

2<br />

r1→1<br />

⎣μr5→∞<br />

⎦ 2R4<br />

K (13)<br />

is used. It is assumed that the relative permeability of the back<br />

iron μ r5<br />

is considerably higher than in the air-gap, and that<br />

the relative permeability of the permanent magnet μr1<br />

is 1.<br />

Realistic values are in the order of μ r5 = 20000 and<br />

μ r1 = 1.05 (for amorphous iron and samarium–cobalt<br />

permanent magnets). Thus, only very small field errors result<br />

due to this approximation.<br />

A. <strong>Motor</strong> winding optimization<br />

Using (13), (8) can be simplified to<br />

2<br />

ˆ<br />

BremR1<br />

T w T 2 Tw2 Tw1<br />

2R4<br />

( )<br />

M<br />

= Lk j R −R<br />

⋅<br />

2 2 2<br />

( R4 + RTw1+ RTw1RTw2 + RTw2)<br />

3 .<br />

(14)<br />

Minimizing P Cu by varying the winding geometry R Tw1<br />

and<br />

R Tw2 for a given L , R 1 , R 4 , and a desired M T indicates that<br />

all available space (namely the air-gap) shall be filled by the<br />

torque winding. So ideally RTw1 = R2<br />

and RTw2 = R4. In<br />

practice this result is not applicable, because there has to be a<br />

clearance between the rotor and the stator. Furthermore, a<br />

radial bearing winding has to be integrated. This reduces the<br />

space available for the motor winding.<br />

B. <strong>Bearing</strong> winding optimization<br />

Using the approximation in (13) the bearing force<br />

magnitude is<br />

3<br />

ˆ 2 RFw2<br />

F ⎛ ⎞<br />

F = Lkw jF Brem<br />

R1<br />

ln ⎜ ⎟.<br />

(15)<br />

2<br />

⎝ RFw1<br />

⎠<br />

This result indicates that the bearing force does not depend on<br />

the inner radius of the back-iron. This is due to the fact that the<br />

stray field B θ adds to the bearing force generation. Increasing<br />

iron radius R 4 decreases the radial field B r but increases the<br />

tangential stray field B θ . These two effects compensate each<br />

other completely in the bearing force windings.<br />

For a given given L , R 1 , R 4 , and a desired F F the copper<br />

losses are proportional to<br />

R<br />

2<br />

Fw2<br />

( ) −<br />

RFw1<br />

RFw2<br />

ln ( R )<br />

1<br />

P ~ F R<br />

.<br />

(16)<br />

2 2<br />

Cu F Fw 1 2<br />

Fw1<br />

Minimizing P Cu by varying R Fw2<br />

and a constant R Fw1<br />

leads<br />

to<br />

RFw2<br />

= 2.2185 .<br />

(17)<br />

RFw1<br />

Therefore. the bearing winding has minimal copper losses if<br />

R Fw1 is chosen as small as possible and R Fw2<br />

is chosen<br />

according to (17). In contrary to the torque winding it is not<br />

optimal to fill the entire air-gap with the force winding.<br />

C. Joint bearing and motor winding optimization<br />

In order to be able to use standard three phase inverters for<br />

the motor and the bearing currents, a design is chosen with<br />

separate torque and force windings. A key advantage of using<br />

separate windings is the “decoupling” of force and torque<br />

generation. Their associated currents can be controlled by<br />

separate controllers. The bearing winding is placed as close as<br />

possible to the rotor. The motor winding fills the rest of the<br />

space between the bearing winding and the inner radius of the<br />

back-iron ( RTw1 = RFw2<br />

and RTw2 = R4).<br />

3973


Optimization of the winding boundary R Fw2<br />

is performed<br />

by minimizing the sum of the copper losses in both windings<br />

for a design torque and force. Figure 2 shows the resulting<br />

copper losses for a given magnet and back-iron geometry, a<br />

torque of 0.1 Nm/m and different force values. Values<br />

exceeding a maximal allowable current density are excluded<br />

from the figure.<br />

V. VERIFICATION USING FEM<br />

A. Centered rotor position<br />

In order to verify the analytical model, force and torque<br />

expressions (10) and (8) are compared to 2D-FEM simulations<br />

for a centered rotor. Unlike in the analytical solution, field<br />

contributions from the winding currents are included in these<br />

force and torque calculation. Results shown in Figure 3 and<br />

Figure 4 show a very good agreement between the analytic<br />

solution and the numerical FEM results.<br />

B. Eccentric rotor position<br />

In contrary to the analytical model, FEM simulations allow<br />

for an analysis of the characteristics of a proposed motor also<br />

when the rotor is displaced from its centered position. For the<br />

following calculations, the self-bearing motor design<br />

presented in Table I is used. The resulting bearing forces are<br />

presented in Figure 5, the resulting torque in Figure 6. The<br />

reluctance force F R,<br />

X is mainly linearly dependent on rotor<br />

displacement. Furthermore, one can see that the maximal<br />

reluctance force F R,<br />

X is much smaller than the maximal<br />

bearing forces available F F,<br />

X . The bearing forces F F,<br />

X ,<br />

F F,<br />

Y and the motor torque M T are almost constant over the<br />

entire displacement range of the rotor. This simplifies motor<br />

control considerably, because in a good approximation it can<br />

be assumed that the <strong>Lorentz</strong>-force and torque to current<br />

relationship is linear and independent of the rotor position.<br />

When the rotor is centered, there is no cross-coupling between<br />

force and torque winding. For large displacements a small<br />

cross coupling can be observed. However, the maximal<br />

possible cross coupling (shown in Figure 5 and Figure 6) is<br />

much smaller than the rated forces and torques. Thus, bearing<br />

and motor currents can be controlled independently of each<br />

other.<br />

Figure 7 depicts the radial negative stiffness per active<br />

motor length versus the inner stator core radius for different<br />

magnet radii. Stiffness values are calculated for a rotor<br />

displacement of 0.1 mm. It can be seen that for decreasing<br />

magnet radius and increasing inner stator core radius the<br />

negative stiffness is decreasing.<br />

VI. SELF-BEARING MOTOR DESIGN<br />

A. Electromagnetic and mechanical layout<br />

With the analytical design and optimization routines in section<br />

III and IV a motor is designed for a rated speed of<br />

500 000 rpm, a rated torque of 14.2 mNm and rated bearing<br />

forces of 0.4 N per bearing winding. Two bearing windings<br />

are attached to each other in z-direction. In contrary, the two<br />

motor windings can be combined into one, which results in<br />

three cable connections less. Similarly, the two back irons and<br />

(P cu,F<br />

+P cu,T<br />

)/L (W/m)<br />

12<br />

10<br />

8<br />

6<br />

4<br />

2<br />

F F<br />

=10 N/m; M T<br />

=0.1 Nm/m<br />

F F<br />

=15 N/m; M T<br />

=0.1 Nm/m<br />

F F<br />

=20 N/m; M T<br />

=0.1 Nm/m<br />

F F<br />

=25 N/m; M T<br />

=0.1 Nm/m<br />

0<br />

5 6 7 8 9 10<br />

R (mm) Fw2<br />

Figure 2. Total copper loss optimization. Winding currents are limited to<br />

2<br />

j = 4A/mm . ( R 1 =3.5 mm, R Fw1<br />

=4.25 mm, R 4 =15 mm)<br />

F F<br />

/L (N/m)<br />

30<br />

25<br />

20<br />

15<br />

10<br />

R1=2.5 mm<br />

R1=3 mm<br />

5<br />

R1=3.5 mm<br />

R1=4 mm<br />

FEM Results<br />

0<br />

10 12 14 16 18 20<br />

R4 (mm)<br />

Figure 3. Comparison between analytic bearing force (lines) and numeric<br />

2<br />

FEM results (gray Xs). ( RFw1 = R1 + 0.75 mm , R Fw2 = 8mm,<br />

j = 4A/mm )<br />

M T<br />

/L (Nm/m)<br />

1<br />

0.9<br />

0.8<br />

0.7<br />

0.6<br />

0.5<br />

0.4<br />

0.3<br />

0.2<br />

0.1<br />

R1=2.5 mm<br />

R1=3 mm<br />

R1=3.5 mm<br />

R1=4 mm<br />

FEM Results<br />

0<br />

10 12 14 16 18 20<br />

R4 (mm)<br />

Figure 4. Comparison between analytic motor torque (lines) and numeric<br />

2<br />

FEM results (gray Xs). ( R Tw1<br />

=8 mm, RTw2 = R4<br />

, j = 4A/mm )<br />

3974


the two permanent magnets are united in order to form one<br />

workpiece each, lowering the manufacturing complexity. The<br />

two bearing windings have to be kept separated as different<br />

forces have to be applied in the two bearings. This results in<br />

winding headers in between the two motors. Therefore, the<br />

permanent magnet and the back iron have to be twice the<br />

active length plus twice the bearing winding header length. A<br />

CAD drawing of the self-bearing motor system is depicted in<br />

Figure 8.<br />

The force requirement results in an active length for the<br />

bearing windings of 16 mm, the motor winding is twice this<br />

length. The rated net current density is 2 A/mm 2 , with a<br />

copper filling factor of 0.5 this results in a copper current<br />

density of 4 A/mm 2 . With a 0.5 mm 2 wire for the bearing<br />

winding and a 1 mm 2 wire for the motor winding this leads to<br />

rated phase currents of 2 A for the bearing and 4 A for the<br />

torque winding, respectively. The inner dimensions and<br />

parameters can be found in Table I.<br />

Beside the self-bearing motor itself, several further<br />

components are required to form a fully functional prototype<br />

system of a <strong>Lorentz</strong>-type, slotless self-bearing motor. The<br />

following sections identify these subsystems, which are all<br />

part of future research.<br />

B. Axial bearing<br />

This paper analyzes a self-bearing motor which can<br />

generate torque in z-direction and forces in x- and y-direction.<br />

However, for a fully functional system the position in z-axis<br />

also has to be controlled actively, because the passive<br />

stabilization is very low due to the large radial air-gap between<br />

magnet and back iron.<br />

For the prototype system to be built the axial stabilization<br />

will be done with one externally pressurized axial air bearing<br />

on each side of the rotor. Active axial magnetic bearings based<br />

on windings using the existing field of the self-bearing motor<br />

topology presented in this paper will be part of future research.<br />

C. Position sensors<br />

The radial position can be detected with commonly used<br />

eddy current sensors. For a high bandwidth measurement with<br />

a high resolution and a compact design a PCB based sensor<br />

has found to be an ideal choice [17], [18]. Two such sensors<br />

can be mounted on each axial end of the rotor.<br />

The axial position does not have to be measured in the<br />

prototype system due to the utilization of air bearings. In the<br />

case of using an active axial magnetic bearing the position<br />

detection can also be done with an eddy current sensor.<br />

The angular position is required for the orientation of the<br />

field of motor winding as well as the field of the bearing<br />

winding. The angular position can be measured with hall<br />

sensors detecting the permanent-magnet field, or with eddycurrent<br />

sensors and an eccentric part of the rotor.<br />

D. Power electronics and control<br />

The two bearing as well as the motor windings are starconnected<br />

three phase windings. Therefore, three three-phase<br />

inverters are required to operate the self-bearing motor system.<br />

This results in 18 semiconductors on power electronics side<br />

and the according gate signals that have to be provided by the<br />

control system. A standard active magnetic bearing and drive<br />

F/L (N/m)<br />

30<br />

25<br />

20<br />

15<br />

10<br />

5<br />

0<br />

F F<br />

(analytic)<br />

F R,X<br />

F F,X<br />

F F,Y<br />

F T,X<br />

F T,Y<br />

0 50 100 150 200 250 300 350 400<br />

Rotor displacement on x-axis ( μm)<br />

Figure 5. <strong>Bearing</strong> forces versus rotor displacement. FRX<br />

, is the resultant<br />

reluctance force due to the negative stiffness. F F,<br />

X and F FY , are resulting<br />

2<br />

bearing forces in x and y-direction when a current desity of j F = 4A/mm is<br />

applied with different phases. F T,<br />

X and F TY , are the forces due to a torque<br />

2<br />

current density of j = 4A/mm .<br />

M/L (Nm/m)<br />

0.45<br />

0.4<br />

0.35<br />

0.3<br />

0.25<br />

0.2<br />

0.15<br />

0.1<br />

0.05<br />

0<br />

T<br />

M T<br />

(analytic)<br />

M T<br />

M F,X<br />

M F,Y<br />

-0.05<br />

0 50 100 150 200 250 300 350 400<br />

Rotor displacement on x-axis ( μm)<br />

Figure 6. <strong>Motor</strong> torque versus rotor displacement. M T is the resulting torque<br />

2<br />

due to a torque current density of j T = 4A/mm . M F,<br />

X and M FY , are due<br />

2<br />

to force current density of j = 4A/mm in different phases.<br />

-k x<br />

/L (kN/m/m)<br />

50<br />

45<br />

40<br />

35<br />

30<br />

25<br />

20<br />

15<br />

10<br />

5<br />

F<br />

R1=2.5 mm<br />

R1=3 mm<br />

R1=3.5 mm<br />

R1=4 mm<br />

0<br />

10 12 14 16 18 20<br />

R4 (mm)<br />

Figure 7. Radial negative stiffness per active motor length versus inner stator<br />

core radius for different magnet radii.<br />

3975


TABLE I<br />

SELF-BEARING MOTOR DESIGN<br />

Symbol Quantity Value<br />

Geometry<br />

R1<br />

Permanent magnet radius 3.5 mm<br />

RFw1<br />

<strong>Bearing</strong> winding inner radius 4.25 mm<br />

RFw2 = RTw1<br />

<strong>Bearing</strong> winding outer radius 8 mm<br />

R4 = R Tw 2<br />

Back-iron inner radius 15 mm<br />

R5<br />

Back-iron outer radius 20 mm<br />

Material properties<br />

Brem<br />

Remanence flux density 1.1 T<br />

Permanent magnet field properties<br />

BˆM , iron Maximal magnetic field in back-iron 0.21 T<br />

k x<br />

Negative stiffness 262 N/m<br />

<strong>Bearing</strong> winding properties<br />

LF<br />

Active length 16 mm<br />

N F<br />

Number of bearing winding turns 12<br />

k I F<br />

Force-current coefficient 0.20 N/A<br />

LdF<br />

, = LqF<br />

,<br />

Winding inductance 3.72 µH<br />

<strong>Motor</strong> winding properties<br />

LT<br />

Active length 32 mm<br />

N F<br />

Number of motor winding turns 42<br />

k I T<br />

Torque-current coefficient 3.54 mNm/A<br />

LdT<br />

, = LqT<br />

,<br />

Winding inductance 90.5 µH<br />

Figure 8. CAD drawing of the novel high-speed, lorentz-type, slotless<br />

self-bearing motor.<br />

with two times two windings (x- and y-direction on both<br />

sides) for the bearings and a three-phase motor, where a total<br />

of four full bridges and a single three-phase inverter is usually<br />

implemented, requires 22 semiconductors and gate signals.<br />

Therefore, the number of semiconductors and gate signals can<br />

be reduced with the topology presented in this paper.<br />

However, the drawback of the presented topology is that<br />

all three-phase currents, in contrary to the common AMB also<br />

the bearing currents, have a fundamental frequency equal to<br />

the mechanical frequency of the rotor. Firstly, this requires<br />

sufficiently low inductances of the windings in order to allow<br />

a limited inverter dc link voltage. This is fulfilled according to<br />

the self-bearing motor design in Table I. Secondly, it requires<br />

a current controller capable of impressing such currents. With<br />

a field-oriented controller this leads to the requirement of fast<br />

coordinate transformations between stationary and rotating<br />

reference frames.<br />

VII. CONCLUSION<br />

The <strong>Lorentz</strong>-type, slotless self-bearing motor presented in<br />

this paper overcomes most limitations of previously presented<br />

high-speed magnetic bearings. It has a simple and robust rotor<br />

construction, low rotor losses, a very low negative stiffness<br />

and low cross-coupling. The achievable bearing forces with<br />

this concept are small compared to other AMBs with equal<br />

rotor radius and length, but the negative stiffness is also very<br />

small. This makes it an ideal choice for high-speed operation<br />

where low external forces are applied to the rotor.<br />

An analytical model for the torque and bearing forces has<br />

been introduced and verified. It shows that the torque and<br />

forces are almost independent of the displacement and linear<br />

to the current, which simplifies position control considerably.<br />

A motor design for 500 000 rpm leads to a torque of<br />

14.2 mNm, bearing forces of 0.40 N per radial bearing and a<br />

negative stiffness of 262 N/m for a net current density of<br />

2 A/mm 2 . The prototype system to be built includes two<br />

motors and allows for simplified manufacturing due to<br />

unification of back iron, motor winding and permanent<br />

magnet.<br />

Further research will include the control of the presented<br />

self-bearing motor, the power electronics, and the integration<br />

of an active axial magnetic bearing.<br />

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