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I. I NTRODUCTION
Fig. 1. State-of-the-art rotor spinning machine.
with the force element dFx acting in the x-direction and dFy
acting in the y-direction. The factor of two in (2) and (3)
results from the two stator sheets. Given the arrangement of
the stator segments, it is obvious that segments 1 and 3 are
intended for force generation in the x-direction and segments
2 and 4 are intended for force generation in the y-direction. The
resultant force in the x-direction of sector 1 can be calculated
Fig. 6. Maxwell force acting on an infinitely small rotor element dS.
by integrating (2) over the surface of this sector, which yields
−π
homogeneous flux density distribution in the air gap, the stator 4
1
sheets are made from one piece with the segments connected Fx1 = ls ds (B0 + BC1 )2 cos ϕdϕ
2μ0
by small bridges. These bridges should be driven nearly to −π
4
saturation by the PM bias flux in order to decrease the magnetic √
permeability in those regions. However, the flux density in the 2 ls d s 2 2
Fx1 = B0 + 2B0 BC1 + BC1 . (4)
air gap adjacent to these saturation bridges should be the same 2 μ0
as in the rest of the air gap to avoid hysteresis and eddy current
losses in the rotor core. A finite-element simulation of this Finally, the total force in the x-direction is calculated by sub-
region is shown in Fig. 5. Due to fringing, the flux density in the tracting the x-component of the force of sector 3 from (4)
air gap is lower than that in the rotor because the axial length of
the stator is in the same ranges as the air gap. Fx = Fx1 − Fx3
√
For force generation, the bias flux of the PMs φ0 is superim- 2 ls d s
posed with the flux of the coils φCi , where subscript i refers to Fx = 2B0 (BC1 − BC3 ) + BC1
2
− BC3
2
. (5)
2 μ0
the coil in the corresponding ith sector. The flux density in the
air gap can be calculated as Equation (5) can be simplified considerably when the current
through coil 3 has the same value as the current through coil 1
4φ0 but with a negative sign
B0 =
πds ls
4φCi BC3 = −BC1 . (6)
BCi =
πds ls Thus, the total force in the x-direction is
where ds and ls denote the diameter of the stator bore and √ ls d s
Fx = 2 2 B0 BC1 .
the length of each stator sheet, respectively. For calculating μ0
the force acting on the rotor, the Maxwell force in the radial
direction on a surface element of one stator sheet dS, as shown The force generation in the y-direction is equivalent when
in Fig. 6, is considered coils 2 and 4 are used instead of coils 1 and 3. By connecting
the coils in series as shown in Fig. 7, condition (6) is met, and
1 the number of bearing phases can be reduced to two, which
dFr = (B0 + BCi )2 ls ds dϕ (1)
4 μ0 makes simplified driver electronics possible.
SILBER et al.: HIGH-SPEED DRIVE FOR TEXTILE ROTOR SPINNING APPLICATIONS 2993
Fig. 8. Passively stabilized DOFs. (a) Axial direction. (b) Tilting directions. Fig. 9. Cross section of the slotless high-speed motor.
Fig. 10. Flux density distribution at nominal torque. (a) Motor with two pole
IV. H IGH -S PEED M OTOR pairs. (b) Motor with three pole pairs.
Fig. 12. Simulation of the phase current and the scaled motor torque for the
VSI with block commutation for a motor speed of 150 000 r/min.
Fig. 13. Simulation of the phase current and the scaled motor torque for the
QCSI with block commutation for a motor speed of 150 000 r/min.
C. QSCI With Block Commutation Fig. 15. Third generation of the prototype spinning unit with integrated
electronics.
On the basis of the VSI topology, the ripple current in
the motor phases can be further reduced when the capacitor
CDCi is omitted. Thus, the inductance required for the dc–dc VII. E XPERIMENTAL R ESULTS
converter is connected in series to equivalent inductance as
The third generation of the experimental spinning unit is
calculated in (7). To avoid overvoltage across the six motor
shown in Fig. 15. The complete system comprising magnetic
MOSFETs, diode D was added. The inverter topology is a
bearing with backup bearing, a high-speed motor, a bearing
combination of a VSI at the output with a current link and is
and motor inverter, and signal electronics is integrated into a
commonly referred to as a quasi-current source inverter (QCSI)
compact housing. With this spinning unit, high-quality yarn
[26]. The schematic of this inverter is shown in Fig. 11(c).
was produced at a rotational speed of 50 000 r/min up to
The improvement of the QCSI over the VSI (both with block
140 000 r/min with various rotor diameters. Compared to a
commutation) is significant and can clearly be seen in Fig. 13.
conventional rotor spinning machine, the power consumption
In the simulation, the value of the inductance was 180 μH, and
is approximately 20% lower at the same rotational speed.
the switching frequency of the dc–dc converter was 125 kHz.
Moreover, this system of material flow has certain advantages in
Since there are several advantages over the VSI with block
relation to textile technology, which will be further investigated
commutation, such as higher efficiency and no dc-link ca-
in the next few steps of development. It was confirmed that the
pacitor, this inverter topology has been selected for the rotor
stiffness of the passively stabilized DOFs is sufficient for the
spinning application.
spinning process.
The radial deflection of the rotor is limited to around ±20 μm
for the full range of operation. Even at very high acceleration
VI. B EARING I NVERTER
rates, where a rotational speed of 140 000 r/min is reached
Two independent full-bridge drivers, as shown in Fig. 14, can within 7.5 s from rest, this orbit is not significantly exceeded, as
be employed to generate bearing forces. Low-side shunt resis- shown in Fig. 16. The measurement of the radial position was
tors Rsx and Rsy enable cost-efficient current measurement. To done with the position sensors of the magnetic bearing.
guarantee efficient operation with low switching losses, always The QCSI operates well across the whole operation range,
one low-side switch is permanently switched on, and the other and good agreement between theoretical prediction and mea-
half bridge is modulated. surements was obtained. This can be seen in Fig. 17 for a
2996 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 61, NO. 6, JUNE 2014
ACKNOWLEDGMENT
This work was conducted within the Austrian Center of
Competence in Mechatronics, which is part of the Competence
Centers for Excellent Technologies K2 program of the Austrian
Government. The authors would like to thank all partners
involved for their support.
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[22] A. Binder and T. Schneider, “High-speed inverter-fed ac drives,” in Proc. Since 2005, he has been working as a Research
Int. ACEMP, Sep. 2007, pp. 9–16. and Designing Engineer at Johannes Kepler Univer-
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a 100 W, 500 000 rpm gas turbine portable power unit,” in Proc. Appl. Milan Moravec received the Dipl.Ing. degree from
Power Electron. Conf., Mar. 2006, pp. 283–289. the Faculty of Electronics, Technical University in
[26] I. Takahashi, T. Koganezawa, G. Su, and K. Oyama, “A super high speed Brno, Brno, Czech Republic.
PM motor drive system by a quasi-current source inverter,” in Conf. Rec. In 1987, he became an Electronics Designer fo-
IEEE IAS Annu. Meeting, Oct. 1993, vol. 1, pp. 657–662. cusing on the development of single-purpose ma-
[27] T. Green, M. Taha, N. Rahim, and B. Williams, “Three-phase step-down chines for Elitex textile machinery CZ. From 1993
reversible ac-dc power converter,” IEEE Trans. Power Electron., vol. 12, to 2004, he developed software for automated textile
no. 2, pp. 319–324, Mar. 1997. machines at the design center of Rieter CZ s.r.o,
Ústí nad Orlicí, Czech Republic, a sister company of
Rieter Machine Works Ltd., Winterthur, Switzerland.
His work focused on control software and robotics
for textile machinery. From 2005 to 2007, he worked on the mechatronics
of yarn quality sensors. Since 2008, he has been a member of the Research
and Development Department of Rieter CZ s.r.o., concentrating on drives and
methods for bobbin winding and magnetic bearings for textile machinery. He
Siegfried Silber (S’95–A’99–M’03) received the
has led an international project in cooperation with the Institute of Mechatronics
Dipl.Ing. degree in electrical engineering from the
at Johannes Kepler University Linz, Linz, Austria. As part of his research
University of Technology, Graz, Austria, in 1995 and
activities, he has submitted several patents in the area of textile machines.
the Ph.D. degree from Johannes Kepler University
Linz, Linz, Austria, in 2000.
Since 2000, he has been a Senior Researcher at
Johannes Kepler University Linz and at the Linz Wolfgang Amrhein was born in Aschaffenburg,
Center of Mechatronics GmbH, Linz, where he is Germany, in 1957. He received the degree in
engaged in research projects. Since 2005, he has electrical engineering at the Technical University
been the Manager of the business unit Electrical Darmstadt, Darmstadt, Germany, in 1982. From
Drives and Actuation Systems. His research interests 1982 to 1990, he was a Scientific Assistant at
include magnetic bearings, bearingless motors, brushless motors, and power the Swiss Federal Institute of Technology Zurich,
electronics. Zurich, Switzerland, and received the Ph.D. degree
in 1988.
In 1990, he joined Papst-Motoren GmbH, St.
Georgen, Germany; in 1992, he became the Head of
the development department of this company. Since
1994, he has been a Professor and, subsequently, the Head of the Institute
for Electric Drives and Power Electronics, Johannes Kepler University Linz,
Linz, Austria. In 2000, he was appointed the Scientific Head of the Linz
Jiri Sloupensky received the M.Sc. degree in elec- Center of Competence in Mechatronics, Linz. His research interests focus on
tronic computer engineering from the Czech Techni- electric drives with special emphasis on small electric motors, magnetic bearing
cal University, Prague, Czech Republic. He received systems, bearingless motors, and power electronics.
the Ph.D. degree from the Prague Technical Univer-
sity, in 1986.
He then worked at the Cotton Industry Research
Institute in Usti nad Orlici, Czech Republic, de- Martin Reisinger received the Dipl.Ing. degree in
veloping microprocessor-based control systems for mechatronics from Johannes Kepler University Linz,
advanced spinning machinery. This activity also Linz, Austria, in 2003.
formed the basis of his Ph.D. work in technical He is currently a Senior Researcher with the Linz
cybernetics at the Faculty of Mechanical Engineering Center of Mechatronics GmbH, Linz, where he has
of the Technical University in Liberec, Czech Republic. Since 1991, he has been engaged in the field of electrical drives and
been leading the Research and Development Department of Rieter CZ, Usti power electronics since 2001. His main research ac-
nad Orlici, which is a subsidiary of the Swiss Rieter Holding, a world leader in tivities are power electronics, basic converter design
textile spinning. He contributes to the development of new designs for textile for electrical drives, and the design of integrated
spinning machinery based on advanced mechatronical concepts. actuators and magnetic bearings.