Magnetic Bearing Preliminary Design Review

Team miniMuffin
Lauren Glogiewicz Jacob Beckner Kevin Bodkin James Holley Philip Terry

Project Description
Different bearing design using magnetic fields Electromagnets will levitate an axle Optical sensors monitor position of axle FPGA interprets data to control electromagnets System less prone to mechanical restraints

Lauren

Why Magnetic Bearings?

Eliminates friction present in mechanical bearings o Higher speed of rotation possible o Fewer parts require maintenance o Not as susceptible to heat

VS

Lauren

Project Objectives

Lauren

Concept: 8-Magnet Bearing

Lauren

First Objective: 1D Proof of Concept Design

Lauren

Final Objective: Magnetic Ring Bearing with Axial Bearing

James

Final Objective: Magnetic Ring Bearing with Axial Bearing

James

Hardware Functional Diagram

James

Software Functional Diagram

8x sensor distance in to FPGA

Convert distance error to current

8-12 bits per magnet sent to current control via FPGA I/O
James

Design Constraints
Speed of Control
o o

Need a tight control loop between sensors & FPGA Electromagnets need to be adjusted continuously

Power
o o

Electromagnets are typically high power Bearings only useful if energy efficient

Budget
o

Certain components could be expensive

James

Major Components
Optical Sensors
FPGA: Hardware & Software Interface Current Control

Electromagnets
Power Supply
Jake

Sensing Devices
Optical sensors will track axle position
Sensors will be paired with electromagnets Vital to the positioning feedback loop

Jake

Altera Flex 6000 FPGA

199 I/O pins o 8 magnet control with 12-bit accuracy Re-programmable with Altera software 100 MHz maximum clock frequency

Jake

Electromagnets
Found source of low-cost, high-power magnets
Currently testing two models:
o o

1" Magnet: 3 V, 5.5 W, 25 lb holding force 2" magnet: 6 V, 7 W, 105 lb holding force

Kevin

Current Control
Will receive information from the FPGA
Information fed to D/A converter to amplifier Amplifier will feed into BJT-based current source Will change the strength of the electromagnets Current limited based on the magnet used

Kevin

Power Supply
Need the following: o 15 V for OpAmps o 6 V +/- mV for magnets o 3.3 V for integrated circuits
Initial work using power supplies & 12 V batteries Final design should use wall power

Kevin

Prediction of Material Costs

Item FPGA Electromagnets Optical Sensors BJT Op Amps Capacitors Resistors High Power Diodes Wire Nuts, Bolts, Screws Aluminum Machining PCB Shipping and Handling Posters/Presentation Part No. Altera FLEX 6000 EM 200 Sharp GP2Y0D805Z0F TRANS NPN 10VCEO 5A Cost $43 $41.61 $3.70 $0.38 $1.00 $0.60 $0.60 $1.71 Quantity 2 15 15 25 25 100 100 15 5 3 1 1 3 6 Total Cost $86.00 $624.15 $55.50 $9.50 $25.00 $60.00 $60.00 $25.65 $90.00 $28.74 $30.22 $200.00 $180.00 $60.00 $70 Total: $1,600.76

Wire T Lead Plastic 22AG

Aluminum (25 pack) 6ft x 1/4" x 2"

$18.00 $9.58 $30.22 $200.00 $60 $10.00 $70

Phil

Sources of Funding
UROP Boettcher Scholar Educational Enrichment Grant Engineering Excellence Fund Mini Grant

Phil

Division of Labor
For preliminary steps, we will divide as follows:
o o o o o

Jake: Interfacing/ programming FPGA

James: Electromagnets and supporting electronics

Kevin: Power electronics Lauren: Mechanical design Phil: Sensors and documentation

Phil

Timeline

Phil

Risks and Contingency Plan

Mechanical Problems
o

Some parts manufactured by other people

Time delay of sensors

o o

Look into components with faster response Different sensing types: capacitive, magnetic field, etc.

Time delay of current control

o

Better components

Phil

Questions?