AE4020 Literature Study

Health & Performance Monitoring Using

Active Magnetic Bearing Systems

Abhinav Raj 4182758

Supervisors: Dr. Arvind G. Rao (TU Delft)

Sreenivas Raghavendran (Shell P&T)

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Contents
1. AMB System & Relevance
2. Advantages of using AMBs
3. Principle of operation
4. Objective
5. Remote monitoring using AMBs
6. Fault Classification
7. System modeling approaches
8. Cases to test
9. Additional Research
10. Deliverables
11. Timeline
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1. AMB System & Relevance

Integration of
Power Electronics
Control Systems / Logic
Rotor Dynamics
Electromagnetic Technology
Computing Technology

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2. Advantages Of AMBs
Application
No wear, noiseless, no lubrication, large range of
operational temperatures, elimination of path for circulating
currents.

Control
Active control of imbalance & vibration, can vary stiffness
and damping as required, monitor system performance.

Performance
Operate in critical environments, no lubrication related
problems, eliminates several components from system,
improved system reliability and longer operating life.
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3. Principle of Operation

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3. Principle of Operation (Contd.)

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4. Objective
To create a health and performance monitoring tool
whose deviation reason matrix will be tested and
established using a rotor dynamic model of the system.
Focus:
New key parameter indicators to capture
misalignments
To create a generic deviation reason matrix for AMBs
To understand the black box operation of AMBs using
rotor dynamics and control Eg: Machine Vibration

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4. Objective (Contd.)
Series of Steps
1.Research various ways to develop a robust model
rotor dynamics perspective.
2.Failure mode analysis for AMB systems.
3.Data available and derivation of necessary parameters.
4.Build a deviation reason matrix based on previous
experience.

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4. Objective (Contd.)
5. Build a rotor dynamic model.
6. Validate the model.
7. Test cases.
8. Add additional diagnostic capability.

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5. Remote Monitoring using AMBs

Data Available From AMBs in SmartConnect:
Current (AC, DC)
Rotor Position (Gap)
Coil Temperature
Power Amplifier Temperature
Rotor Unbalance
Flux
Voltage

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6. Fault Classification

External Faults

Internal Faults

Rotor impact

Power electronics

Rotor mass loss

Transducer malfunctions

Base motion

Loss of I/O board channel

Rotor deformation

Magnetic bearing coil failures

Sudden changes in loading

Computer software errors

Rotor rub

Computer hardware failures

Misalignment

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7. System Modeling Approaches

Softwares Ansys, ROMAC codes, Maple, Matlab / Simulink, FEMM
Complexity
Rotor Jeffcott, nDOF
AMB N, Ag, I, g, Permeability of medium
Control Logic PID, H-Infinity, Mu-synthesis, ADR etc.
Control System Centralized, Voltage vs Current
Rotor / System Dynamics

Validation

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8. Cases to Test
Coil Saturation Dynamics
Stable Rotordynamics
Unstable Rotordynamics Continuous Disturbance
Unstable Rotordynamics Disturbance Outside Limits
Rotor Levitation Centering
Effect of increased unbalance Variation in Current

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9. Additional Research
Key aspects of specifying an AMB system
Design Considerations
Rotordynamic Considerations
Diagnostic Considerations

Real time thrust force

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10. Deliverables
Creating new KPIs Early detection of incipient faults
Faster capture of machine health deviation
Easier interpretation of data from the machine

AMB supported rotor model to explain the black-box

operation of AMBs.
Experimentally backed Deviation Reason Matrix
How to specify an AMB system for first time users.

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11. Timeline
Modeling & Validation First half of January
Model of Rotor, AMB with advanced controller
Validation with existing results

Testing cases & result interpretation Second half of

January
Report, consultation and defense First half of
February

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THANK YOU

Questions Please!!

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Fault Classification Final List

Performance

Radial

Axial

Fouling

Rotor Deformation Change in Vibration

Corrosion

Change in
Vibration

Impeller Damage

Coil Saturation

Coil Saturation

Surge

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Relationship Matrix - Faults

General Parameters:
FAILURE MODES
Loss of Performance
INDICATORS

Fouling

Corrosion

Performance Head Deviation

Process Efficiency Deviation

Indicators
Outlet
Temp.
Deviation
Polytropic Efficiency

Surge

Impeller
Damage
H

H Upper limit violation of indicator value.

L Lower limit violation of indicator value.
X Upper or lower limit violation of indicator value.

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Relationship Matrix - Faults

Radial Bearing Parameters:

FAILURE MODES
Rotor Faults Radial
INDICATORS

Change in
Vibration
X

Coil Saturation

Current

Rotor
Deformation
X

Position

Unbalance

Temperature

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Relationship Matrix - Faults

Axial Bearing Parameters:

FAILURE MODES
Rotor Faults Axial
INDICATORS

Change in Vibration

Coil Saturation

Current

Position

Temperature

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System Modeling
UVa RotorLab
Rotor Modeling
M, D, K Matrix Extraction
AMB Supported Rotor option

FEMM Finite Element Method Magnetics: Core

Electromagnet Design
Optimized AMB Design
Magnetic Flux analysis Number of turns, cross section shape,
position of electromagnets, etc.

COMSOL Multiphysics & MSC Software ADAMS, PATRAN

Conflicting license issues

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System Modeling
Maple
Solving 2nd order differential equations

MatLab / Simulink Approaches

Pure MatLab
Ansys + MatLab
Matlab + Simulink
Pure Simulink

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System Modeling Rotor

Matrices from FEM softwares versus from papers
More accurate rotor model, more DOF, larger matrix size (102
x 102), slower computation.
FEM model matrix reduction as compared to simple assembly.
Cross coupling between AMB system and rotor might not be
captured.
Validation concerns

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System Modeling Rotor

Jeffcott Rotor vs Real Sized
nDOF
Mass matrix
Stiffness matrix
Damping matrix
Gyroscopic matrix When in Motion

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System Modeling AMB

Depth of modeling
Coils
Number of turns, resistance, inductance

Cross-sectional area of the electromagnet in the gap

Current supplied
AMB Force relation per electromagnet vs per pair vs
per system

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System Modeling Control Logic

Centralized vs Decentralized Control
Voltage controlled vs Current Controlled
Simple vs Complex

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System Modeling Control Logic

PID
PD control logic is simple and most widely applied
It is better to omit the integral part since it destabilizes
control logic in cases of sudden peaks or drops.
Why then is PID preferred over a simple PD control for a
AMB supported rotor model?
Disadv Lower frequency & higher nonlinear region

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System Modeling Control Logic

Feedback Linearization
Back-stepping approach
Neural Network Control
Fuzzy Logic Control
Iterative Learning Control
Automatic Learning Control

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System Modeling Control Logic

H-Infinity Closed Loop Shaping
H-Infinity Open Loop Shaping
Q Parameterization
Mu Synthesis
ADR
Sliding mode control

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System Modeling Control Logic

Problems associated with an advanced control logic
a fine line
Too much control
Difficult to capture faults
Adaptive nature might smother the possibility of
knowing faults in the machine
To detect faults or have a system that keeps running
even when there are faults.

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System Modeling Rotordynamics

Bode Plots
Frequency response of the system
Effect of changing damping on the system

Impulse Response
Transfer Function
Extracting transfer function from the state space
matrices of the system

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System Modeling Rotordynamics

Poles
Zeros
Natural Frequency
Resonant Frequency
Critical Speeds
Structural Resonance

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System Modeling Rotordynamics

Damping Ratio
DC Gain
Nyquist Plot
Eigen Values, Eigen Vectors
Campbell Diagram

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5. Series Of Steps
1. Research various ways to develop a robust model that
can provide a good representation of the dynamics of
the system from rotor dynamics point of view.
2. Research on the various failure mode analysis for a
rotor on AMB system.
3. Get a good overview of the system from an
operational point of view to understand what
parameters are crucial in order to assess the health of
the system.

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5. Series Of Steps (Contd.)

4. Check for what data is available from an AMB system and
how the required parameters can be derived from them.
Current focus here involves extracting real time thrust
measurements and vibration values using rotor properties,
data sheets and real time incoming data. Both these
parameters can be extracted by developing a relation map
between available and design data.
For thrust bearing, a 3-way relation between thrust force, control
current and gap needs to be established.
For vibration data, a relation will have to be built between current
and position. The interest here is not the vibration seen with the
increased control current but the vibration amplitudes of the rotor
when simply levitated but not controlled. The increasing vibration
trend can provide a good idea of fouling or rotor damage.

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5. Series Of Steps (Contd.)

5. Build a cause and effect matrix where the failures are
matched against the parameter values. This matrix will
represent how certain parameter values going out of
bound on the upper or lower limit can indicate the
incipient faults in the system.
6. Build a rotordynamic model to explain the working of an
AMB system along with crucial plots of orbits, Campbell
diagram etc. This model will be used to open up the black
box operation of the AMB system.
7. Test the matrix validity using case data from sites and the
model.
8. Adding additional diagnostic capability by using an
algorithm to check for sensor faults. This will be valid only
for slow failures or faults in the sensors.

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Case Studies
Coil Saturation Dynamics
Stable Rotordynamics
Unstable Rotordynamics Continuous Disturbance
Unstable Rotordynamics Disturbance Outside Limits
Rotor Levitation
Effect of increased unbalance Variation in Current

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Other Research Thrust Force

IMP\KPIs\Book1.xlsx
IMP\THRUST CALCULATIONS\02.Design_and_analysis_of
_thrust_active_magnetic_bearing.pdf

Challenges
Available data
Validation
Accuracy

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Other Research User Note

Key aspects of specifying an AMB

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Timeline
Modeling & Validation December End
Model of Rotor, AMB with advanced controller
Validation with existing results
Replace advanced controller with PD/PID if control is too
high

Testing cases & result interpretation First half of

January
Report, consultation and defense Second half of
January

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