Maglev Controller Modules for Faster Manufacturing and Maintenance
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Solution Overview
Problem
The complexity and time-consuming nature of manufacturing and maintenance of magnetic bearing controllers due to their intricate structure and high number of discrete components, such as switching amplifiers and gate drivers, hinder efficient operation in magnetic levitation systems.
Innovation Solution
A modular controller design that integrates discrete components like gate drivers, IGBTs, and power MOSFETs into current source modules, simplifying the structure and facilitating maintenance by combining these components into a single package, with a control connection for managing electric current switching to coils in magnetic levitation equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If discrete components (gate drivers, IGBTs, power MOSFETs) are used separately in switching amplifiers, then control functionality is achieved, but device complexity and manufacturing time increase
Solution Approach 1:
The patent combines gate drivers, IGBTs, power MOSFETs, and other discrete components into an integrated current source module. This merging of previously separate components into a single modular unit directly reduces device complexity and enables faster manufacturing, as the integrated module can be produced as a complete functional unit rather than assembling multiple discrete parts.
2Ease of repair
If multiple discrete components are used in switching amplifiers, then current control channels are provided, but maintenance time increases
Solution Approach 1:
By integrating all necessary components (gate drivers, power switches, current channels) into a single current source module, the patent enables rapid maintenance through simple module replacement rather than complex component-level repairs. This significantly reduces maintenance time and improves ease of repair.
3Ease of manufacture
If a high number of discrete components are used, then controlled current channels are achieved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple discrete components into an integrated current source module that provides multiple controlled current channels internally. This approach simplifies manufacturing by reducing the number of separate components that need to be handled and assembled, while still achieving the required multi-channel current control functionality.
Data Source
AI summary
There is provided a controller for magnetic levitation equipment comprising a plurality of current source modules for connecting to at least one power supply for direct current, DC, and said current source modules comprising current channels for actuating coils of the magnetic levitation equipment, and a controller device connected to the current source modules by a control connection for controlling switching of electric current by the current source modules to the current channels. The current source modules combine discrete components for amplifying and switching electric current to the current channels into a single package. In this way, manufacturing and maintenance of the controller is facilitated, since manufacturing and maintenance may be based on the current source modules instead of discrete components, e.g. gate drivers, IGBTs, power mosfets and diodes.