Modular Magnetic Levitation Controller for Easier 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 for magnetic levitation equipment is introduced, comprising current source modules that combine discrete components like IGBTs, power MOSFETs, and diodes into a single package, simplifying manufacturing and maintenance by allowing replacement of modules rather than individual components, and utilizing integrated power modules (IPMs) for amplifying and switching electric current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If discrete components (IGBTs, power MOSFETs, diodes) are used separately in switching amplifiers and gate drivers, then the magnetic bearing controller can provide precise current control for magnetic levitation, but the device complexity and manufacturing complexity increase significantly
Solution Approach 1:
The patent combines multiple discrete components (IGBTs, power MOSFETs, diodes, and control circuits) into an integrated power module package. This merging reduces the number of separate components and connections while maintaining the precise current control functionality needed for magnetic levitation, thereby reducing device complexity without sacrificing control precision
2Manufacturing precision
If a high number of discrete components are used in switching amplifiers with H-bridge or 3-phase bridge topology, then the magnetic levitation system can achieve precise position control, but the manufacturing time and maintenance complexity increase
Solution Approach 1:
The patent integrates multiple discrete components into a single power module package, reducing the number of assembly steps and components that need to be manually handled during manufacturing. This integration maintains the precise position control capability while significantly improving manufacturing ease and reducing production time
3Adaptability or versatility
If separate gate drivers are used for controlling power switches in each current channel, then the magnetic bearing controller can independently control each current channel, but the device complexity and maintenance difficulty increase
Solution Approach 1:
The patent combines multiple current channel control circuits and their associated gate drivers into a single integrated power module. This integration maintains the ability to independently control each current channel for precise magnetic bearing operation while simplifying maintenance, as the entire control assembly can be replaced as a single unit rather than troubleshooting individual gate drivers
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This modular approach reduces the complexity of manufacturing and maintenance, facilitates faster troubleshooting, and enhances the operational efficiency of magnetic levitation systems by integrating discrete components into a single package, thereby improving the overall control and reliability of magnetic levitation equipment.
Implementation Method 1
Positions of levitated objects can be controlled by electric currents that are fed to coils that generate the magnetic fields
Implementation Method 2
In magnetic levitation, forces exerted by magnetic fields are used to counteract other forces e.g. the gravity, whereby levitation of objects is achieved
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.