Modular Magnetic Levitation Controller for Simpler Current Switching
Find Innovative SolutionsGenerate Solutions
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 gate drivers, IGBTs, and diodes, in switching amplifiers used for magnetic levitation equipment.
Innovation Solution
A modular controller for magnetic levitation equipment that combines discrete components like gate drivers, IGBTs, and diodes into current source modules, simplifying manufacturing and maintenance by allowing replacement of modules rather than individual components, and utilizing integrated power modules (IPMs) to amplify and switch electric current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If discrete components (gate drivers, IGBTs, diodes) are used to build switching amplifiers for magnetic levitation control, then the controller can provide controlled current sources for multiple current channels, but the structure becomes complex and manufacturing/maintenance becomes time-consuming
Solution Approach 1:
The patent divides the switching amplifier into multiple independent current source modules, where each module handles a specific current channel. This segmentation allows the complex controller to be broken down into manageable, replaceable units that can be manufactured and maintained more efficiently while still providing the required controlled current sources for magnetic levitation control.
2Productivity
If a high number of discrete components are used to create ten controlled current channels in a switching amplifier, then the magnetic bearing controller can achieve precise control, but manufacturing and maintenance become complex and time consuming
Solution Approach 1:
The controller is segmented into multiple current source modules, each capable of providing controlled current for specific channels. This allows parallel manufacturing of modules and faster replacement during maintenance, reducing the time loss associated with handling ten discrete current channels while maintaining precise control capability.
Solution Approach 2:
Multiple discrete components (gate drivers, IGBTs, diodes) are merged into integrated current source modules. This combining reduces the number of individual components that need to be manufactured and maintained separately, thereby reducing manufacturing and maintenance time while still achieving the required ten controlled current channels for precise magnetic bearing control.
3Extent of automation
If separate gate drivers are used for controlling power switches in each current channel, then precise switching control is achieved, but the overall controller structure becomes complicated
Solution Approach 1:
The gate driver, power switches (IGBTs), and diodes are merged into a single integrated current source module. This consolidation maintains precise switching control capability while simplifying the overall controller structure by eliminating the need for separate gate driver circuits for each current channel, thereby reducing structural complexity.
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 simplifies the manufacturing and maintenance of magnetic levitation controllers, reducing complexity and time by allowing for faster replacement of current source modules, thereby improving operational efficiency and reducing troubleshooting efforts.
Implementation Method 1
The current source modules combine discrete components for amplifying and switching electric current to the current channels
Implementation Method 2
Positions of levitated objects can be controlled by electric currents that are fed to coils that generate the magnetic fields
Implementation Method 3
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.