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Electrical Design Considerations for a Bearingless Axial-Force/Torque Motor

A axial-force/torque motor (AFTM) establishes a completely new bearingless drive concept. The presented Lorentz-force-type actuator features a compact and integrated design using a very specific permanent-magnet excitation system and a concentric nonoverlapping air-gap stator winding. The end windings of the bent air-core coils, which are shaped in a circumferential rotor direction, provide active axial suspension forces. Thus, no additional (bearing) coils are needed for stable axial levitation. The four remaining degrees of freedom of the rotor are stabilized by passive magnetic ring bearings. This paper concentrates on the determination of the lumped parameters for the dynamic system modeling of the AFTM. After introducing a coordinate transformation for the decoupling of the control variables, the axial suspension force, and the drive torque, the relations for coil dimensioning are developed, followed by a discussion of the coil turn number selection process. Active levitation forces and drive torque specifications both must be concurrently fulfilled at a nominal rotor speed with only one common winding system, respecting several electrical, thermal, and mechanical boundaries likewise. Provided that the stator winding topology is designed properly, a simple closed-loop control strategy permits the autonomous manipulation of both control variables. A short presentation of the first experimental setup highlights the possible fields of application for the compact drive concept.