Magnetic Levitation System PDF

Mechatronics
Magnetic Levitation System

Dynamic System Investigation
Kevin Craig
Rensselaer Polytechnic Institute
Mechatronics K. Craig
Magnetic Levitation System 1
Magnetic Levitation System A Genuine Mechatronic System
Electromagnet
Phototransistor
Infrared LED
Levitated Ball
Overall Objective
The objective of this exercise is to build and test
a one-degree-of-freedom magnetic levitation
device, i.e., a device to keep a ferromagnetic
object suspended, without contact, beneath an
electromagnet, and perform a complete dynamic
system investigation.
By measuring the location of the object using a
non-contact sensor, and adjusting the current in
the electromagnet based on this measurement,
the levitated object can be maintained at a
predetermined location.
Dynamic System Investigation
Parameter
Identification
Physical Physical Mathematical

System Model Model
Experimental Mathematical
Comparison
Analysis Analysis
Design
Mechatronics Changes K. Craig
This system is both inherently nonlinear and
open-loop unstable.
Steps for a Dynamic System Investigation
Physical System Description
Physical Modeling (Truth Model vs. Design Model)
Model Parameter Identification
Mathematical Modeling
Dynamic System Behavior Prediction
Experiments to Validate Analytical Model
Feedback Control System Design and Implementation
Testing to Evaluate System Performance
Determine Design Improvements
Required Background
Electromechanics: Elementary Electromagnet
Linearization of Nonlinear Physical Effects
Electronic Components
Resistor, Capacitor, Inductor
Electrical Impedance & Analogies
Potentiometer and Voltage Divider
Op-Amp Basics + Buffer, Summer, Difference, Inverting
Active Lead / Lag Controller
Diode and Light-Emitting Diode (LED)
Transistor: npn BJT, pnp BJT, Phototransistor
Physical System Description
The Magnetic Levitation System consists of the

following subsystems:
Electromagnet Actuator mounted in a stand
Ball-position Sensor: Infrared LED and
Phototransistor, positioned in the stand
Analog Circuitry on a breadboard
Lead Controller (analog implementation)
Current Amplifier
Assorted op-amps, resistors, capacitors, potentiometers, and
diodes for controller implementation, sensor adjustment,
buffering, gain adjustment, summing, and inverting.
Required Power Supplies include:
15 volts for op-amps
+ 15 volts for electromagnet and phototransistor
+ 15 volts for command and bias voltage generation
+ 5 volts for infrared LED
Current requirements: 300 mA maximum
Microcontroller for Digital Control
Implementation
Blue Earth Micro 485
Microprocessor: Intel 8051 - 12 MHz
Digital I/O: 27 bi-directional TTL-compatible pins
Analog Inputs: 4 12-bit, 0-5 V, A/D converter channels
Serial Communication: RS 232
128K battery-backed RAM; 32K ROM
Magnetic Levitation System A Genuine Mechatronic System
Electromagnet
i Phototransistor
Vsensor = 5.44 V
At Equilibrium
Infrared LED
+x
Levitated Ball Equilibrium Conditions
m = 0.008 kg x0 = 0.003 m
r = 0.0062 m = 0.24 in i0 = 0.222 A
Electromagnet Actuator
Current flowing through the coil windings of the
electromagnet generates a magnetic field.
The ferromagnetic core of the electromagnet provides
a low-reluctance path in the which the magnetic field
is concentrated.
The magnetic field induces an attractive force on the
ferromagnetic ball.
Electromagnetic Force
Proportional to the square
of the current
and FI i
2
Inversely proportional to the HK

f ( x, i) = C
x
square of the gap distance
The electromagnet uses a - inch steel bolt as the core with
approximately 3000 turns of 26-gauge magnet wire wound
around it.
The resistance of the electromagnet at room temperature is
approximately 32 .
0.25"
1.4"
2.6"
1.5"
Core Windings
+5V +15V
Phototransistor
1 K
-
+ Vsensor
62
Unity Gain
Buffer Op-Amp
200 K
Infrared Ball-Position Sensor
LED LED Blocked: Vsensor = 0 V
LED Unblocked: Vsensor = 10 V
iemitter = 15 mA
Equilibrium Position: Vsensor 5.40 V
Ksensor 4 V/mm Range 1mm
Emitter Detector
Ball-Position Sensor
The sensor consists of an infrared diode (emitter) and
a phototransistor (detector) which are placed facing
each other across the gap where the ball is levitated.
Infrared light is emitted from the diode and sensed at
the base of the phototransistor which then allows a
proportional amount of current to flow from the
transistor collector to the transistor emitter.
When the path between the emitter and detector is
completely blocked, no current flows.
When no object is placed between the emitter and
detector, a maximum amount of current flows.
The current flowing through the transistor is
converted to a voltage potential across a resistor.
The voltage across the resistor, Vsensor, is sent through
a unity-gain, follower op-amp to buffer the signal and
avoid any circuit loading effects.
Vsensor is proportional to the vertical position of the ball
with respect to its operating point; this is compared to
the voltage corresponding to the desired ball position.
The emitter potentiometer allows for changes in the
current flowing through the infrared LED which affects
the light intensity, beam width, and sensor gain.
The transistor potentiometer adjusts the phototransistor
current-to-voltage conversion sensitivity and allows
adjustment of the sensors voltage range; a 0 - 10 volt
range allows for maximum sensor sensitivity without
saturation of the downstream buffer op-amp.
Vbias
Vdesired
+ i
+ Gc(s)

Current G(s)
- Controller + Amplifier Magnet + Ball
Vactual H(s) X
Sensor
From Equilibrium:
As i , x, & Vsensor
As i , x , & Vsensor
Block Diagram
Linear Feedback Control System
to Levitate Steel Ball
about an Equilibrium Position
Corresponding to Equilibrium Gap x0
and Equilibrium Current i0
+15V Unity Gain
Buffer Op-Amp
Command and Error Signal
-
Generation
+ Vcommand
10 K
Vcommand 100 K 100 K
Voltage 100 K -
Vsensor
Divider -Verror
+
From Equilibrium:
As i , x, & Vsensor Difference
100 K
Op-Amp
As i , x , & Vsensor
Active
C 2 = 0.01 F
Lead Controller
R 4 = 50 K
R1 = 100 K R 2 = 100 K
-Verror
- R 3 = 1.6 K
-
+
C1 = 0.1 F
+
Vcontrol
51 K Lead Controller 1.6 K
Inverting
Op-Amp
Vcontrol R 2 R 1C1s + 1 R 4 R 4 0.01s + 1

= =
Verror R1 R 2 C 2s + 1 R 3 R 3 0.001s + 1
+15V Vbias with
Unity Gain Vbias Generation &
-
Buffer Op-Amp Summation with Vcontrol
+ Vbias
Unity Gain
10 K
Inverting
Op-Amp
Vbias 10 K 10 K
Voltage 10 K
Divider
- 10 K
Vcontrol -
10 K +
+ Vbias
Summing +
Op-Amp 5.1 K 5.1 K Vcontrol
Vbias = 1.77 V
At Equilibrium
Current Amplifier +Vsupply
R2 Vsupply = 15 V
i em = ( Vcontrol + Vbias ) > 9.65 V R3
R 1R 3
Vsupply
R2 = isat
R em + R 3
Vcontrol > 9.65 V
+ - pnp BJT
Transistor
Vbias +
+
< 9.93 V iem
- npn BJT
Transistor
Electro-
diode Magnet
R1 = 1000
< 9.93 mA
R 2 = 510 R1
Rem = 32
R 3 = 17.8 (20W) i 0 = 0.222 A
x 0 = 3.0 mm
i
Electromagnet Control System Design
F iI 2 +x
f ( x, i) = C
H xK Ball (mass m) Linearization:
mg
i2 i2 2i 2 2i
Equation of Motion: C 2 C 2 C 3 x + C 2 i
x x x x
i2
mx = mg C 2
x i 2
2 i 2
2i
mx = mg C 2 + C 3 x C 2 i
At Equilibrium: x x x
i 2 2 i 2
2i
mg = C 2 mx = C 3 x C 2 i
x x x
Vbias
Vdesired Kamp = 0.0287 A/V
+ i
+ Gc(s)

Current G(s)
- Controller + Amplifier Magnet + Ball
Vactual H(s) X
Sensor
Ksensor 4 V/mm
m = 0.008
g = 9.81 i2
mg = C 2 C = 1.4332E 5
x = 0.003 x
i = 0.222
2 i 2
2i
mx = C 3 x C 2 i x 88
x x = 2
i ( s 6540 )
x = 6540x 88i

Open-Loop 88
( 0.0287 )( 3000 )
Transfer Function ( s 6540 )
2
R 4 0.01s + 1 0.01s + 1
Controller R 0.001s + 1 = 4 0.001s + 1
3
Digital Implementation of Controller
The analog controller has a high bandwidth needed to
compensate for inherent instability and nonlinearities.
Digital controllers have an advantage in that the control system
is implemented in software rather than in hardware, and is
therefore much easier to modify.
However, a controller implemented digitally has the
disadvantages of quantization and limited sampling rate, which
can adversely affect system performance.
12-bit A/D
-Verror Scaling Digital Scale &

8-bit D/A
Circuit Controller Offset
DAC 08
05V Ts Gc(z) Circuitry
Microcontroller
With To
A/D Converter Buffer Op-Amp

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Mechatronics

Magnetic Levitation System

Physical Physical Mathematical

The Magnetic Levitation System consists of the

Inversely proportional to the HK

Vcontrol R 2 R 1C1s + 1 R 4 R 4 0.01s + 1

-Verror Scaling Digital Scale &

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