A Real-Time Numerical Decoupling Method for Multi-DoF Magnetic Levitation Rotary Table

Abstract

Magnetic levitation technology shows promise for realizing multiple degrees of free precision motion for modern manufacturing, as the bearing and guiding parts are not used. However, motion decoupling in a magnetically levitated (maglev) system is difficult because it is hard to derive accurate magnetic force and a torque model considering the translation and rotation in all axes. In this work, a magnetic levitation rotary table that has the potential to realize unlimited rotation around the vertical axis and a relatively long stroke in the horizontal plane is proposed and analyzed, and the corresponding real-time numerical decoupling method is presented. The numerical magnetic force and torque model solves the current to magnetic force and torque transformation matrix, and the matrix is used to allocate the exact current in each coil phase to produce the required motion in the magnetically levitated (maglev) system. Next, utilizing a high-level synthesis tool and hardware description language, the proposed motion-decoupling module is implemented on a field programmable gate array (FPGA). To realize real-time computation, a pipelined program architecture and finite-state machine with a strict timing sequence are employed for maximum data throughput. In the last decoupling module of the maglev system, the delay for each sampling point is less than 200 μ s. To illustrate and evaluate real-time solutions, they are presented via the DAC adapter on the oscilloscope and stored in the SD card. The error ratios of the force and torque results solved by the numerical wrench model were less than 5 % and 10 % using the solutions from the boundary element method (BEM) program package RadiaTM as a benchmark.