A Study on Characteristics of Flow Field of Air Gap in Maglev Spherical Active Joints for Multi-DOF Spindle System.
Zhang, Fan ; Zeng, Li ; Li, Yan 等
A Study on Characteristics of Flow Field of Air Gap in Maglev Spherical Active Joints for Multi-DOF Spindle System.
1. Introduction
Spindle tools capable of six-degree-of-freedom spatial movement in
any posture is one of the key features of existing advanced CNC machine
tools. The multi-degree-of-freedom spindle systems are generally
classified into two types: new spindle with parallel structure and
traditional spindle with cascaded structure [1]. The former changes its
position and posture by employing several servo-motor or hydraulically
driven links with controllable lengths, whereas the latter utilizes
multiple mechanical rotating structures, each of which controls the
rotation for only one degree-of-freedom, thus controlling the direction
of spindle tool (Fig. 1).Both types of spindles are faced with the
following defects: 1. numerous joints complicates the mechanical
structure and worsens the driving efficiency and reliability; 2. serious
abrasion caused on the friction surfaces of joints response speed and
dynamic characteristics; and 3. accumulation of mechanical errors
resulting in lowering the accuracy of control system.
To address these defects, quasi-human joints with better efficiency
could be constructed based on simplified spherical joints, that is to
say to utilize maglev spherical active joints supported and driven by
motors with spherical surface in contact [2-7]. Using such kind of
active joints in a CNC machine will reduce the complexity of multi-DOF
spindles and improve their position and posture accuracies and response
speed. Under high-speed operation of spindles, rotor surface drives the
air in gap to rotate along with the rotor and form a circumferential air
circulation in gap, thereby engendering an air film in the flow field of
air gap between the stator and the rotor to generate a levitating force
or resistance [8]. For the film, how its flow field pressure and dynamic
characteristics are distributed and changed exerts direct influence upon
the dynamic and static performance of joint. However, present studies
normally ignore the effects of the levitating force or resistance
generated by the air film upon rotor's movement and dynamic
performance, which explains the deviation between theoretical analysis
and reality in terms of their motions. A lot of scholars [9-16] have
achieved some valuable results in both terms of theoretical modeling and
experimental verification, which have been practiced in engineering.
However, studies on the characteristics of flow field of air gap in
maglev spherical active joint have been little reported in both China
and other countries. This paper explored the flow field of air gap in
maglev spherical active joint and its dynamic & static
characteristics based on aerodynamics, established mathematical models
for dynamic & static pressures and kinetic parameters of flow field
of air gap, and, with simulation and experiment, investigated how the
flow field of air gap impacts its static load-carrying capacity and
dynamic characteristics.
2. Principles of maglev spherical active joints and variation
pattern of air gap
2.1. Principles of joint generating electromagnetic torque and
levitating force
However, the difference from conventional motors is that, the
joints should extend its rotor from uni-dimensional rotation around a
fixed axis to spatial rotation around a fixed point. In this case,
rotor's angular velocity vector [omega] has to be changed from a
directed scalar to a spatial vector in an arbitrary direction. [omega] =
[[omega].sub.x]i + [[omega].sub.y]j+ [[omega].sub.z]k, where i, j and k
represent unit vectors in three arbitrary axes, respectively. However,
nonlinear coupling relations are shown among mechanical equilibrium
equations of three orthogonal axes. Thus, to effectively and separately
manipulate the three vector components of angular velocity for the rotor
of joint, three axial electromagnetic torques [M.sub.x], [M.sub.y] and
[M.sub.z], which are independently controllable. In an orthogonal
coordinate system, the three torque vector components are combined as M
= [M.sub.x]i + [M.sub.y]j+ [M.sub.z]k, and the resultant torque is a
spatial vector in an arbitrary direction.
To yield electromagnetic torques in arbitrary controllable spatial
directions, the maglev spherical active joint should produce a resultant
magnetic field, whose amplitude and axis direction can totally be
manipulated. Based on a Cartesian coordinate system, this paper prepared
three-phase AC windings around each coordinate axis. A two-dimensional
magnetic field vector was formed by electrifying symmetrical three-phase
windings with symmetrical three-phase alternating currents, and the
magnetic field vector rotated round its axis. These magnetic field
vector could also be formed by two phase AC windings with two quadrature
alternating currents. Then combining 2D magnetic field vectors of all 3
coordinate axes with each other formed a 3D magnetic field, which
rotated around an arbitrary axis passing through a fixed spatial point.
As shown in Fig. 2, three windings that generated 2D magnetic fields are
represented by [W.sub.x], [W.sub.y] and [W.sub.z], respectively.
Therefore, the structure of a maglev spherical active joint can be
designed according to the formation mechanisms of a spatial rotating
magnetic field, as shown in Fig. 3. The core of stator also provided a
spherical surface internally to accommodate to the spherical rotor and
engender a uniform air gap between them.
Three windings (corresponding to three coordinate axes) with axes
mutually orthogonal were also embedded into the slotted core of stator.
Each winding was divided into two sections, which were symmetrically
wrapped around the core of stator in two hemispherical slots. Fig. 4
shows the electromagnetic winding in z direction of the rotor of maglev
spherical active joint, where [W.sub.z] is divided into two symmetrical
windings [W.sub.z.sup.+] and [W.sub.z.sup.-], representing the positive
and negative hemispherical windings of stator, respectively, with 1 and
2 referring to the spherical rotor and stator of joint, respectively.
Windings wrapped around 3 axes were energized by adjustable 3-phase
alternating currents [i.sub.A], iB and iC and a controller was employed
to control torques and speeds (or angular displacements) for both
winding sections on each axis, thereby generating parallel
electromagnetic torques with same direction to drive the rotor to rotate
around this axis. For example, providing the generated resultant
electromagnetic torque in z-axis was [M.sub.z] =[M.sub.z.sup.+]
+[M.sub.z.sup.-] . The levitated rotor shares the same working
principles with those traditional electromagnet bearings. As illustrated
in Fig. 4, when the rotor in z direction deviated from its balanced
position under interference, its gap in positive z-axis shrank. For such
conditions, to return the rotor back to stator's centre
(that's the balanced position) under closed-loop control, the
currents applied onto the hemispherical windings of joint's stator
below the rotor were increased by [DELTA][i.sub.z], whereas the currents
applied onto other side were reduced by [DELTA][i.sub.z]. The difference
between electromagnet pulls generated by upper and lower hemispherical
windings of stator enabled the rotor to return to the balanced position
at the centre of stator and the resultant levitating force was [F.sub.z]
= [F.sub.z.sup.+] -[F.sub.z.sup.-], as shown in Fig. 4. The rotation and
levitation mechanisms in x-axis and y-axis can be analysed in the same
way.
2.2. Variation pattern of air gap in maglev joint
When the rotor of maglev spherical active joint rotates at a high
speed around the spindle, the air circulation in the flow field of air
gap can directly affect the dynamic & static performances of joint.
The characteristics of air circulation are in close relation with the
variation pattern of air gap length. As shown in Fig. 5, a, a 3D
coordinate system was established for the maglev spherical active joint.
The air gap is illustrated in Fig. 5, b when there is no deviation
for the centre of sphere of rotor, where r is the outer radius of rotor;
R is the inner radius of stator; and c is the average length of air gap
when the centre of sphere of stator coincides with the centre of sphere
of rotor. Fig. 5, c shows the case where the centre of sphere of rotor
deviates from the balanced position, where h is the air gap length
between stator and rotor at arbitrary spatial positions.
[h.sub.11](t) = x(t)-[m.sub.11](t). (1)
Radius vector R in the coordinate system Oxyz is represented as
[17] 17:
R = isin[theta]cos[phi] + jsin[theta]sin[phi] + kcos[theta]. (2)
The eccentricity from the geometrical centre of rotor [O.sub.1] to
the geometrical centre of stator O is represented as:
e = i * x + j * y + k * z., (3)
Take the geometrical centre of rotor [O.sub.1] as the origin of a
radius vector, which intersects with the internal surface of stator at
point P. As the eccentricity e is far less than r and R,
[angle][O.sub.1]PO is little and it can be obtained that
[angle][O.sub.1]PO [approximately equal to] 1, so in the triangle as
shown in the figure, the relation is as follows :
h + r = R - e * R, (4)
or
h=c- xsin[theta]cos[phi] - ysin[theta]sin[phi] - zcos[theta]. (5)
3. Static load-carrying capacity model for flow field of air gap in
maglev joint
3.1. Static pressure distribution model for air film in air gap of
maglev joint.
When the rotor rotates at a high speed, the air in gap will form a
layer of air film against the stator. The static pressure distribution
on the air film can be derived from continuity equation of fluid,
equation of motion, state equation of fluid and energy equation. A
pressure distribution equation can also be derived for the compressive
flow field in a spherical coordinate system and its dimensionless form
is expressed as follows:
[mathematical expression not reproducible] (6)
where: [LAMBDA] is the load-carrying coefficient, [mu] is the
dynamic viscosity of fluid; r is the radius of joint's rotor; P is
the dimensionless pressure of flow field and P=p/[p.sub.a]; [p.sub.a] is
the ambient atmospheric pressure (Pa); H is the dimensionless thickness
of air film, H= [h/c] = 1 - [[epsilon].sub.x]sin[theta]cos[phi] -
[[epsilon].sub.y]sin[theta]sin[phi] - [[epsilon].sub.z]cos[theta],
[[epsilon].sub.x] = [x/c], [[epsilon].sub.y] = [y/c], [[epsilon].sub.z]
= [z/c], [tau] = [omega]t, t is the time and [omega] is the circular
frequency for rotor working.
3.2. Static load-carrying capacity of air film in air gap of maglev
joint
As the static pressure distribution equation of air film has no
relation with the time, each of following static variables is
represented with a subscript 0 for the purpose of being distinguished.
So according to Eq. (6), the static pressure distribution equation we
can obtain is as follows:
[mathematical expression not reproducible] (7)
[mathematical expression not reproducible] (8)
Then solve for the boundary conditions: 1) At the place where the
air gap contacts with the atmosphere, [P.sub.0] = [P.sub.a]; 2) The
rotor has an eccentric angle [[phi].sub.0] =
arctan([[epsilon].sub.y]/[[epsilon].sub.x]), and let [P.sub.0] =
[P.sub.a] at the place where [phi] = arctan([[epsilon].sub.y]
/[[epsilon].sub.x]) + [pi].
We can combine Eq. (7) and Eq. (8) to get the thickness [H.sub.0]
and the pressure [P.sub.0] of air film. Further, after we obtain the
steady state, the load on the static air film and the damping moment of
air film with the direction along the axis of rotation can be expressed
as:
[mathematical expression not reproducible] (9)
where: d[OMEGA] = ([R.sup.2]sin[theta]) d[phi] * d[theta].
4. Kinetic model for flow field of air gap in maglev spherical
active joint
Due to effects from mass centre and external forces, the rotor
rotating at a high speed could suffer turbulence at its balanced
position. The dynamic response of air film affects the stability of
rotor, so it is necessary to study its dynamic characteristics.
4.1. Dynamic pressure distribution model for air circulation in air
gap of maglev joint
Under turbulence, the rotor will deviate from its balanced point,
where the three coordinate components of the turbulence are represented
by [E.sub.x0], [E.sub.y0] and [E.sub.z0], respectively. Assuming the
turbulence appears in a sinusoidal form, the rotor position at any time
can be expressed as [18]:
[mathematical expression not reproducible] (10)
where: f is the dimensionless turbulence frequency, f =
[[nu]/[omega]], v is the turbulence frequency of rotor; i is the
imaginary unit.
So we can obtain the thickness of air film for the rotor at any
position:
H=[H.sub.0]-[H.sub.d], (11)
where: [H.sub.0] is the thickness of static air film and [H.sub.d]
is the thickness of dynamic air film.
[mathematical expression not reproducible] (12)
where: [H.sub.d0] is the amplitude of dynamic air film, a complex
number.
Under slight turbulence, the pressure of dynamic air film can be
expressed as:
P = [P.sub.0] + [P.sub.d] = [P.sub.0] + [P.sub.d0][exp.sup.ift],
(13)
where: [P.sub.d] is the pressure of dynamic air film and [P.sub.d0]
is the pressure amplitude of dynamic air film, a complex number.
Substituting Eq. (12) and Eq. (13) into Eq. (6) gives the following
dynamic equation of air film:
[mathematical expression not reproducible] (14)
This dynamic equation of air film (14) implies the turbulence
components [E.sub.x0], [E.sub.y 0] and [E.sub.z 0]. In order to obtain
the dynamic stiffness and damping coefficient of the air film under
dynamic pressure, the partial derivative method is used. Let:
[mathematical expression not reproducible] , [mathematical expression
not reproducible].
Finding the derivative of Eq. (14) and [H.sub.d 0] gives the
equations for [P.sub.Ex], [P.sub.Ey], and [P.sub.Ez]. Equations for
[P.sub.Ex] are:
[mathematical expression not reproducible] (15)
[H.sub.Ex]=cos[phi]sin[theta]. (16)
Then solve for the boundary conditions:
1. At the place where the air gap contacts with the atmosphere,
[P.sub.0] =[P.sub.a] ;
2. The rotor has an eccentric angle [[phi].sub.0]
=arctan([[epsilon].sub.y]/[[epsilon].sub.x]) and let [P.sub.0] =
[P.sub.a] at the place where [phi] = arctan ( [epsilon] / [epsilon]) +
[pi] .
We can combine with Eq. (15) to obtain [P.sub.Ex]. Then, [P.sub.Ey]
and PEz can be obtained in the same way.
4.2. Dynamic characteristic parameters for flow field of air gap in
maglev joint
By obtaining the pressure [P.sub.0] of static air film and
substituting it into the dynamic equation of air film, we can obtain the
dynamic pressure distribution of air film. With [P.sub.Ex], [P.sub.Ey]
and [P.sub.Ez] known, we can obtain the dimensionless dynamic stiffness
and the dynamic damping coefficient, expressed as follows, respectively:
[mathematical expression not reproducible] (17)
5. Simulation and experimental study for static & dynamic
performances of flow field of air gap in maglev spherical active joint
Write a program via finite difference method based on above
analysis results to calculate the static & dynamic performances of
air film in the spherical joint. By investigating how the eccentric
position and speed of the rotor affect the static pressure and damping
moment of the air film, as well as how the turbulence frequency of rotor
influences the dynamic stiffness and damping coefficient of the air
film, we can obtain the parameters of spherical joint and its operation
parameters, as listed in Table 1.
5.1. Performance simulation for flow field of air gap in maglev
spherical active joint
Fig. 6 illustrates the distribution pattern of loaded pressure for
the flow field of air gap in joint. The loaded pressure of the flow
field of air gap would be in proportion to the load-carrying stiffness
of the air gap if a controller is used to maintain the air gap.
Therefore, analysing the variation pattern of load-carrying capacity for
the air gap could manifest the variance tendency of the air film
stiffness. Many factors, mainly the average length of air gap, the speed
of rotor and the eccentricity, can impact the distribution pattern of
load-carrying capacity or stiffness of air film in the flow field of air
gap.
How the load-carrying capacity of air film varies with the average
length of air gap is shown in Fig. 7, where the load-carrying capacity
drops as the average length goes up. The reason is that the
load-carrying capacity will exponentially drop as the average length
goes up.
Fig. 8 shows the variation of the load-carrying capacity of air
film with the angular velocity of rotor, where it can be found both the
load-carrying capacity and the stiffness increase as the rotation speed
increases, because the load-carrying coefficient of air film as the
rotation speed increases. However, since the film is communicated to the
atmosphere, the load-carrying capacity and the stiffness cannot increase
endlessly but their variances tend to be gentle in the end.
Fig. 9 exhibits the variation of the load-carrying capacity of air
film with the eccentricity, where the load-carrying capacity
significantly increases as the eccentricity goes up. The reason is that
once the film thickness h at a position changes, the film pressure will
alter correspondingly to maintain continuity.
Providing the rotation speed of joint is 100000 r/min and the
turbulence displacement in positive x-axis is 1[micro]m, three contour
plots, as shown in Fig. 10, can be obtained to illustrate the dynamic
pressure change of air film when the air gap in z-axis lower spherical
surface of joint is set at 0.5 s, 2 s and 5 s, respectively. According
to simulation results, the dynamic pressure zone of the air gap keeps
changing with the rotation of rotor, and the film pressure under
turbulence displacement is higher than that under static balance, which
is because the turbulence displacement increases the eccentricity,
enabling the film pressure to be increased as well. Based on the colour
distribution in these plots, the pressure around z-axis approximately
shows a sinusoidal (or cosine) distribution.
Fig. 11 shows the dynamic stiffness diagram and the dynamic damping
coefficient diagram of air film when the eccentricity is set to
[[epsilon].sub.x] = 0.4, [[epsilon].sub.y] = 0.4 and [[epsilon].sub.z] =
-0.6.
We can see from Fig. 11 that the dynamic stiffness and the damping
coefficient show close relations with the turbulence frequency of rotor.
Generally, when f < 2, as the turbulence turns more frequent, dynamic
stiffness [K.sub.xx], [K.sub.yy] and [K.sub.zz] increase, while the
absolute values of [K.sub.xy], [K.sub.xz], [K.sub.yx], [K.sub.yz],
[K.sub.zx] and [K.sub.zy] decrease. All absolute values of dynamic 5.2.
Experiment for load-carrying capacity of flow field of air gap
Fig. 12 shows an experiment setup for controlling an inductive
maglev spherical active joint studied in this paper, and this setup was
consisted of a joint, an input channel for data collected in the
experiment, an output channel for control, and a high-speed processor.
First, the experiment setup as shown in Fig. 12 was used to measure
the resultant supporting force of joint's rotor. Then, subtract the
measured electromagnetic levitation force from the resultant supporting
force according to Newton's second law, and the obtained result was
approximately equal to the force by which the air film in the flow field
of air gap supported the rotor rotating at a high speed. we only
compared the abovementioned theoretical simulation results with the
experimental results in terms of variation pattern or tendency. When the
rotor of the maglev spherical active joint rotated at a high speed
around the z-axis, the air circulation pressure distribution pattern in
the flow field of air gap, which was located in the lower hemispherical
surface of joint's stator and vertical to the spindle and passed
through the section with maximum load, is shown in Fig. 13. Its
distribution pattern and the air film pressure simulation results are
similar to those shown in Fig. 10. The air circulation pressure
distribution pattern mainly was dependent on [c/r], the ratio between
air gap length (clearance) and rotor radius. As shown in the figure,
when the gap was small, the air film acted as a fluid plain bearing and
the Reynolds number effect occurred. But when the ratio increased, the
Bernoulli effect arose, which caused the rotor to vibrate and displace,
leading to increased flow rate and decreased pressure at the side where
the gap decreased. As the vibration displacement increased further, the
rotor in vibrating would lose its stability, thus determining the
boundary condition for the stability of vibration of rotor [19].
[[omega].sub.c][less than or equal to]2[[omega].sub.n]. (18)
Where: [[omega].sub.c] is the critical speed of the rotor losing
stability; and [omega]n is the intrinsic frequency of rotor.
Fig. 14 reflects major factors affecting the load-carrying capacity
of air film. Fig. 14, a shows how the load-carrying capacity of air film
changes with the rotation speed in general, the capacity increases as
the speed increases, with the variation tendency and the simulation
analysis results as shown in Fig. 7. However, due to restricted
practical test conditions and test errors, there was little consistency
between test data and theoretical data. Fig.14, b represents how the
load-carrying capacity of air film changes with the air gap under
different rotation speeds of the joint, where it can be found that, the
shown tendency of the radial load-carrying capacity changing with the
air gap under different rotation speeds is basically consistent with the
theoretical simulation analysis results shown in Fig. 7 i.e. the
capacity drops as the air gap increases.
Fig. 14, c shows how the load-carrying capacity of air film changes
with the eccentricity under different rotation speeds of joint. It can
be found in this figure that regardless of the speed of joint, all
curves show basically the same variation pattern, which is generally
consistent with the theoretical simulation analysis results. As
eccentricity goes up, the load-carrying capacity of air film increases
and its hydrodynamic effect turns more significant, which can benefit
the operation performance of joint.
6. Conclusions
Since a machine spindle requires multi-DOF movement, this paper
proposes a multi-DOF maglev spherical active joint, and analyses the
three-dimensional rotation of active joint rotor around any axis of a
fixed spatial point, as well as the principle of maglev fields. It also
established the mathematical models for static & dynamic pressures
and dynamic parameters of air gap flow field in the maglev spherical
active joint, based on Reynold's equation of dynamic pressure of
flow field air. In addition, simulation and experimental study are
performed on air film's load-carrying capacity in the air gap flow
field, as well as its dynamic characteristics. The experimental and
simulation results are qualitatively compared to validate the
effectiveness of air gap flow field model, with discussions on the main
factors affecting the joint's load-carrying capacity. The research
shows that in the drive application of multi-DOF active joint, the
influence of air gap flow field is ignored, but its effect grows more
significant with the increase of spindle rotor speed. Therefore, the
research in this paper provides a new idea and method to make better use
of 6-DOF maglev spherical active joint in spindle research and
development, and to explore the dynamic characteristics of high-speed
spindle and the use of pneumatic structure.
Acknowledgments
This work was financially supported by China Natural Science
Foundation under Grant No. 51375427, Jiangsu Natural Science Foundation
under Grant No. BY2014117-08 and No. BY2015061-04, Jiangsu
Industry-University-Research Foundation for Prospective Joint Study
under Grant No. BY2014117-08 and No. BY2015 061-04, and Yangzhou
City-University-Cooperation Research Foundation under Grant No.
YZ2016255. The support is gratefully acknowledged.
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Fan ZHANG (*), Li ZENG (**), Yan LI (***), Zi ZENG (****), Zhida
ZHU (*****), Jin SUN (******), Min DAI (*******)
(*) School of Mechanical Engineering, Yangzhou University,
Yangzhou225127, China, E-mail: fzhang@yzu.edu.cn
(**) School of Mechanical Engineering, Yangzhou University,
Yangzhou225127, China, E-mail: lizengcf@163.com
(***) School of Mechanical Engineering, Yangzhou University,
Yangzhou225127, China, E-mail: yli@yzu.edu.cn
(****) School of Mechanical Engineering, Yangzhou University,
Yangzhou225127, China, E-mail: zzeng@yzu.edu.cn
(*****) School of Mechanical Engineering, Yangzhou University,
Yangzhou225127, China, E-mail: zdzhu@yzu.edu.cn
(******) School of Mechanical Engineering, Yangzhou University,
Yangzhou225127, China, E-mail: jinsun@yzu.edu.cn
(*******) School of Mechanical Engineering, Yangzhou University,
Yangzhou225127, China, E-mail: mdai@yzu.edu.cn
http://dx.doi.org/10.5755/j01.mech.24.5.19492
Received February 13, 2018
Accepted October 18, 2018
Table 1 Parameters of spherical joint
Rotor radius Radius gap Ambient pressure Dynamic viscosity of air
r/mm c/mm p/Pa [mu]/(Pa*s)
38.5 0.3 1.013x[10.sup.5] 1.8x[10.sup.-5]
Rotor radius Angular frequency for rotor working Number of bearings
r/mm [omega]/(r*[min.sup.-1]) [LAMBDA]
38.5 2x[10.sup.5] 3.5
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