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Modeling and Control for Tubular Linear Permanent

Magnet Synchronous Machines with Gas Springs in


Drilling Applications
Shujun Zhang, Lars Einar Norum
Department of Electrical Power Engineering
Norwegian University of Science and Technology, Trondheim, 7491, Norway
Abstract- A novel idea employing Tubular Linear Permanent
Magnet Synchronous Motors (TLPMSM) with two gas springs is
presented in this paper. The mathematical model of TLPMSM is
developed for the aim of controlling the stroke length of
TLPMSM for drilling application. The control strategy based on
transfer function model is designed. The simulation result of the
control system shows the validity of design of controller. The
good dynamic and static performance predicts the intended
drive performance.

I.

INTRODUCTION

In recent years, linear electric machines have been more


extensively employed in industrial applications, such as
industrial robots, deep-mining, elevator doors, compressors
and artificial hearts. These machines have significant
advantages in terms of good dynamic characteristics,
efficiency, force control, position accuracy, and reliability [15]. In this paper, the oscillatory motion of linear electric
machines is proposed. It can be effectively utilized in
demanding offshore oil industry drilling application. The
proposed tubular linear permanent magnet synchronous
machine (TLPMSM) with two gas springs is suited as linear
hammer, especially for hard rock drilling with mud as drilling
fluid. This machine can directly transmit power from electric
source to drill bit without any mechanical equipments like
gears, bearings, driving shaft, and so on.
In order to facilitate the design optimization and accurate
dynamic modeling of linear permanent magnet synchronous
machine, a variety of techniques have been developed to
realize optimal control performances. To control the position,
speed, acceleration and force of linear permanent magnet
synchronous machine, modeling, dynamic analysis, and
parameter estimation have been done in [6-9]. Prescribed
closed-loop speed control method offered an accurate
realization in [10, 11]. Sensorless control method for a
miniature application has been validated in [12]. An advanced
scheme, based on Neural Network, has been proposed in [13]
to compensate for sudden variations of the load.
The TLPMSM used in this work has been introduced in [5,
14]. Analysis of the force performance of this machine is
carried out in [5]. Therefore, this paper deals with TLPMSM
modeling and controller design and predicts the performance
for the drilling application.

II. MODELING AND DYNAMIC ANALYSIS


Fig. 1 shows the TLPMSM prototype built for drilling
application in offshore oil industry. The machine is connected
to the shaft by an external spring. The machine consists of
casing with stator winding, piston with permanent magnets,
gas spring in each end of the casing. The very high pressure at
the ends of the piston results in a high oscillation frequency of
the system. The piston moves back and forth at the forced
resonant mode by the electromagnetic force. The casing will
move at the mode of forced vibration under forces by the gas
springs when the piston is moving up and down.
The electromagnetic force is produce by the interaction
between the magnetic fields in the airgap from the permanent
magnet and current in the stator winding.
In the modeling, the following assumptions have also been
made for the purpose of simplification:
1) No magnetic saturation due to large airgap.
2) No fringing of the magnetic circuit.
3) Eddy currents and hysteresis effects are neglected.
4) Air gap field is axial and independent of piston position.
5) No leakage between two gas chambers.
6) Temperature effects are negligible.
A. Machine design description
The TLPMSM is axi-symmetric and the outer casing seals
the whole unit. The winding of the coils is made around a
plastic casing used as a low friction bearing for the moving

Fig. 1. Tubular linear permanent magnet synchronous machine

piston. The stator winding lies in the middle of the casing. balance can be expressed as follows:
The piston is an assembly of laminated iron disks and
d 2 y (t )
mp
= f e f fp f gas f g
(3)
permanent magnet disks. Each disk has a hole in the center so
dt 2
that these disks can be held together by a rod of stainless steel.
where
At each end of the piston there is a disk of stainless steel
m p mass of the piston
which creates a sealing against the plastic casing.
fe
electromagnetic force
Two small size springs are connected on each end of the
piston in order to keep the piston in the middle of the
f fp
force of friction between piston and casing
TLPMSM when TLPMSM is at rest.
f gas force from gas springs
B. Gas springs
fg
gravity of piston
Employing gas springs makes a relatively heavy piston
Same as the piston, we can get the forces of the casing as
oscillate at high frequency. The stiffness coefficient of gas
follows:
spring can be changed by changing the initial pressure of the
d 2 yT ( t )
gas in the chambers, by this the natural frequency of the
mT
= f gas f fT fT fTg
(4)
system can be changed. Therefore, TLPMSM with gas
dt 2
springs can output a higher power than other designs.
where
The function of force and displacement is defined by:
yT ( t ) displacement of casing from the zero position
m T mass of TLPMSM
y y
g
g
f gas = A p0
(1)


f fT
friction force between casing and surroundings
y g y y g + y

fT
force from external spring
where
f Tg gravity of TLPMSM
yg maximum distance the piston can move
Here, f g will be neglected because another coil will be
y displacement of the piston from the zero position
designed to offset gravity of piston, and then these two
A cross-sectional area of the piston
springs will hold piston in the middle of casing when piston is
p0 initial pressure for the gas springs
at standstill. A strong force will impose on the shaft when the
adiabatic constant of gas
machine works. Therefore, the gravity of TLPMSM f Tg will
Fig. 2 gives a characteristic curve of gas springs according be neglected when analyzing the forces. The friction force
to (1). It shows that the forces increase with the displacement will be proportional to the velocity for simplicity [15].
of the piston and the characteristic curve of gas springs can be
The electromagnetic force is calculated using the wellapproximately taken as a linear curve when the displacement known interaction formula between a magnetic field and a
is very small or yg  y . So, the force function can be moving point charge, in this case embedded in a currentapproximated by:
carrying conductor. This relationship is described by the
f gas K gas y
(2) Lorentz's force equation by (5).
Fe ( t ) = i ( t ) (l Bg )
(5)
where
K gas stiffness coefficient of two gas springs
where
Fe ( t ) electromagnetic force vector
We have found the value of K gas from Fig.2.
l
vector of length in the direction of current i
Bg
flux density vector of the air-gap
C. Force analysis
Fig.3 shows the forces on the piston. The forces acting on
Piston
the piston include electromagnetic force, force of friction,
gravity of piston and forces from gas springs. The force
400

f gas

300

f fp

200

force(N)

X: 0.01
Y: 42.22

100

0
-100
-200

fg

Direction of
moving

-300
-400
-0.02

fe
-0.015

-0.01

-0.005
0
0.005
displacement of piston(m)

0.01

0.015

0.02

Fig.2. Curve shape of force and displacement of piston

Fig. 3. Force analysis for the piston (Here, o-x axis designates the origin. The
forces are distributed on o-x axial to make them understood easily.)

Maximum force is generated in this application when l medium of magnetic flux density Bg , and the magnitude of
and Bg are orthogonal ( = 2 ). It is a common practice to the induced voltage of the conductor is given by
ensure this relationship in designs. Therefore the magnitude
d ( y (t ) )
uemf ( t ) = N Bg D v p ( t ) = K e
.
(11)
of electromagnetic force in scalar is given by (6) in TLPMSM.
dt
f e ( t ) = N Bg D i ( t )
(6)
where
where
K e =N Bg D
number of turns of the stator winding
N
v p ( t ) velocity of piston
Bg
flux density of permanent magnet
And then, the mathematics model of TLPMSM can be
D
diameter of the coil
developed from (6-8) and (10-11). Application of the Laplace
transformation with zero initial condition to the differential
D. Forced vibration
The system behaves as two spring-mass-damper systems by equations gives the transfer function of TLPMSM as
Y ( s)
analyzing (3) and (4) in this case: one is gas springs-pistonGT ( s ) = T
=
U ( s)
damper; another is Spring-TLPMSM-damper. Motion
. (12)
function of the piston in mathematics is
Ke Kgas
2
d y (t )
dy ( t )
mp
+ bp
+ K gas y ( t ) = f e ( t ) .
(7)
( mT s2 + bT s + Ks ) ( Ls + R) ( mp s2 + bp s + Kgas ) + Ke2s
2
dt
dt
Substituting the values of the various parameters from table
where
1
into
(12), the model of TLPMSM is obtained:
bp
friction coefficient between piston and casing
1
When the sinusoidal current i m sin ( t ) is supplied to the
GT ( s ) =

2
( 0.606s + 0.01s + 54180.1875)
coil the electromagnetic force produced by the coil will force
(13)
the piston move at the mode of forced damped vibration. The
30.6418 5722
frequency of the input current should be exactly same as the
( 0.0004s + 4.74 ) ( 0.064s 2 + 0.001s + 5722 ) + 30.64182 s
natural frequency of spring-piston-damper system to achieve
the maximum energy transform.
The system is stable because all the roots of the transfer
The TLPMSM moves up and down at the mode of forced function denominator polynomial have negative real parts. To
damped vibration and the force comes from gas springs. And ensure a robust control a controller is needed here. A PID
motion function of TLPMSM in mathematics is
controller with a control equation is given by (14)
d 2 yT ( t )
dyT ( t )

de(t ) 1
mT
+ bT
+ K s yT ( t ) = K gas y ( t ) . (8)
u (t ) = K p e(t ) + Td
+ e(t )dt .
(14)
2
dt
dt
dt
Ti

where
where
bT friction coefficient between casing and surroundings
K p proportional gain
K s stiffness coefficient of external spring
T derivative time

E. Output power to the drill bit


Assuming no restrictions on the movement i.e. no hammer
effect, the outputting mechanical power will be only friction.
It can be expressed [1] as
1
2
Pmec = bT ( yTm ) .
(9)
2
where
frequency of resonance motion
yTm maximum value of displacement of TLPMSM
When the casing hits the drill bit, the friction coefficient
between casing and surroundings will increase to a very large
value rapidly.
III. CONTROL MODEL AND CONTROL ANALYSIS
According to the Kirchhoff's voltage law, the voltage
equation in the coil circuit is as follows:
di ( t )
(10)
u (t ) = R i (t ) + L
+ uemf ( t )
dt
Similarly, based on Faraday's law of electromagnetic
induction, which implies that a back electromagnetic force,
u emf is induced in a conductor moving at a velocity in a

Ti
integral time
The transfer function of PID is

U ( s)
1
Gc ( s) =
= K p 1 + Td s +
.
E (s )
Ti s

TABLE I
PARAMETERS OF TLPMSM

Mass of TLPMSM ( m T )

4.74
0.0004H
0.606kg

Friction coefficient of TLPMSM ( b T )

0.01Ns m

Stiffness coefficient of spring ( K s )

54180.1875 N m

Mass of piston ( m p )

0.064kg

Friction coefficient of piston ( b p )

0.001Ns m

Stiffness coefficient of gas springs(including


two mechanical springs) ( K gas )

5722 N m

Flux density of permanent magnet ( Bg )

1.2 Wb m 2

Diameter of piston ( D )
Number of turns in coil ( N )

0.016m
508

Resistance of coil ( R )
Inductance of coil ( L )

(15)

With the transfer function of the system and the controller


derived, the parameters of the controller have to be
determined so that the desired performance of the system
would be achieved. Fig. 4 shows schematic block of the
system with a compensator.
IV. IMPLEMENTATION OF TLPMSM CONTROL SYSTEM
The control objective is to keep the stroke length constant.
A PI controller can be used, but the step response of this
system with PI controller exhibits the hidden oscillation
according to simulations. Therefore, a compensator shown in
equation (16) is designed to control TLPMSM.
1
1

(16)
Gc ( s ) = 47.4048 1 +

0.003486 s 0.25 s + 1
The developed system with accepted parameters is
simulated with MATLAB and the result shown in Fig.5 is
satisfied.
V. CONCLUSION
The development of a TLPMSM control system with two
gas springs has been presented. Compared with the other
machine for drilling application, the use of TLPMSM as
described, has the advantages of high efficiency, strong force
and high frequency. The mathematic model of TLPMSM is
established and a control scheme is developed based on this
model. The simulation result shows that the system achieves
good dynamic and static performance and the control strategy
is feasible for light load. This system will be applied to
drilling application in the offshore in future.

Fig. 4. Schematic model for control

Fig. 5. Step response of the closed-loop system

ACKNOWLEDGMENT
This work was supported by Research Council of Norway
(NFR) and Resonator AS.
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