Control of flexible rotor systems with active magnetic bearings

An approach is presented for the analysis and design of magnetic suspension systems with large flexible rotordynamics models including dynamics, control, and simulation. The objective is to formulate and synthesize a large-order, flexible shaft rotordynamics model for a flywheel supported with magnetic bearings. A finite element model of the rotor system is assembled and then employed to develop a magnetic suspension compensator to provide good reliability and disturbance rejection. Stable operation over the complete speed range and optimization of the closed-loop rotordynamic properties are obtained via synthesis of eigenvalue analysis, Campbell plots, waterfall plots, and mode shapes. The large order of the rotor model and high spin speed of the rotor present a challenge for magnetic suspension control. A flywheel system is studied as an example for realizing a physical controller that provides stable rotor suspension and good disturbance rejection in all operating states. The baseline flywheel system control is determined from extensive rotordynamics synthesis and analysis for rotor critical speeds, mode shapes, frequency responses, and time responses.