Design and Decoupled Compensation Methods of a PM Motor Capable of 6-D Force/Torque Actuation for Minimum Bearing Reaction

This paper presents a methodology to design and control a permanent magnet (PM) motor capable of 6-D force/torque actuation for real-time compensation of external loads to achieve minimum bearing reaction (MBR). Unlike conventional multiphase designs, the current inputs to the stator-electromagnets (EMs) can be flexibly configured to enable 6-D force and/or torque actuation in one motor; two common motor structures (radial and axial types) are illustrated. Both the forward and inverse force/torque models are presented in terms of coordinate-independent kernel functions that characterize the force between an EM and a PM pole pair. Two closed-form solutions to the inverse model that solves for the current-input vector minimizing the total input energy to generate a desired force/torque vector, which can be computed within 1 ms, are derived and verified numerically. A feedforward MBR compensator designed to argument the proportional-integral-derivative (PID) speed regulator has been experimentally evaluated on a structurally smart spindle system to minimize bearing reactions. Experiments show that the MBR compensation effectively reduces vibrations and improves cutting quality.