Design Analysis of a Distributed Actuation-Sensing System Using Direct Field-Feedback for Eddy-Current Pattern Control

Author(s):  
Min Li ◽  
Kok-Meng Lee

Abstract This paper presents a direct field-feedback method with an observer for precise control of an eddy-current density (ECD) field induced in an electrically conductive-plate by a set of individually manipulatable currents. The magnetic flux density (MFD) generated by the ECD is measured by an array of MFD sensors, and fed back for compensating external disturbances and time-varying effects of the system parameters and ECD model inaccuracy. For feedback control of the multiple-input and multiple-output (MIMO) distributed-parameter system, a distributed current source (DCS) method is used to formulate the ECD system in state space, where the conductor is discretized into elemental ECD sources as system state variables providing a basis to design the state controller and observer. Based on the observability of the MFD sensing system and the controllability of the EM actuation system, the controller and observer were designed using a pole-placement method. Results illustrating the design concept are presented, demonstrating the feasibility and efficiency of the proposed method; both well-defined and arbitrary EC contours are considered. While illustrated in the context of controlling an EC pattern, the methods presented here provide the essential basis for designing and controlling a distributed-parameter system utilizing the physical fields of the system for state feedback and error compensation with a distributed set of actuators and sensors.

Author(s):  
Zhengya Guo ◽  
Kok-Meng Lee ◽  
Bingjie Hao ◽  
Zhenhua Xiong

Abstract This paper presents a parametric study of an eddy current (EC) sensor that measures the magnetic flux density (MFD) for detecting lack-of-fusion defects commonly found in metal additive manufacturing (Metal-AM). In this study, the EC-sensing system is simulated using a two-stage method that decomposes the EC-based detection of a defective conductor into two subproblems; the first analytically solves for the EC assuming no defects, and the second solves for the EC perturbation in the focused regions near the defects using a distributed current source method. Based on the proposed EC model, the effects of geometrical parameters on the sensitivity of an EC-sensing system were analyzed and verified by comparing with finite-element analysis (FEA). The study leads to the identification of two key parameters that significantly affect the sensitivity and accuracy of an EC sensor for detecting small defects, which are the locations and axes of the MFD sensors relative to the coil. The ECD distributions are simulated for two EC-sensor design scenarios: fixed at specified locations, and scanning over the entire specimen. Both DCS-based and FEA results match excellently well when images are at a fixed senor location. When scanning, DCS-based images are much smoother and require significantly less time to scan as compared to FEA that requires remeshing between steps and exhibits significant numerical noise, demonstrating the accuracy and efficiency of the proposed numerical model.


Author(s):  
Alexander V. Pesterev ◽  
Lawrence A. Bergman

Abstract The problem of calculating the dynamic response of a one-dimensional distributed parameter system excited by an oscillator traversing the system with an arbitrarily varying speed is investigated. An improved series representation for the solution is derived that takes into account the jump in the shear force at the point of the attachment of the oscillator, which makes it possible to efficiently calculate the distributed shear force and, where applicable, bending moment. The improvement is achieved through the introduction of the “quasi-static” solution, an approximation to the desired one, which makes it possible to apply to the moving oscillator problem the “mode-acceleration” technique conventionally used for acceleration of series in problems related to the steady-state vibration of distributed systems. Numerical results illustrating the efficiency of the method are presented.


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