Tunable Magnets: modeling and validation for dynamic and precision applications

Abstract: Actuator self-heating limits the achievable force and can cause unwanted structural deformations. This is especially apparent in quasi-static actuation systems that require the actuator to maintain a stable position over an extended period. As a solution, we use the concept of a Tunable Magnet. Tunable magnets rely on in-situ magnetization state tuning of AlNico to create an infinitely adjustable magnetic flux. They consist of an AlNiCo low coercivity permanent magnet together with a magnetizing coil. After tuning, the AlNiCo retains its magnetic field without further energy input, which eliminates the static heat dissipation. To enable implementation in actuation systems, the AlNiCo needs to be robustly tunable in the presence of a varying system air-gap. We achieve this by implementing a magnetization state tuning method, based on a magnetic circuit model of the actuator, measured AlNiCo BH data and air-gap flux feedback control. The proposed tuning method consists of 2 main steps. The prediction step, during which the required magnet operating point is determined, and the demagnetization step, where a feedback controller drives a demagnetization current to approach this operating point. With this method implemented for an AlNiCo 5 tunable magnet in a reluctance actuator configuration, we achieve tuning with a maximum error of 15.86 "mT" and a minimum precision of 0.67 "mT" over an air-gap range of 200 "{\mu}m". With this tuning accuracy, actuator heating during static periods is almost eliminated. Only a small bias current is needed to compensate for the tuning error.