Design and Experimental Validation of a Fuzzy Cascade Controller for a Zero-Power Permanent Magnetic Suspension System with Variable Flux Path Control

Magnetic suspension technology has been a promising method to achieve contactless movement, and its advantages are smooth motion, no wear, no noise and low maintenance. In previous studies, the suspension force was mainly controlled by the current in the coils, which can lead to energy loss. To solve the problem of energy loss, we have proposed a novel zero-power permanent magnetic suspension system with variable flux path control (ZPPMSS-VFPC); moreover, the interference suppression and response of the ZPPMSS-VFPC need to be further investigated. This paper aims to improve the robustness and decrease the response time for the ZPPMSS-VFPC; as a result, a fuzzy cascade controller composed of a fuzzy controller and a cascade controller is designed and applied, in which the investigated fuzzy cascade control methods include the position loop fuzzy cascade control (PLFCC) and angle loop fuzzy cascade control (ALFCC). The structure and the working principle of the proposed ZPPMSS-VFPC are introduced, and the theoretical modeling and the fuzzy cascade controller design of the system are exhibited. An experimental setup is established to validate the simulation results and to investigate the control effect of the designed controller. The experimental results demonstrate that the response times of the fuzzy cascade controller at the displacement disturbance and the force disturbance are 0.5 s and 0.6 s faster than those of the cascade control, respectively. Furthermore, the control effect of the PLFCC is better than that of the ALFCC. Overall, the fuzzy cascade controller not only has the characteristics of strong adaptability but also has the characteristics of easy adjustment parameters, which can be applied to the complex magnetic suspension system