Embedded Files
Reconfigurable 3D Magnetic Control System
Exploded View of Final CAD Frame Design
Exploded View of Final CAD Top and Bottom Frame Design
The MAE Detachable 3D Magnetic Control System was able to produce a magnetic field density of up to 80 mT in the Z-direction and 10 mT in the X and Y directions. The project consists of the following major components: Aluminum base sheet, T-bar Frame, Transformer Solenoids, and 2 types of controls systems.
Overall Design of 3D Magnetic Control System
Top View of 3D Magnetic Control System
Base Plate of 3D Magnetic Control System
15" X 15" X 0.5" Aluminum base plate consist of grooves that allows for modularity of the frame design in the horizontal axis. The holes are drilled to secure the T-bar frame at specified distances that the end user can adjust depending on their needs.
1 in Corner Bracket
1.5 in Corner Bracket
T-bar frame for support
The T-bar frame and the corner brackets gives structural support to the design. The corner brackets are used to secure the T-bar frame's vertical and horizontal distance while also locking the T-bar frame in different distances. They can be reconfigured in different positions to enable the frame to be modular. The T-bar frame is an important part of the design as it holds the transformer solenoid in place.
Transformer Solenoid
Solenoid pairs in horizontal and vertical directions
The Transformer Solenoid is a custom design created by the team which combines elements from both transformer magnets and solenoids to create a powerful magnetic field. Six transformer solenoids were positioned within the system to create magnetic field density vectors in three dimensions. The transformer solenoids were able to attain a magnetic field density of 80 mT during testing.
Workspace support
Integration of workplace support
Workspace support is designed to support 50mm X 50mm X 50mm workspace where the magnetic putty is placed for research purposes. The workspace support is supported by 3 legs and the part being 3D printed.
Arduino-Based Analog Control and Power Supply Box
Analog Control
Analog Control
The Analog control system converts single voltage power supplies to 3 channels of variable output on a budget.
The user manipulates 4 knobs to define the desired magnetic field: 1 to limit overall power as a safety feature and 3 to control each bidirectional channel running to X, Y, and Z directions. An LCD screen displays current to the user in real time to help key in on the desired current value and define the strength of the magnetic field in each direction.
The power supply box isolates all high power lines from the user, but can be easily opened to allow repairs and improvements to the internal circuitry.
Analog System Circuitry
Analog System Circuitry
Potentiometers are used for user input. The current is measured using ammeters directly from each of the three output channels and digitally filtered. An Arduino Mega 2560 and three Cytron 10A motor driver shields were used to limit output from Meanwell single output 12V, 30A and 24V, 15A power supplies. The Analog system runs independently from a computer and only requires a power outlet and a 5V USB-A charging port.
Gui control
Gui control
The MATLAB-based GUI enables the end user to attain high degrees of precision when working with the 3D magnetic control system. The GUI has sliders and switches which enable the user to control how much current is output to each pair of electromagnets and in which direction. Dropdown menus enable the user to specify the solenoid separation distance to ensure an accurate magnetic field density simulation. The update simulation button takes into account the current provided to each of the transformer solenoids, which direction that current is flowing, and the solenoid separation distance to produce an accurate simulation. Once the user is satisfied with the simulation results, they can press the “Send Signal to System” button which will power on the motor drivers and send current through the 10A Cytron motor drivers as specified in the prior steps. The MATLAB program will process information provided by ammeters and a proportional gain feedback loop to produce the correct current output. When the user is done with the system, they can press the red “Power Off” button to cut power to the motor drivers and turn off the system.
MATLAB-Based GUI
Coil Wrapping Jig
Coil Wrapping Jig
The Coil Wrapping Jig enables the user to maintain tension while wrapping, to wrap tightly within an exact working space defined by the machined groove in the iron cores. while permitting smooth transfer of wire into the iron core groove. Once the wrapping jig is assembled, the wires are wrapped tightly around the base. The top of the wrapping jig is removed before transferring the wire to the iron core groove. The ring of wrapping jig permits smooth transfer of wire into the iron core groove.
Exploded View of the Coil Wrapping Jig
Transferring Wrapped Wire to Iron Core Groove
Page updated
Report abuse